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FIELD OF THE INVENTION
[0001] The present invention relates to incorporation of a carboxylation system into the bleach plant of a wood pulp mill to provide carboxylated cellulosic fibers.
BACKGROUND OF THE INVENTION
[0002] Cellulose is a carbohydrate consisting of a long chain of glucose units, all β-linked through the 1′-4 positions. Native plant cellulose molecules may have upwards of 2200 anhydroglucose units. The number of units is normally referred to as degree of polymerization (D.P.). Some loss of D.P. inevitably occurs during purification. A D.P. approaching 2000 is usually found only in purified cotton linters. Wood derived celluloses rarely exceed a D.P. of about 1700. The structure of cellulose can be represented as follows:
[0003] Chemical derivatives of cellulose have been commercially important for almost a century and a half. Nitrocellulose plasticized with camphor was the first synthetic plastic and has been in use since 1868. A number of cellulose ether and ester derivatives are presently commercially available and find wide use in many fields of commerce. Virtually all cellulose derivatives take advantage of the reactivity of the three available hydroxyl groups (i.e., C2, C3, and C6). Substitution at these groups can vary from very low, about 0.01, to a maximum of 3. Among important cellulose derivatives are cellulose acetate, used in fibers and transparent films; nitrocellulose, widely used in lacquers and gunpowder; ethyl cellulose, widely used in impact resistant tool handles; methyl cellulose, hydroxyethyl, hydroxypropyl, and sodium carboxymethyl cellulose, water soluble ethers widely used in detergents, as thickeners in foodstuffs, and in papermaking. Cellulose itself has been modified for various purposes. Cellulose fibers are naturally anionic in nature as are many papermaking additives. A cationic cellulose is described in U.S. Pat. No. 4,505,775, issued to Harding et al. This cellulose has greater affinity for anionic papermaking additives such as fillers and pigments and is particularly receptive to acid and anionic dyes. U.S. Pat. No. 5,667,637, issued to Jewell et al., describes a low degree of substitution (D.S.) carboxyethyl cellulose which, along with a cationic resin, improves the wet to dry tensile and burst ratios when used as a papermaking additive. U.S. Pat. No. 5,755,828, issued to Westland, describes a method for increasing the strength of articles made from crosslinked cellulose fibers having free carboxylic acid groups obtained by covalently coupling a polycarboxylic acid to the fibers.
[0004] For some purposes, cellulose has been oxidized to make it more anionic to improve compatibility with cationic papermaking additives and dyes. Various oxidation treatments have been used. Among these are nitrogen dioxide and periodate oxidation coupled with resin treatment of cotton fabrics for improvement in crease recovery as suggested by Shet, R. T. and A. M. Nabani, Textile Research Journal , November 1981: 740-744. Earlier work by Datye, K. V. and G. M. Nabar, Textile Research Journal, July 1963: 500-510, describes oxidation by metaperiodates and dichromic acid followed by treatment with chlorous acid for 72 hours or 0.05 M sodium borohydride for 24 hours. Copper number was greatly reduced by borohydride treatment and less so by chlorous acid. Carboxyl content was slightly reduced by borohydride and significantly increased by chlorous acid. The products were subsequently reacted with formaldehyde. Southern pine kraft springwood and summer wood fibers were oxidized with potassium dichromate in oxalic acid. Luner, P., et al., Tappi 50(3):117-120 (1967). Handsheets made with the fibers showed improved wet strength believed to be due to aldehyde groups. Pulps have also been oxidized with chlorite or reduced with sodium borohydride. Luner, P., et al., Tappi 50(5):227-230, 1967. Handsheets made from pulps treated with the reducing agent showed improved sheet properties over those not so treated. Young, R. A., Wood and Fiber 10(2):112-119, 1978 describes oxidation primarily by dichromate in oxalic acid to introduce aldehyde groups in sulfite pulps for wet strength improvement in papers. Shenai, V. A. and A. S. Narkhede, Textile Dyer and Primer , May 20, 1987: 17-22 describe the accelerated reaction of hypochlorite oxidation of cotton yarns in the presence of physically deposited cobalt sulfide. The authors note that partial oxidation has been studied for the past hundred years in conjunction with efforts to prevent degradation during bleaching. They also discuss in some detail the use of 0.1 M sodium borohydride as a reducing agent following oxidation. The treatment was described as a useful method of characterizing the types of reducing groups as well as acidic groups formed during oxidation. The borohydride treatment noticeably reduced copper number of the oxidized cellulose. Copper number gives an estimate of the reducing groups such as aldehydes present on the cellulose. Borohydride treatment also reduced alkali solubility of the oxidized product, but this may have been related to an approximate 40% reduction in carboxyl content of the samples. Andersson, R., et al. in Carbohydrate Research 206: 340-346 (1990) describes oxidation of cellulose with sodium nitrite in orthophosphoric acid and describe nuclear magnetic resonance elucidation of the reaction products. Davis, N. J., and S. L. Flitsch, Tetrahedron Letters 34(7): 1181-1184 (1993) describe the use and reaction mechanism of 2,2,6,6-tetramethylpiperidinyloxy free radical (TEMPO) with sodium hypochlorite to achieve selective oxidation of primary hydroxyl groups of monosaccharides. Following the Davis et al. paper this route to carboxylation then began to be more widely explored. de Nooy, A. E. J., et al., Receuil des Travaux Chimiques des Pays - Bas 113: 165-166 (1994) reports similar results using TEMPO and hypobromite for oxidation of primary alcohol groups in potato starch and inulin. The following year, these same authors in Carbohydrate Research 269:89-98 (1995) report highly selective oxidation of primary alcohol groups in water soluble glucans using TEMPO and a hypochlorite/bromide oxidant.
[0005] WO 95/07303 (Besemer et al.) describes a method of oxidizing water soluble carbohydrates having a primary alcohol group, using TEMPO with sodium hypochlorite and sodium bromide. Cellulose is mentioned in passing in the background although the examples are principally limited to starches. The method is said to selectively oxidize the primary alcohol at C-6 to carboxylic acid group. None of the products studied were fibrous in nature.
[0006] WO 99/23117 (Viikari et al.) describes oxidation using TEMPO in combination with the enzyme laccase or other enzymes along with air or oxygen as the effective oxidizing agents of cellulose fibers, including kraft pine pulps.
[0007] A year following the above noted Besemer publication, the same authors, in Cellulose Derivatives , Heinze, T. J. and W. G. Glasser, eds., Ch. 5, pp. 73-82 (1996), describe methods for selective oxidation of cellulose to 2,3-dicarboxy cellulose and 6-carboxy cellulose using various oxidants. Among the oxidants used were a periodate/chlorite/hydrogen peroxide system, oxidation in phosphoric acid with sodium nitrate/nitrite, and with TEMPO and a hypochlorite/bromide primary oxidant. Results with the TEMPO system were poorly reproduced and equivocal. In the case of TEMPO oxidation of cellulose, little or none would have been expected to go into solution. The homogeneous solution of cellulose in phosphoric acid used for the sodium nitrate/sodium nitrite oxidation was later treated with sodium borohydride to remove any carbonyl function present.
[0008] Chang, P. S. and J. F. Robyt, Journal of Carbohydrate Chemistry 15(7):819-830 (1996), describe oxidation of ten polysaccharides including α-cellulose at 0 and 25° C. using TEMPO with sodium hypochlorite and sodium bromide. Ethanol addition was used to quench the oxidation reaction. The resulting oxidized α-cellulose had a water solubility of 9.4%. The authors did not further describe the nature of the α-cellulose. It is presumed to have been a so-called dissolving pulp or cotton linter cellulose. Barzyk, D., et al., in Transactions of the 11 th Fundamental Research Symposium , Vol. 2, 893-907 (1997), note that carboxyl groups on cellulose fibers increase swelling and impact flexibility, bonded area and strength. They designed experiments to increase surface carboxylation of fibers. However, they ruled out oxidation to avoid fiber degradation and chose to form carboxymethyl cellulose in an isopropanol/methanol system.
[0009] Isogai, A. and Y. Kato, in Cellulose 5:153-164, 1998 describe treatment of several native, mercerized, and regenerated celluloses with TEMPO to obtain water soluble and insoluble polyglucuronic acids. They note that the water soluble products had almost 100% carboxyl substitution at the C-6 site. They further note that oxidation proceeds heterogeneously at the more accessible regions on solid cellulose.
[0010] Kitaoka, T., A. Isogai, and F. Onabe, in Nordic Pulp and Paper Research Journal 14(4):279-284, 1999, describe the treatment of bleached hardwood kraft pulp using TEMPO oxidation. Increasing amounts of carboxyl content gave some improvement in dry tensile index, Young's modulus, and brightness, with decreases in elongation at breaking point and opacity. Other strength properties were unaffected. Retention of PAE-type wet strength resins was somewhat increased. The products described did not have any stabilization treatment after the TEMPO oxidation.
[0011] U.S. Pat. No. 6,379,494 describes a method for making stable carboxylated cellulose fibers using a nitroxide-catalyzed process. In the method, cellulose is first oxidized by nitroxide catalyst to provide carboxylated as well as aldehyde and ketone substituted cellulose. The oxidized cellulose is then stabilized by reduction of the aldehyde and ketone substituents to provide the carboxylated fiber product. Nitroxide-catalyzed cellulose oxidation occurs predominately at the primary hydroxyl group on C-6 of the anhydroglucose moiety. In contrast to some of the other routes to oxidized cellulose, only very minor oxidation occurs at the secondary hydroxyl groups at C-2 and C-3.
[0012] In nitroxide oxidation of cellulose, primary alcohol oxidation at C-6 proceeds through an intermediate aldehyde stage. In the process, the nitroxide is not irreversibly consumed in the reaction, but is continuously regenerated by a secondary oxidant (e.g., hypohalite) into the nitrosonium (or oxyammonium or oxammonium) ion, which is the actual oxidant. In the oxidation, the nitrosonium ion is reduced to the hydroxylamine, which can be re-oxidized to the nitroxide. Thus, in the method, it is the secondary oxidant (e.g., hypohalite) that is consumed. The nitroxide may be reclaimed or recycled from the aqueous system.
[0013] The resulting oxidized cellulose product is an equilibrium mixture including carboxyl and aldehyde substitution. Aldehyde substituents on cellulose are known to cause degeneration over time and under certain environmental conditions. In addition, minor quantities of ketone may be formed at C-2 and C-3 of the anhydroglucose units and these will also lead to degradation. Marked degree of polymerization loss, fiber strength loss, crosslinking, and yellowing are among the consequent problems. Thus, to prepare a stabilized carboxylated product, aldehyde and ketone substituents formed in the oxidation step are reduced to hydroxyl groups, or aldehyde substituents are oxidized to a carboxyl group in a stabilization step.
[0014] In addition to TEMPO, other nitroxide derivatives for making carboxylated cellulose fibers have been described. See, for example, U.S. Pat. No. 6,379,494 and WO 01/29309, Methods for Making Carboxylated Cellulose Fibers and Products of the Method.
[0015] A method of preparation of carboxylic acids or their salts by oxidation of primary alcohols using hindered N-chloro hindered cyclic amines and hypochlorite, in aqueous solutions or in mixed solvent systems containing ethyleneglycol dimethyl ether, diethyleneglycol dimethyl ether, triethyleneglycol dimethyl ether, toluene, acetonitrile, ethylacetate, t-butanol and other solvents is described in JP10130195, “Manufacturing Method of Carboxylic Acid and Its Salts”. Other oxidants described include chlorine, hypobromite, bromite, trichloro isocyanuric acid, tribromo isocyanuric acid, or combinations.
[0016] Despite the advances made in the development of methods for making carboxylated cellulose pulps including catalytic oxidation systems, there remains a need for improved methods and catalysts for making carboxylated cellulose pulp. The present invention seeks to fulfill these needs and provides further related advantages.
SUMMARY OF THE INVENTION
[0017] A carboxylation system and process for wood pulp which may be placed in an existing pulp mill bleach plant, or incorporated into a new bleach plant with little additional equipment. A carboxylation system and process for wood pulp which will allow the mill to transition from regular pulp to carboxylated pulp and back with ease.
[0018] What is needed is a process and equipment that allows pulp to be carboxylated in an existing pulp mill without large capital costs.
[0019] Long reaction times require large tanks, land on which to put the tanks and a great deal of capital. One of the aspects of the present carboxylation reaction is the ability to place the needed equipment into the confines of an existing pulp mill bleach plant. This required reducing the time of reaction so that it could take place within the confines of the equipment in the plant.
[0020] A wood pulp carboxylation system has a first stage in which the pulp is oxidized to provide a pulp containing both carboxyl and aldehyde functional groups and second stage in which the aldehyde groups are converted to carboxyl groups. The first stage is a carboxylation stage and the second stage is a stabilization stage.
[0021] It was initially thought that the first stage of carboxylation would require at least 15 minutes so that carboxylating wood pulp would require two additional units after the bleach plant. The first unit would be a tank for the carboxylation process and the second unit would be another tank for the stabilization reaction. These would be expensive to install.
[0022] After much work the time for the first stage was reduced to 2 minutes. This still required a separate tank for the first stage carboxylation.
[0023] Additional work reduced the time for the first stage to 1 minute. The carboxylation unit could be placed between the extraction stage and the chlorine dioxide stage of the bleach plant, but additional piping was required to provide the necessary reaction time. The chlorine dioxide tower could be used for the stabilization reaction. Again the carboxylation unit would be expensive to install, though not as expensive as with longer reaction times.
[0024] Additional work reduced the first stage reaction time to 30 seconds or less. Now it was possible to use the existing pulp mill equipment with only the addition of mixers and supply lines and supply storage.
[0025] By using advantageous chemical loadings and chemicals it was found that the time for the first stage of carboxylation could be shortened into a range of less than a minute. Times of 1 second to 60 seconds are preferred and times of 5 to 30 seconds most preferred.
[0026] The first stage of the carboxylation unit can now be a short length of pipe between the extraction stage washer and the chlorine dioxide tower. The length and diameter of pipe will depend on the time required for the first stage of carboxylation process. The chlorine dioxide tower can be the stabilization unit. In mills which have two chlorine dioxide towers with a washer between them, the unit for the first stage of carboxylation can be placed between the first chlorine dioxide washer and the second chlorine dioxide tower.
[0027] Another aspect was to use chemicals normally found at the pulp mill and keep new chemicals to a minimum.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is diagram of an extraction stage and a chlorine dioxide stage of a standard pulp mill.
[0029] FIGS. 2 and 3 are diagrams of an extraction stage and a chlorine dioxide stage showing the changes to provide a carboxylation reaction.
DETAILED DESCRIPTION OF THE INVENTION
[0030] In Applicant's copending U.S. patent application Ser. No. 09/875,177 filed Jun. 6, 2001, which is incorporated herein by reference in its entirety, the use of chlorine dioxide is disclosed as a secondary oxidant for use with a hindered cyclic oxammonium salt as the primary oxidant.
[0031] This application discusses the nitroxide, oxammonium salt, amine or hydroxylamine of a corresponding hindered heterocyclic amine compound. The oxammonium salt is the catalytically active form but this is an intermediate compound that is formed from a nitroxide, continuously used to become a hydroxylamine, and then regenerated, presumably back to the nitroxide. The secondary oxidant will convert the amine form to the free radical nitroxide compound. The term “nitroxide” is normally used for the compound in the literature. The secondary oxidant will also regenerate the oxammonium salt from the hydroxylamine.
[0032] The method described in the application is suitable for carboxylation of chemical fibrous cellulose pulp. This may be bleached sulfite, kraft, or pre-hydrolyzed kraft hardwood or softwood pulps or mixtures of hardwood or softwood pulps.
[0033] The cellulose fiber in an aqueous slurry or suspension is first oxidized by addition of a primary oxidizer comprising a cyclic oxammonium salt. This may conveniently be formed in situ from a corresponding amine, hydroxylamine or nitroxyl compound which lacks any α-hydrogen substitution on either of the carbon atoms adjacent the nitroxyl nitrogen atom. Substitution on these carbon atoms is preferably a one or two carbon alkyl group. For sake of convenience in description it will be assumed, unless otherwise noted, that a nitroxide is used as the primary oxidant and that term should be understood to include all of the precursors of the corresponding nitroxide or its oxammonium salt.
[0034] Nitroxides having both five and six membered rings have been found to be satisfactory. Both five and six membered rings may have either a methylene group or a heterocyclic atom selected from nitrogen, sulfur or oxygen at the four position in the ring, and both rings may have one or two substituent groups at this location.
[0035] A large group of nitroxide compounds have been found to be suitable. 2,2,6,6-tetramethylpiperidinyl-1-oxy free radical (TEMPO) is among the exemplary nitroxides found useful. Another suitable product linked in a mirror image relationship to TEMPO is 2,2,2′,2′,6,6,6′,6′-octamethyl-4,4′-bipiperidinyl-1,1′-dioxy di-free radical (BITEMPO). Similarly, 2,2,6,6-tetramethyl-4-hydroxypipereidinyl-1-oxy free radical; 2,2,6,6-tetramethyl-4-methoxypiperidinyl-1-oxy free radical; and 2,2,6,6-tetramethyl-4-benzyloxypiperidinyl-1-oxy free radical; 2,2,6,6-tetramethyl-4-aminopiperidinyl-1-oxy free radical; 2,2,6,6-tetramethyl-4-acetylaminopiperidinyl-1-oxy free radical; 2,2,6,6-tetramethyl-4-piperidone-1-oxy free radical and ketals of this compound are examples of compounds with substitution at the 4 position of TEMPO that have been found to be very satisfactory oxidants. Among the nitroxides with a second hetero atom in the ring at the four position (relative to the nitrogen atom), 3,3,5,5-tetramethylmorpholine-1-oxy free radical (TEMMO) is useful.
[0036] The nitroxides are not limited to those with saturated rings. One compound anticipated to be a very effective oxidant is 3,4-dehydro-2,2,6,6-tetramethyl-piperidinyl-1-oxy free radical.
[0037] Six membered ring compounds with double substitution at the four position have been especially useful because of their relative ease of synthesis and lower cost. Exemplary among these are the 1,2-ethanediol, 1,2-propanediol, 2,2-dimethyl-1-3-propanediol (1,3-neopentyldiol) and glyceryl cyclic ketals of 2,2,6,6-tetramethyl-4-piperidone-1-oxy free radical.
[0038] Among the five membered ring products, 2,2,5,5-tetramethyl-pyrrolidinyl-1-oxy free radical is anticipated to be very effective.
[0039] The following groups of nitroxyl compounds and their corresponding amines or hydroxylamines are known to be effective primary oxidants:
in which R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may together be included in a five or six carbon alicyclic ring structure; X is sulfur or oxygen; and R 5 is hydrogen, C 1 -C 12 alkyl, benzyl, 2-dioxanyl, a dialkyl ether, an alkyl polyether, or a hydroxyalkyl, and X with R 5 being absent may be hydrogen or a mirror image moiety to form a bipiperidinyl nitroxide. Specific compounds in this group known to be very effective are 2,2,6,6-tetramethylpiperidinyl-1-oxy free radical (TEMPO); 2,2,2′,2′,6,6,6′,6′-octamethyl-4,4′-bipiperidinyl-1,1′-dioxy di-free radical (BI-TEMPO); 2,2,6,6-tetramethyl-4-hydroxypiperidinyl-1-oxy free radical (4-hydroxy TEMPO); 2,2,6,6-tetramethyl-4-methoxypiperidinyl-1-oxy free radical (4-methoxy-TEMPO); and 2,2,6,6-tetramethyl-4-benzyloxypiperidinyl-1-oxy free radical (4-benzyloxy-TEMPO).
in which R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may together be included in a five or six carbon alicyclic ring structure; R 6 is hydrogen, C 1 -C 5 alkyl, R 7 is hydrogen, C 1 -C 8 alkyl, phenyl, carbamoyl, alkyl carbamoyl, phenyl carbamoyl, or C 1 -C 8 acyl. Exemplary of this group is 2,2,6,6-tetramethyl-4-aminopiperidinyl-1-oxy free radical (4-amino TEMPO); and 2,2,6,6-tetramethyl-4-acetylaminopipdereidinyl-1-oxy free radical (4-acetyl amino-TEMPO).
in which R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may together be included in a five or six carbon alicyclic ring structure; and X is oxygen, sulfur, NH, N-alkyl, NOH, or NO R 8 where R 8 is lower alkyl. An example might be 2,2,6,6-tetramethyl-4-oxopiperidinyl-1-oxy free radical (2,2,6,6-tetramethyl-4-piperidone-1-oxy free radical).
wherein R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may be linked into a five or six carbon alicyclic ring structure; and X is oxygen, sulfur, -alkyl amino, or acyl amino. An example is 3,3,5,5-tetramethylmorpholine-4-oxy free radical. In this case the oxygen atom takes precedence for numbering but the dimethyl substituted carbons remain adjacent the nitroxide moiety.
wherein R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may be linked into a five or six carbon alicyclic ring structure. An example of a suitable compound is 3,4-dehydro-2,2,6,6-tetramethylpiperidinyl-1-oxy free radical.
wherein R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may together be included in a five or six carbon alicyclic ring structure; X is methylene, oxygen, sulfur, or alkylamino; and R 9 and R 10 are one to five carbon alkyl groups and may together be included in a five or six member ring structure, which in turn may have one to four lower alkyl or hydroxy alkyl substitutients. Examples include the 1,2-ethanediol; 1,3-propanediol,2,2-dimethyl-1,3-propanediol, and glyceryl cyclic ketals of 2,2,6,6-tetramethyl-4-piperidone-1-oxy free radical. These compounds are especially preferred primary oxidants because of their effectiveness, lower cost, ease of synthesis, and suitable water solubility.
in which R 1 -R 4 are one to four carbon alkyl groups but R 1 with R 2 and R 3 with R 4 may together be included in a five or six carbon alicyclic ring structure; X may be methylene, sulfur, oxygen, —NH, or NR 11 , in which R 11 is a lower alkyl. An example of these five member ring compounds is 2,2,5,5-tetramethylpyrrolidinyl-1-oxy free radical.
[0047] Where the term “lower alkyl” is used it should be understood to mean an aliphatic straight or branched chain alky moiety having from one to four carbon atoms.
[0048] The above named compounds should only be considered as exemplary among the many representatives of the nitroxides suitable for use with the invention and those named are not intended to be limited in any way.
[0049] During the oxidation reaction the nitroxide is consumed and converted to an oxammonium salt then to a hydroxylamine. Evidence indicates that the nitroxide is continuously regenerated by the presence of a secondary oxidant. Chlorine dioxide, or a latent source, is a preferred secondary oxidant. Since the nitroxide is not irreversibly consumed in the oxidation reaction only a catalytic amount of it is required. During the course of the reaction it is the secondary oxidant which will be depleted.
[0050] The amount of nitroxide required is in the range of about 0.0005% to 1.0% by weight based on carbohydrate present, preferably about 0.005-0.25%. The nitroxide is known to preferentially oxidize the primary hydroxyl which is located on C-6 of the anhydroglucose moiety in the case of cellulose or starches. It can be assumed that a similar oxidation will occur at primary alcohol groups on hemicellulose or other carbohydrates having primary alcohol groups.
[0051] The chlorine dioxide secondary oxidant is present in an amount of 0.2-35% by weight of the carbohydrate being oxidized, preferably about 0.5-10% by weight.
[0052] Abundant laboratory data indicates that a nitroxide catalyzed cellulose oxidation predominantly occurs at the primary hydroxyl group on C-6 of the anhydroglucose moiety. In contrast to some of the other routes to oxidized cellulose, only very minor reaction has been observed to occur at the secondary hydroxyl groups at the C-2 and C-3 locations. Using TEMPO as an example, the mechanism to formation of a carboxyl group at the C-6 location proceeds through an intermediate aldehyde stage.
[0053] The TEMPO is not irreversibly consumed in the reaction but is continuously regenerated. It is converted by the secondary oxidant into the oxammonium (or nitrosonium) ion which is the actual oxidant. During oxidation the oxammonium ion is reduced to the hydroxylamine from which TEMPO is again formed. Thus, it is the secondary oxidant which is actually consumed. TEMPO may be reclaimed or recycled from the aqueous system. The reaction is postulated to be as follows:
[0054] The resulting oxidized cellulose product will have a mixture of carboxyl and aldehyde substitution. Aldehyde substituents on cellulose are know to cause degeneration over time and under certain environmental conditions. In addition, minor quantities of ketone carbonyls may be formed at the C-2 and C-3 positions of the anhydroglucose units and these will also lead to degradation. Marked D.P., fiber strength loss, crosslinking, and yellowing are among the problems encountered. For these reasons it is desirable to oxidize aldehyde substituents to carboxyl groups, or to reduce aldehyde and ketone groups to hydroxyl groups, to ensure stability of the product.
[0055] To achieve maximum stability and D.P. retention the oxidized product may be treated with a stabilizing agent to convert any substituent groups, such as aldehydes or ketones, to hydroxyl or carboxyl groups. The stabilizing agent may either be another oxidizing agent or a reducing agent. Unstabilized oxidized cellulose pulps have objectionable color reversion and may self crosslink upon drying, thereby reducing their ability to redisperse and form strong bonds when used in sheeted products. It has been found that acidifying the initial reaction mixture to the pH range given for chlorites without without draining or washing the product is often sufficient to convert the aldehyde moieties to carboxyl functions. Peroxide and acid is also a desirable stabilizing mixture under the conditions shown for chlorite. Otherwise one of the following oxidation treatments may be used. Alkali methyl chlorites are one class of oxidizing agents used as stabilizers, sodium chlorite being preferred because of the cost factor. Other compounds that may serve equally well as oxidizers are permanganates, chromic acid, bromine, silver oxide, and peracids. A combination of chlorine dioxide and hydrogen peroxide is also a suitable oxidizer when used at the pH range designated for sodium chlorite. Oxidation using sodium chlorite may be carried out at a pH in the range of about 0-5, preferably 2-4, at temperatures between about 10°-110° C., preferably about 20°-95° C., for times from about 0.5 minutes to 50 hours, preferably about 10 minutes to 2 hours. One factor that favors oxidants as opposed to reducing agents is that aldehyde groups on the oxidized carbohydrate are converted to additional carboxyl groups, thus resulting in a more highly carboxylated product. These oxidants are referred to as “tertiary oxidizers” to distinguish them from the nitroxide/chlorine dioxide primary/secondary oxidizers. The tertiary oxidizer is used in a molar ratio of about 1.0-15 times the presumed aldehyde content of the oxidized carbohydrate, preferably about 5-10 times. In a more convenient way of measuring the needed tertiary oxidizer, the preferred sodium chlorite usage should fall within about 0.01-20% based on carbohydrate, preferably about 1-9% by weight based on carbohydrate, the chlorite being calculated on a 100% active material basis.
[0056] When stabilizing with a chlorine dioxide and hydrogen peroxide mixture, the concentration of chlorine dioxide present should be in a range of about 0.01-20% by weight of carbohydrate, preferably about 0.3-1.0%, and concentration of hydrogen peroxide should fall within the range of about 0.01-10% by weight of carbohydrate, preferably 0.05-1.0%. Time will generally fall within the range of 0.5 minutes to 50 hours, preferably about 10 minutes to 2 hours and temperature within the range of about 10°-110° C., preferably about 30′-95° C. The pH of the system is preferably about 3 but may be in the range of 0-5.
[0057] In Applicant's copending U.S. patent application Ser. No. ______ (attorney's docket 25065) filed contemporaneously herewith, which also is incorporated herein by reference in its entirety, the use of chlorine dioxide is a secondary oxidant for use with N-halo hindered cyclic amine compounds as the primary oxidant. The N-halo hindered cyclic amine compounds are as effective as TEMPO and other related nitroxides in methods for making carboxylated cellulose fibers.
[0058] The N-halo hindered cyclic amine compounds are fully alkylated at the carbon atoms adjacent to the amino nitrogen atom (i.e., the N—Cl or N—Br) and have from 4 to 8 atoms in the ring. In one embodiment, the N-halo hindered cyclic amine compounds are six-membered ring compounds. In another embodiment, the N-halo hindered cyclic amine compounds are five-membered ring compounds.
[0059] Representative N-halo hindered cyclic amine compounds useful in the method of the invention for making carboxylated cellulose pulp fibers include Structures (I)-(VII).
[0060] For Structure (I), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be sulfur or oxygen. R 5 can be hydrogen, C1-C12 straight-chain or branched alkyl or alkoxy, aryl, aryloxy, benzyl, 2-dioxanyl, dialkyl ether, alkyl polyether, or hydroxyalkyl group. Alternatively, R 5 can be absent and X can be hydrogen or a mirror image moiety to form a bipiperidinyl compound. A is a halogen, for example, chloro or bromo. Representative compounds of Structure (I) include N-halo-2,2,6,6-tetramethylpiperidine; N,N′-dihalo-2,2,2′,2′,6,6,6′,6-octamethyl-4,4′-bipiperidine; N-halo-2,2,6,6-tetramethyl-4-hydroxypiperidine; N-halo-2,2,6,6-tetramethyl-4-methoxypiperidine; and N-halo-2,2,6,6-tetramethyl-4-benzyloxypiperidine.
[0061] For Structure (II), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be oxygen or sulfur. R 6 can be hydrogen, C1-C6 straight-chain or branched alkyl groups. R 7 can be hydrogen, C1-C8 straight-chain or branched alkyl groups, phenyl, carbamoyl, alkyl carbamoyl, phenyl carbamoyl, or C1-C8 acyl. A is a halogen, for example, chloro or bromo. Representative compounds of Structure (II) include N-halo-2,2,6,6-tetramethyl-4-aminopiperidine and N-halo-2,2,6,6-tetramethyl-4-acetylaminopiperidine.
[0062] For Structure (II), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be oxygen, sulfur, NH, alkylamino (i.e., NH-alkyl), dialkylamino, NOH, or NOR 10 , where R 10 is a C1-C6 straight-chain or branched alkyl group. A is a halogen, for example, chloro or bromo. A representative compound of Structure (III) is N-halo-2,2,6,6-tetramethylpiperidin-4-one.
[0063] For Structure (IV), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be oxygen, sulfur, alkylamino (i.e., N—R 10 ), or acylamino (i.e., N—C(═O)—R 10 ), where R 10 is a C1-C6 straight-chain or branched alkyl group. A is a halogen, for example, chloro or bromo. A representative compound of Structure (IV) is N-halo-3,3,5,5-tetramethylmorpholine.
[0064] For Structure (V), R—R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. A is a halogen, for example, chloro or bromo. A representative compound of Structure (V) is N-halo-3,4-dehydro-2,2,6,6,-tetramethylpiperidine.
[0065] For Structure (VI), R—R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be methylene (i.e., CH 2 ), oxygen, sulfur, or alkylamino. R 8 and R 9 can be independently selected from C 1 -C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 8 and R 9 taken together can form a five- or six-membered ring, which can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. A is a halogen, for example, chloro or bromo. Representative compounds of Structure (VI) include N-halo-4-piperidone ketals, such as ethylene, propylene, glyceryl, and neopentyl ketals. Representative compounds of Structure (VI) include N-halo-2,2,6,6-tetramethyl-4-piperidone ethylene ketal, N-halo-2,2,6,6-tetramethyl-4-piperidone propylene ketal, N-halo-2,2,6,6-tetramethyl-4-piperidone glyceryl ketal, and N-halo-2,2,6,6-tetramethyl-4-piperidone neopentyl ketal.
[0066] For Structure (VIII), R 1 -R 4 can be C1-C6 straight-chain or branched alkyl groups, for example, methyl, ethyl, propyl, butyl, pentyl, or hexyl groups. Alternatively, R 1 and R 2 taken together can form a five- or six-carbon cycloalkyl group, and R 3 and R 4 taken together can form a five- or six-carbon cycloalkyl group. The cycloalkyl group can be further substituted with, for example, one or more C1-C6 alkyl groups or other substituents. X can be methylene, oxygen, sulfur, NH, (i.e., N—R 10 ), or acylamino (i.e., N—C(═O)—R 10 ), where R 10 is a C1-C6 straight-chain or branched alkyl group. A is a halogen, for example, chloro or bromo. A representative compound of Structure (VII) is N-halo-2,2,5,5-tetramethylpyrrolidine.
[0067] In general, the N-halo hindered cyclic amine compounds noted above can be prepared by chlorination or bromination of the corresponding amine compounds.
[0068] Carboxylated cellulose pulp fibers can be made using hindered cyclic amine compounds or N-halo hindered cyclic amine compound in aqueous media under heterogeneous conditions. In the method, the hindered cyclic amine compound or the N-halo hindered cyclic amine compound reacts with a secondary oxidizing agent (e.g., chlorine dioxide, peracids, hypochlorites, chlorites, ozone, hydrogen peroxide, potassium superoxide) to provide a primary oxidizing agent that reacts with cellulose pulp fibers to provide cellulose pulp fibers containing both carboxyl and aldehyde functional groups. In one embodiment, the cellulosic fibers containing carboxyl and aldehyde functional groups are further treated to provide stable carboxylated cellulosic fibers. In the method, under basic pH conditions and in the presence of a secondary oxidizing agent, the primary oxidizing agent is generated from the hindered cyclic amine compound or the N-halo hindered cyclic amine compound. In one embodiment, the cellulosic fibers containing both carboxyl and aldehyde functional groups obtained at the end of the first stage of the carboxylation process are further treated to provide stable carboxylated cellulosic fibers.
[0069] As noted above, in one embodiment, the method for making carboxylated cellulose pulp fibers includes two steps: (1) a first stage of carboxylation; and (2) a stabilization step in which any remaining aldehyde groups are converted to carboxyl groups providing a stable pulp.
[0070] In the first stage of carboxylation, cellulose pulp fibers are oxidized (i.e., oxidized to aldehyde and carboxyl functional groups) under basic pH conditions and in the presence of a secondary oxidizing agent, such as chlorine dioxide, hypochlorite, peracids, or certain metal ions, with a catalytically active species (e.g., an oxammonium ion) generated from a N-halo hindered cyclic amine compound described above.
[0071] The first stage of the carboxylation process generally takes place at a temperature from about 20° C. to about 90° C. The hindered cyclic amine compound or the N-halo hindered cyclic amine compound is present in an amount from about 0.002% to about 0.25% by weight based on the total weight of the pulp. The secondary oxidizing agent is present in an amount from about 0.1 to about 10% by weight based on the total weight of the pulp. Reaction times for the first stage of carboxylating the pulp range from about 5 seconds to about 10 hours, depending upon reaction temperature and the amount of hindered cyclic amine compound or N-halo hindered cyclic amine compound and secondary oxidizing agent.
[0072] Chlorine dioxide is a suitable secondary oxidizing agent. The pH during oxidation should generally be maintained within the range of about 6.0 to 1, preferably about 6.0 to 10, and most preferably about 6.25 to 9.0. The oxidation reaction will proceed at higher and lower pH values, but at lower efficiencies.
[0073] A study was conducted to determine effects of time and chemical loadings on the carboxyl content and viscosity of the pulp. The study was conducted at 50° C. and 70° C.
[0074] In each set of studies, water sufficient to achieve a final pulp consistency of 7.5% was placed in a Quantum mixer. The water was heated to the desired temperature (50° C. or 70° C.). Sodium hydroxide was added to the water in the amounts shown in Tables 2 and 3. 32.1% never-dried partially bleached softwood pulp from the Weyerhaeuser Prince Albert SK mill was added to the water. The pulp was taken from the E2 bleach stage. It weighed 150 g. on an oven-dry basis. The sample was quickly mixed at 100% power.
[0075] 2.25 grams of 2% EGK-TAA (ethylene glycol ketal of triacetonamine) was added to a chlorine dioxide solution. The amount of EGK-TAA was 0.03 weight % of the dry oven dry weight of the pulp. The amount of chlorine dioxide was varied as shown in the Tables 2 through 5.
[0076] The EGK-TAA/chlorine dioxide mixture was injected into the mixer while it was being stirred. Time 0 is the time that the injection of the mixture started.
[0077] At the end of the reaction time the stabilizing mixture was pressure injected into the pulp to quench the stage 1 oxidation and start the stage 2 stabilization. The pulp was stabilized with 0.5% HOOH and 3.9% sulfuric acid (pH<4) for 1 hours. The pH was not measured, but based on earlier experience the pH would have been below 4 and was probably between 2 and 3. There was a yellow color indicating the regeneration of chlorine dioxide by the reaction of chlorite with aldehyde groups which also indicated that the pH was below 4. Each sample was stabilized for about 1 hour. The stabilization temperature was targeted to be either 50° C. or 70° C. All samples were washed with DI water, treated with NaOH to convert the carboxylic acid groups on the pulp to the sodium salt form and washed. The samples were analyzed for carboxyl, viscosity, brightness and brightness reversion.
[0078] The control was the uncarboxylated pulp. The carboxyl content, viscosity, brightness and brightness reversion are shown in table 1.
TABLE 1 Carboxyl Visc Brightness Brightness Example meq/100 g mPa * s ISO Reversion 1 4.61 33.0 85.37 84.17
[0079] The results of the 70° C. tests are shown in Table 2 and the results of the 50° C. tests are shown in Table 3. The results of the 70° C. and 50° C. tests are listed by carboxyl content in Tables 4 and 5, respectively.
TABLE 2 Time ClO 2 NaOH Ratio Carboxyl Visc Brightness Brightness Ex. sec wt. % wt % ClO 2 :NaOH meq/100 g mPa * s ISO Reversion 2 5 1.0 0.70 0.70 7.14 28.0 91.07 89.61 3 5 1.0 1.00 1.00 7.56 24.5 91.74 90.37 4 15 1.0 0.85 0.85 7.85 25.4 91.90 90.45 5 25 1.0 0.70 0.70 8.02 25.8 91.23 89.32 6 25 1.0 1.00 1.00 6.88 19.4 91.39 89.80 7 5 1.2 1.02 0.85 8.35 24.1 91.48 89.99 8 15 1.2 0.84 0.70 8.53 24.8 91.56 90.26 9 15 1.2 1.02 0.85 7.74 20.3 91.55 90.20 10 15 1.2 1.02 0.85 8.11 20.0 92.14 90.56 11 15 1.2 1.02 0.85 8.21 20.2 91.93 90.61 12 15 1.2 1.20 1.00 7.59 19.4 91.64 90.19 13 25 1.2 1.02 0.85 7.32 18.9 91.19 89.73 14 5 1.4 1.40 1.00 7.81 21.6 91.73 90.38 15 5 1.4 0.98 0.70 8.71 24.1 92.00 90.79 16 15 1.4 1.19 0.85 8.77 19.4 92.07 90.65 17 25 1.4 0.98 0.70 9.23 24.8 91.61 90.06 18 25 1.4 1.40 1.00 8.23 17.5 92.22 90.69
[0080]
TABLE 3
Time
ClO 2
NaOH
Ratio
Carboxyl
Visc
Brightness
Brightness
Ex.
sec
wt. %
wt %
ClO 2 :NaOH
meq/100 g
mPa * s
ISO
Reversion
20
5
1.0
0.70
0.70
7.58
29.0
91.66
90.18
19
5
1.0
1.00
1.00
7.12
26.0
91.81
90.34
21
15
1.0
0.85
0.85
6.82
24.8
92.08
90.49
23
25
1.0
0.70
0.70
7.71
27.3
90.87
89.00
22
25
1.0
1.00
1.00
6.74
21.7
92.14
90.71
24
5
1.2
1.02
0.85
7.90
26.0
92.18
90.45
28
15
1.2
0.84
0.70
8.60
27.9
90.91
89.50
26
15
1.2
1.02
0.85
7.58
22.8
91.88
90.35
27
15
1.2
1.02
0.85
8.14
24.9
91.81
90.32
29
15
1.2
1.02
0.85
8.54
25.1
92.13
90.76
30
25
1.2
1.02
0.85
8.21
24.4
92.16
90.69
25
15
1.2
1.20
1.00
6.96
24.2
92.52
91.00
32
5
1.4
0.98
0.70
8.83
26.0
92.19
90.63
31
5
1.4
1.40
1.00
7.85
23.4
92.90
91.42
33
15
1.4
1.19
0.85
8.63
23.6
91.87
90.13
34
25
1.4
0.98
0.70
9.34
27.9
91.77
90.29
35
25
1.4
1.40
1.00
8.03
19.8
92.41
90.79
[0081]
TABLE 4
Time
ClO 2
NaOH
Ratio
Carboxyl
Visc
Brightness
Brightness
Ex.
sec
wt. %
wt %
ClO 2 :NaOH
meq/100 g
mPa * s
ISO
Reversion
6
25
1.0
1.00
1.00
6.88
19.4
91.39
89.80
2
5
1.0
0.70
0.70
7.14
28.0
91.07
89.61
13
25
1.2
1.02
0.85
7.32
18.9
91.19
89.73
3
5
1.0
1.00
1.00
7.56
24.5
91.74
90.37
12
15
1.2
1.20
1.00
7.59
19.4
91.64
90.19
9
15
1.2
1.02
0.85
7.74
20.3
91.55
90.20
14
5
1.4
1.40
1.00
7.81
21.6
91.73
90.38
4
15
1.0
0.85
0.85
7.85
25.4
91.90
90.45
5
25
1.0
0.70
0.70
8.02
25.8
91.23
89.32
7
5
1.2
1.02
0.85
8.35
24.1
91.48
89.99
10
15
1.2
1.02
0.85
8.11
20.0
92.14
90.56
11
15
1.2
1.02
0.85
8.21
20.2
91.93
90.61
18
25
1.4
1.40
1.00
8.23
17.5
92.22
90.69
8
15
1.2
0.84
0.70
8.53
24.8
91.56
90.26
15
5
1.4
0.98
0.70
8.71
24.1
92.00
90.79
16
15
1.4
1.19
0.85
8.77
19.4
92.07
90.65
17
25
1.4
0.98
0.70
9.23
24.8
91.61
90.06
[0082]
TABLE 5
Time
ClO 2
NaOH
Ratio
Carboxyl
Visc
Brightness
Brightness
Ex.
sec
wt. %
wt %
ClO 2 :NaOH
meq/100 g
mPa * s
ISO
Reversion
22
25
1.0
1.00
1.00
6.74
21.7
92.14
90.71
21
15
1.0
0.85
0.85
6.82
24.8
92.08
90.49
25
15
1.2
1.20
1.00
6.96
24.2
92.52
91.00
19
5
1.0
1.00
1.00
7.12
26.0
91.81
90.34
20
5
1.0
0.70
0.70
7.58
29.0
91.66
90.18
26
15
1.2
1.02
0.85
7.58
22.8
91.88
90.35
23
25
1.0
0.70
0.70
7.71
27.3
90.87
89.00
31
5
1.4
1.40
1.00
7.85
23.4
92.90
91.42
24
5
1.2
1.02
0.85
7.90
26.0
92.18
90.45
35
25
1.4
1.40
1.00
8.03
19.8
92.41
90.79
27
15
1.2
1.02
0.85
8.14
24.9
91.81
90.32
30
25
1.2
1.02
0.85
8.21
24.4
92.16
90.69
29
15
1.2
1.02
0.85
8.54
25.1
92.13
90.76
28
15
1.2
0.84
0.70
8.60
27.9
90.91
89.50
33
15
1.4
1.19
0.85
8.63
23.6
91.87
90.13
32
5
1.4
0.98
0.70
8.83
26.0
92.19
90.63
34
25
1.4
0.98
0.70
9.34
27.9
91.77
90.29
[0083] Another set of studies was conducted to determine carboxylation at times of 15 seconds, 30 seconds, 60 seconds, 120 seconds, 180 seconds and 240 seconds.
EXAMPLE 35
[0084] Never-dried partially bleached softwood pulp collected after the E2 bleach stage of the Weyerhaeuser Prince Albert SK mill pulp having an oven dry weight of 60 g, and 9.2 g sodium carbonate was added to 310 g of DI water and the mixture was heated to 70° C. 98 mL of chlorine dioxide, 6.7 g/L, and 1.2 g of ethylene glycol ketal of triacetoneamine (EGK-TAA) were mixed and added to the pulp. The pulp was mixed rapidly by hand. Samples were taken at 15, 30, 60, 120, 180 and 240 seconds after the ClO 2 /EGK-TAA solution first contacted the pulp. Each of the samples were placed in a solution of 0.5 g NaBH 4 in 100 mL of water and left overnight at room temperature with periodic stirring. The pulps were then tested for carboxyl content. The carboxyl content in meq/100 g were as follows: 15 seconds-6.7, 30 seconds-6.8, 60 seconds-7.2, 120 ds-7.5, 180 seconds-7.55, 240 seconds-7.6.
EXAMPLE 36
[0085] Northern softwood partially bleached kraft pulp collected after the E2 stage of the Weyerhaeuser Prince Albert, SK pulp mill was dewatered to 25-30% solids with a screw press.
[0086] All percentages are weight percentages based on the oven dry weight of the pulp.
[0087] The pulp was slurried in water and fed to a twin roll press which delivered pulp at a predetermined constant rate of 3.0 kg/minute pulp solids at 8-9% consistency (weight of pulp/weight of water) to a pilot process. Just after the twin roll press, sodium hydroxide was sprayed on the pulp stream at a rate of 0.65%. The pulp slurry was then mixed and heated in a steam mixer and fed to a Seepex progressive cavity pump which provided pulp slurry flow through two high intensity mixers and an upflow tower. The upflow tower fed a downflow tower by gravity. Pulp product was mined from the bottom of the downflow tower, adjusted to pH 7-9 with sodium hydroxide and dewatered on a belt washer.
[0088] EGK-TAA was dissolved in water and metered into a chlorine dioxide line. The mixture was 0.03% EGK-TAA and 0.88% chlorine dioxide. This line was connected to the pulp slurry process pipe just before it entered the first high intensity mixer. The Chorine dioxide/EGK-TAA mixture was injected into the flowing pulp slurry and immediately mixed in the first high intensity mixer. Just before the second high intensity mixer, a mixture of sulfuric acid (0.17%) and hydrogen peroxide (0.5%) was injected into the pulp slurry. The distance between the 1 st high intensity mixers and the injection of the sulfuric acid/hydrogen peroxide, and the speed of the pulp slurry will determine the reaction time for the first stage of the carboxylation of the pulp. This setup allowed times as short as 6 seconds, but was preferred to be 15-30 seconds. In this example the time was 6 seconds. The pulp immediately enters the 2 nd high intensity mixer and mixed again. The pulp slurry flowed into the upflow tower and spent approximately 30 minutes there before entering the downflow tower where it spent approximately an hour. It was then mined from the bottom of the downflow tower.
[0089] The temperature at the bottom of the upflow tower was maintained at 50° C. by adjustments to the steam flow to the steam mixer. The pH was monitored near the end of the retention pipe prior to the sulfuric acid/hydrogen peroxide injection and was maintained at 6.25-6.75 by minor adjustments to the sodium hydroxide addition level to the pulp after the twin wire press. The pH was monitored at the bottom of the upflow tower and was maintained at 3.5-4.0 by minor adjustments to the sulfuric acid flow.
[0090] The dewatered pulp product had a carboxyl level of 8.5 meq/100 g, an ISO brightness of 90.38% and a viscosity of 25.6 mPa-s.
[0091] It can be seen that short reaction times are possible and that it is possible to use existing equipment with little modification to carboxylate wood pulp.
[0092] FIG. 1 shows a standard extract stage and a chlorine dioxide stage of a pulp mill. Pulp, in slurry form, which has been bleached with a bleaching chemical such as chlorine, chlorine dioxide or hydrogen peroxide is treated with sodium hydroxide is extraction tower 10 . Sodium hydroxide solubilizes the chemicals in the pulp that have reacted with the bleaching chemical. The pulp is carried to washer 12 in which the solubilized material is washed from the pulp.
[0093] The pulp slurry is moved from the washer 12 to the next stage by pump 18 (shown in FIGS. 2 and 3 ) and then mixed with chlorine dioxide in mixer 24 (shown in FIGS. 2 and 3 ) and flows into the upflow section 13 of chlorine dioxide tower 14 . The pulp slurry then passes through the downflow section 15 of the tower 14 where it continues to react with the chlorine dioxide. The slurry then leaves the tower 14 and is washed in a washer 16 (shown in FIGS. 2 and 3 ).
[0094] The short reaction time of the first stage of the carboxylation process allows a simple modification to the standard extraction and chlorine dioxide stage to allow carboxylation and stabilization in these units.
[0095] This is shown in FIGS. 2 and 3 . These are different representations of the process.
[0096] There is an additional mixer and a reaction chamber between the washer 12 and the chlorine dioxide tower 14 .
[0097] The pump 18 mixes a base chemical with the pulp slurry. The base chemical is any chemical which will provide an appropriate pH for the slurry. Sodium hydroxide or sodium carbonate are preferred. Sodium hydroxide is the most preferred because it is the chemical used in the extraction reaction and no new chemical is required. The base chemical is supplied from unit 17 through line 19 . The base chemical may be supplied to the slurry either before or at the pump 18 . The base chemical should be mixed thoroughly with the slurry before the addition of the carboxylation chemicals.
[0098] The mixer 20 mixes the carboxylation chemicals with the pulp slurry. The carboxylation chemicals are supplied from units 21 or 21 ′ through lines 22 and 22 ′. The carboxylation chemicals may be supplied to the slurry either before or at mixer 20 . The carboxylation chemicals may be any of those mentioned. The preferred secondary oxidant is chlorine dioxide. The preferred primary oxidant is triacetoneamine ethylene glycol ketal (TAA-EGK).
[0099] The pulp slurry then enters the reaction chamber 23 in which the first stage of the carboxylation process occurs. The size of the reaction chamber 23 will depend on the length of time of the catalytic oxidation reaction. The reaction chamber will be a tank if the reaction is over 1 minute. It will be a good-sized tank if the reaction is over 2 minutes and a large tank if the reaction is over 15 minutes. The reaction chamber 23 can be a pipe if the reaction is under a minute. It will be a large and probably curved pipe, as shown, if the reaction is over 30 seconds. It can be a straight pipe, and possibly the existing pipe, if the reaction is 30 seconds or less. The reaction can be around 15 seconds and can, in certain instances, be as short as 1 second. The diameter and length will be of a size that will accommodate the flow of pulp slurry for the time required for the oxidation reaction.
[0100] Mixer 24 mixes the stabilization chemicals with the pulp slurry. The stabilization chemicals are supplied from units 25 and 25 ′ through lines 26 and 26 ′. The chemcials may be supplied to the slurry either before or at mixer 24 . The stabilization chemicals can be any of those mentioned. Alkali metal chlorites, hydrogen peroxide, acid, chlorine dioxide and peracids are among the chemicals that may be used. It is preferred that an acid, such as sulfuric acid, and a peroxide, such as hydrogen peroxide, be used. It is most preferred that an acid be used.
[0101] The pulp slurry then enters the upflow section 13 of the chlorine dioxide tower 14 and then transfers to the downflow section 15 of tower 14 . The stabilization reaction occurs in tower sections 13 and 15 .
[0102] While the system has been described in terms of an extraction stage 10 , it can also be used in systems in which there are two chlorine dioxide towers separated by a washing stage. The system would be identical to that described herein except that extraction tower 10 would be a chlorine dioxide tower. It may be necessary to use more chlorine dioxide in this system.
[0103] It can be seen that the system can be changed from a regular pulp bleach stage to a carboxylation stage may simply adding or removing chemicals from the system. The addition of the base chemicals, the catalyst, the acid and the peroxide turns it into a carboxylation unit, the absence of these chemicals returns it to a standard pulp bleach stage.
[0104] Those skilled in the art will recognize that the present invention is capable of many modifications and variations without departing from the scope thereof. Accordingly, the detailed description set forth above is meant to be illustrative only and is not intended to limit, in any manner, the scope of the invention as set forth in the appended claims. It will be noted that other catalytic oxidation and stabilization chemicals may be used, but the chemicals noted are the preferred chemicals.
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An apparatus for carboxylating wood pulp which utilizes the wood pulp bleach plant and the method of carboxylating the pulp which takes place in the bleach plant.
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This application is the national phase of international application PCT/FI95/00501 filed Sep. 14, 1995 which designated the U.S.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a microprocessor environment, wherein a plurality of peripheral devices are connected to a microprocessor (CPU), the microprocessor writing data to and reading data from the peripheral devices. To be more specific, the present invention relates to a method circuit arrangement for implementing timing between a microprocessor and its peripheral devices.
2. Description of the Related Art
FIG. 1 shows a hardware environment as described above, wherein four different (having different speeds) peripheral devices A . . . D are connected to a microprocessor 10 by means of its data bus 11 and address bus 12 in a manner known per se. (It should be noted that in the figures presented below, the signal lines are connected to one another only at those points which are indicated by small circles) . In this exemplifying case, the peripheral device A is a medium-speed (one wait state) EPROM, the peripheral device B is a high-speed (no wait states) SRAM (Static Random Access Memory), the peripheral device C is a low-speed (two wait states) peripheral device, and the peripheral device D is a very low-speed (three wait states) peripheral device. It is also assumed that the address hold time of the peripheral device C is two clock cycles, and that the address hold time of the peripheral device D is three clock cycles. (Address hold time will be defined below). The peripheral devices C and D may be for instance serial input-output controllers or A/D converters.
The wait state mentioned above, which represents the speed of a peripheral device, means that a microprocessor extends the assertion period of signals according to the assertion of a corresponding control signal (if the control signal is not asserted, the microprocessor operates as quickly as it is able to). The control signal is usually referred to as a WAIT signal, and in this exemplifying case, this signal is generated in a decoder 13, wherefrom it is applied to the microprocessor. (In some processors, for instance in processors manufactured by Motorola, a corresponding function is implemented with a signal referred to as ACKNOWLEDGE). In the manner described above, it is thus possible to adjust a microprocessor to wait for slower peripheral devices.
The signals used in FIG. 1 have the meanings represented in the following table. The reference of a signal is formed from its generally used English "name", which is shown in brackets after the reference.
______________________________________Signal Definition______________________________________OE (Output Enable) Opens the data bus buffer of a peripheral device in order for the peripheral device to be able to feed data to the data busWE (Write Enable) A signal which enables data to be written to a peripheral deviceCE (Chip Enable) A peripheral device selection signal by which one peripheral device at a time is se1ected to be active______________________________________
In addition, FIG. 1 shows a clock signal CLK and a WAIT signal, and a control signal STB, the meaning of which will be explained below.
Signals OE are occasionally also referred to by an alternative abbreviation RD (i.e. Read; the microprocessor reads from a peripheral device), and signals WE, correspondingly, by an abbreviation WR (i.e. Write; the microprocessor writes to a peripheral device). When a signal WE is valid, desired data must appear in the inputs of the input register of the peripheral device, and when the signal WE is negated, the desired data remains in the peripheral device (i.e. the new data visible in the inputs is no longer able to be written to the peripheral device).
Selection signals CE are typically generated by combination logic in the decoder 13 from the address appearing over the address bus 11, i.e. the signals CE are activated according to the address appearing over the address bus. A certain address range thus corresponds to each peripheral device in such a manner that when the address is located in this range, a corresponding selection signal CEn (n=1, 2, 3 or 4, depending on which peripheral device is concerned) is active.
Whether it is necessary to generate selection signals CE at all depends on the type of the peripheral device. For instance in peripheral devices wherein only one register is provided, such registers being for instance LED control registers, mere OE and WE signals are required.
When selection signals CEn are used (as is done in the exemplifying case of FIG. 1), the OE and WE signals generated by the microprocessor 10 are applied directly to input pins of the peripheral devices A . . . D corresponding to them.
In the known solution described above, the timing of read and write signals (timing refers to the occurring moments of the rising and/or falling edges of signals, i.e. to the duration of pulses) can be changed only by means of the waiting procedure described above, i.e. by extending the duration of pulses by a certain number of clock cycles by means of control carried out by a WAIT signal.
In the environment described above, it is sometimes problematic as to how the timing requirements of a peripheral device are adapted to those of the microprocessor. This applies especially to writing performed to the peripheral device, since writing takes place on the terms of the peripheral device. As for reading, it is not usually problematic, since it takes place on the terms of the microprocessor. A peripheral device may for instance require a very long address hold time. An address hold time is illustrated in FIG. 2, which shows an address signal ADDR appearing over the bus 12 and a signal WE controlling writing. An address hold time is the time T for which the address ADDR must be active even after the signal WE has been negated (a signal is valid when it is in a logical "0" state). In FIG. 2, a reference symbol ti indicates the moment at which the signal WE is negated, and a reference symbol t2 indicates the moment at which the address is deactivated. An address hold time is sometimes defined also in relation to a selection signal CE in the data books of circuit manufacturers. If hold time requirements are defined in relation to both signals (WE and CE), both requirements must naturally be fulfilled.
Different peripheral devices have different requirements as to how long the address hold time should at least be. These different requirements are due to structural differences between peripheral devices (for instance signal transmission time differences within a peripheral device). A long address hold time cannot however be implemented with the wait state solution described above, because the difference between the moments t1 and t2 generated by the microprocessor will be fixed (constant) in any case.
The problem described above is solved in the known solutions (FIG. 1 is further referred to) by arranging a latch circuit 14 between the microprocessor and a peripheral circuit, and applying the address signal ADDR to the latch circuit. In practice, the latch circuit is a register in which the address is stored until a new address value is applied to the register by means of a separate control signal STB. The control signal is formed from the selection signals CE3 and CE4 of the peripheral devices concerned (in this example, n=3 and n=4, corresponding to the "slow" peripheral devices C and D), which selection signals are connected to the inputs of an AND gate 15. The control signal STB is obtained from the output of the AND gate 15, the control signal being in a logical "0" state when at least one of the selection signals is in a logical "0" state (i.e. is valid) . The signal STB thus determines the moment at which the new address value is stored in the circuit 14, whereby the signal can be used for extending the period for which the address is valid with respect to the peripheral device. In other words, it is a way of extending the address hold time.
However, incorporating a latch circuit and the control required for it in a circuit board renders the practical solution more complicated and thus more expensive. The solution increases especially the number of signal conductors required on the circuit board, which makes circuit board design more difficult.
BRIEF SUMMARY OF THE INVENTION
The object of the present invention is to obviate the disadvantages mentioned above and to provide a solution by means of which the timing requirements of the peripheral devices can be fulfilled by a simpler circuit solution.
The invention generates a signal in the address decoder, the signal controlling at least writing, in such a manner that the timing of the signal (i.e. the rising and falling moments of pulses) is dependent on the address located over the data bus, and is at the same time, within the address cycle relating to the peripheral device, independent of the timing determined by the microprocessor. A signal controlling reading can also be generated in a corresponding manner, even though this is not as useful, since writing is usually a more problematic event with respect to timing requirements.
Due to the solution of the invention, the timing requirements of peripheral devices can be implemented without the latch circuit described above, whereby control circuits required by it and for instance wirings from the latch circuit to the peripheral devices are not needed. This simplification can thus also be seen in the simplification of circuit board design.
In the following, the invention and its preferred embodiments will be described in more detail with reference to FIGS. 3-7d in the examples according to the appended drawings, in which
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a known solution for implementing timing requirements between a microprocessor and its peripheral devices,
FIG. 2 illustrates an address hold time required by a peripheral device,
FIG. 3 shows the solution of the invention for implementing timing requirements between a microprocessor and its peripheral devices,
FIG. 4a is a timing diagram illustrating signals appearing in the hardware environment according to FIG. 3 as regards a fast peripheral device A,
FIG. 4b is a timing diagram illustrating signals appearing in the hardware environment according to FIG. 3 as regards a slow peripheral device D,
FIG. 5 shows a conventional decoder structure,
FIG. 6 shows a decoder structure of the invention, and
FIGS. 7a-7d show write and read cycles corresponding to selection signals generated by the decoder according to FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 shows the solution according to the invention for solving the timing problems described above in a simpler manner. The same components are indicated by the same reference numerals as in FIG. 1.
In the circuit according to FIG. 3, the global signals controlling writing and reading, GWE and GOE, are generated in the address decoder 13 ("global" refers to the fact that the signals are applied to all peripheral devices or at least to the majority of them), and the timing of these signals (i.e. the moments at which said signals are asserted and the moments at which said signals are negated) is determined according to the address range in which the address located over the address bus is currently situated. Thus, when the address is situated in a certain predetermined range, the timing of GWE and GOE signals follows a certain predetermined timing (which is restricted to this range). (It should be noted that only that peripheral device to which the selection signal CEn corresponding to which is valid is active and uses the signals). By binding the timing of signals controlling writing and reading to a valid address (i.e. to a peripheral device) it is possible to solve the specific timing needs, such as the address hold time requirement described above, required by each peripheral device.
FIGS. 4a and 4b illustrate timing as regards a fast peripheral device A (SRAM) and a slow peripheral device D, respectively. In addressing the peripheral device A (FIG. 4a), the microprocessor operates at the highest possible speed, the address hold time characteristic of the microprocessor being indicated by a reference T1. The microprocessor would generate an address hold time of this length irrespective of how long the WAIT signal is active, if the solution according to prior art were used (cf. FIG. 1). If prior art were used in addressing the peripheral device D, the signal controlling writing would thus be valid for a considerably longer time. The moment at which the signal would be negated is indicated by a reference t13 in FIG. 4b. Since the signal controlling writing (GWE) is generated dependently on the address in the decoder 13 in the present invention, however, the address hold time T2 can be significantly extended. The procedure to be followed is thus as follows.
When the address becomes valid at a moment t10, the decoder detects this at the next leading edge of the clock signal CLK, whereby the state counter of the decoder is started, and the signal GWE changes its state (is asserted) at a moment tll. After this, the state counter counts a number of clock cycles (5 clock cycles in this exemplifying case), the number being dependent on the address (i.e. also on the peripheral device), and then negates the signal GWE (moment t12) . If the address were some other address, the state counter could count for instance four or six clock cycles instead of five before negating the signal GWE.
FIGS. 4a and 4b illustrate the idea of the invention only by means of a signal GWE controlling writing, since the idea of the invention is primarily applied to this signal.
In the following, a way of implementing the decoder will be described in detail by describing first a known decoder implementation so that the differences of the invention over the prior art would be better described.
FIG. 5 shows a known decoder structure wherein two selection signals CE0 and CE1, a WAIT signal, and also a write signal WriteStrobe and a read signal OutputEnable are generated. The write signal WriteStrobe is a signal for controlling writing that is active only in a certain address range. As for the read signal OutputEnable, it is a signal for controlling reading which is active only in a certain address range. The signal WriteStrobe is generated by applying one output signal of a decoder circuit 51 and a WE signal generated by a microprocessor to the (inverting) inputs of a first AND gate 52. The signal OutputEnable is generated by applying a second output signal of the decoder circuit 51 and an OE signal generated by the microprocessor to the (inverting) inputs of a second AND gate 53. In the decoder 13 shown in FIG. 1, the part in which WriteStrobe and OutputEnable signals are generated is not needed, the part being indicated by a reference A, but the decoder generating these signals is shown in order to be able to illustrate better the difference of the present invention over the prior art. According to the prior art, it is thus possible to generate write and read signals WriteStrobe and OutputEnable which are active only in a certain address range. The timing of these signals is however not dependent on the valid address, and these signals are not used globally, but they are peripheral device-specific (memory area-specific).
The decoder circuit 51 is a combination logic circuit wherein each output is formed from inputs by means of combination logic. The circuit may be for instance of type 74138, even though all the components of FIG. 5 can be integrated into a single programmable logic device (PLD).
In the circuit of FIG. 5, the WAIT signal is generated in the part indicated by a reference B, by which signal the length of a memory cycle relating to a selection signal CEn is adjusted (in a manner known per se) . The selection signal (CE1 in this case) is applied to the (inverting) Count Enable input CEn and to the reset input CLR (Clear) of a three-bit binary counter 54. The outputs of the counter are connected to the inputs of an AND gate 55 (the middle one of which is inverting), and the output of the AND gate is connected to the R input of an SR flip-flop 56. The selection signal CE1 is connected to the S input of the flip-flop. The WAIT signal is obtained from the (inverting) output of the flip-flop. The clock signal CLK is connected to the clock inputs CLK of the counter 54 and the SR flip-flop.
The known basic structure described above is utilized in the decoder of the invention shown in FIG. 6. The components corresponding to one another have therefore been indicated by the same reference numerals as in FIG. 5. In this case, both of the selection signals are applied to the (inverting) inputs of an OR gate 61, and an input signal to a binary three condition counter is obtained from the (inverting) output of the OR gate in the manner shown in FIG. 5. The selection signals (CE0 and CE1) and the control signals (WE and OE) generated by the microprocessor are also applied to a combination logic part in a block 60, which comprises two logic parts C and D corresponding to each other and an OR gate 64. It should be noted that in this case, the control signals WE and OE generated by the microprocessor are not used for timing in any way, but they are used for only detecting whether a write or read event is concerned (i.e. whether it is necessary to generate a signal controlling writing or reading). Independence from timing determined by a microprocessor is thus achieved by the fact that such signals the timing of which is, within the addressing cycle relating to a peripheral device, dependent on the timing determined by the microprocessor are not used in generating the significant moments of GWE or GOE signals.
In part C is generated the global signal according to the invention for controlling writing, the signal indicated by a reference GWE in this case (as distinct from the signal WE generated by the microprocessor). In the part D, correspondingly, the global signal GOE according to the invention controlling reading is generated. The logic part C comprises (a) a first AND gate, to the inputs of which are applied the. output signals of the counter 54 (the first two inputs are inverting), the selection signal CE1 (an inverting input) and the WE signal generated by the microprocessor (an inverting input), (b) a second AND gate, to the inputs of which are applied the output signals of the counter 54 (the middle one of said inputs is inverting), the selection signal CE0 (an inverting input), and the WE signal generated by the microprocessor (an inverting input), (c) a first OR gate, to the (inverting) inputs of which are applied the selection signals, (d) a second OR gate, to the inputs of which are connected the outputs of the first and the second AND gate, (e) a third AND gate, to the inputs of which are applied the output of the first OR gate and the control signal WE (an inverting input), and (f) a flip-flop SR, to the S input of which is connected the output of the second OR gate and to the R input of which is connected the output of the third AND gate. The part D has a corresponding configuration, but the signal WE is replaced with a signal OE. (In addition, that input of the first AND gate which corresponds to the middle bit of the counter is non-inverting in the case of the block D, and that input of the second AND gate to which the first bit of the counter is applied is inverting and that input to which the second bit of the counter is applied is non-inverting).
The selection signals are applied to the (inverting) inputs of the OR gate 64, and the output of the OR gate is connected to the S input of the SR flip-flop 56. The output of the AND gate 55 is connected to the R input of the SR flip-flop 56 in the same manner as in the known solution (FIG. 5) to generate a WAIT signal to the (inverting) output of the SR flip-flop.
The selection signals CE0 and CE1 are thus formed first from the address located over the bus, after which S and R signals are generated from said selection signals and the output signal of the counter 54 by means of the combination logic according to the figure, the rising and falling edges of the signals GWE and GOE being generated by means of the S and R signals in the SR flip-flops.
FIGS. 7a-7d illustrate writing and reading cycles corresponding to the selection signals of the decoder of FIG. 6. The events represented in the figures are alternative, because writing and reading events cannot take place simultaneously. FIGS. 7a and 7b show the reading and writing events relating to the selection signal CE0, and FIGS. 7c and 7d show correspondingly the reading and writing events relating to the selection signal CE1. The pulse of the signal OE (FIG. 7a) generated by the microprocessor 10 has a fixed duration, and in addition to this, an application-specific signal GOE controlling reading has been generated according to the invention, the timing of said signal being adjustable with respect to the signal OE, i.e. the assertion period of the signal GOE can be adjusted to begin and end with an accuracy of one clock cycle in an arbitrary location. In this exemplifying case, the period begins after the second clock pulse and ends after the seventh clock pulse. FIG. 7b shows correspondingly an application-specific signal GWE controlling writing, the assertion period of which begins after the second clock pulse and ends after the fifth clock pulse. Since the address ADDR is valid simultaneously with the selection signal, the time period T3 (i.e. the address hold time), for instance, may in some cases be too short as regards the peripheral device. The hold time can now be extended by generating a global signal GWE controlling writing, the assertion period of which signal can be adjusted, depending on the address, to begin and end with an accuracy of one clock cycle in an arbitrary location. By means of a WAIT signal, the events are extended in such a manner that the signal WE is valid for a sufficiently long time and that there will be sufficient hold time even after that. The rising edges indicated by circled numerals 1-3 are interconnected in time domain; the waiting signal WAIT is applied to the microprocessor, as a result of which the microprocessor negates the signal WE (the moment corresponding to the circled numeral two) after a certain constant time (1.5 clock cycles in this example), and after that it also negates the selection signal after a certain second constant time (the moment corresponding to the circled numeral three) . If the transient moment of the waiting signal is delayed, the edges of the other mentioned signals are delayed correspondingly.
FIGS. 7c and 7d show the corresponding events as regards the selection signal CE1. The essential point is thus that the transient moments of the signals GOE and GWE are dependent on the address. These transient moments are also, within the addressing cycle relating to a peripheral device, independent of the timing determined by the microprocessor (which timing is based on control signals, the location of which on the time axis is "fixed", cf. the time instants indicated by the circled numerals 1-3 in FIG. 7b). An addressing cycle refers to the cycle for which a certain address (which addresses a peripheral device) is valid. The addressing cycle relating to a certain peripheral device thus ends when the address is negated, also if the next asserted address is directed to the same peripheral device.
As a summary of FIGS. 6 and 7a-7d, the following can be stated. The signal GWE is asserted after one of the selection signals is asserted and after the signal WE is asserted. The signal GWE is negated when the selection signal is active and when the counter 54 reaches its predetermined value (4 or 5 in this example). The signal GOE is asserted after either of the selection signals is asserted and when the signal OE is asserted. The signal GOE is negated when the selection signal is active and when the counter 54 reaches its predetermined value (6). The WAIT signal is asserted after either of the selection signals is asserted and is negated when the counter has reached a predetermined value (4). The counter 54 remains zeroed (the output value is zero) when neither of the selection signals is in a logical "0" state, and counting is allowed when one of the selection signals is asserted (in a logical "0" state).
Even though the invention has been described above with reference to the examples according to the accompanying drawings, it will be apparent that the invention is not so restricted, but it can be modified within the scope of the inventive concept disclosed above and in the appended claims. Thus, even though the problem existing in the background of the invention is illustrated above by using the address hold time required by a peripheral device as an example, it will be apparent that the invention can be used in a corresponding manner for adapting the timing to correspond to the requirements relating to also other parameters of the peripheral device. The detailed circuitry by which the timing of the signals is made dependent on the address may also vary in various ways. It is also possible to generate the signals with their own decoder from the address, but for the sake of simplicity it is preferable to use the same circuit for generation by which the selection signals are generated.
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A method and a circuit arrangement for implementing timing between a microprocessor and its peripheral devices. An address bus and a data bus connect the microprocessor to the peripheral devices to transfer data from the microprocessor to a selected peripheral device, corresponding to writing to the peripheral device, and from a selected peripheral device to the microprocessor, corresponding to reading from the peripheral device. The method comprises generating to the peripheral devices (a) a signal controlling reading (Output Enable), which enables a peripheral device to apply data to the data bus, and (b) a signal controlling writing (Write Enable), which enables data to be written from the data bus to a peripheral device. In order to simplify the equipment and circuit design, at least the signal (GWE) controlling writing is generated by means of an address decoder from the address currently valid on the address bus in such a manner that the moments of the rising and/or falling edges of the signal are dependent on the value of the address and at the same time independent, within the addressing cycle relating to the peripheral device, of the timing determined by the microprocessor, whereby the assertion period of the signal can be adjusted by means of the value of the address.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to Korean Patent Application No. 10-2010-0067412 filed in the Korean Intellectual Property Office on Jul. 13, 2010, the entire contents of which is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a variable compression ratio apparatus. More particularly, the present invention relates to a variable compression ratio apparatus that changes compression ratio of gas mixture in a combustion chamber in accordance with operational conditions of an engine.
[0004] 2. Description of Related Art
[0005] In general, thermal efficiency of heat engines increases when compression ratio is high and when igniting timing increases to a predetermined level in spark ignition engines. However, the spark ignition engines have a limit in increasing the ignition timing because the engines may be damaged by abnormal combustion when the ignition timing is increased at high compression ratio, which necessarily reduce the output power.
[0006] A variable compression ratio (VCR) apparatus is an apparatus that changes compression ratio of gas mixture in accordance with operational conditions of the engine. According to the compression ratio apparatus, fuel efficiency is improved by increasing the compression ratio of gas mixture under the low load condition of the engine, and knocking is prevented and the engine output is improved by reducing the compression ratio of the gas mixture under the high load condition of the engine.
[0007] In order to achieve the variable compression ratio, an oil chamber is formed inside a bias ring disposed in a small portion of a connecting rod and the bias ring is eccentrically rotated by hydraulic pressure generated by supplying oil into the oil chamber, which has been proposed; however, the variable compression ratio apparatus according to the related art has a problem that the distance from the bias ring to the center of the oil chamber is small, such that pressure for maintaining the position of the bias ring in the oil chamber is largely increased when explosion pressure is applied, and it is difficult to maintain the compression ratio.
[0008] Further, there is a problem requiring excessive oil pressure, which is needed to change the compression ratio.
[0009] The information disclosed in this Background of the Invention section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
BRIEF SUMMARY OF THE INVENTION
[0010] Various aspects of the present invention are directed to provide a variable compression ratio apparatus having advantages of having an improved structure to efficiently change compression ratio in a cylinder.
[0011] In an aspect of the present invention, the variable compression ratio apparatus including an external piston, a piston pin mounted in the external piston, a crankshaft, and a connecting rod pivotally connecting the external piston with the crankshaft, may include an internal piston including a slot and sliding up or down in close contact to an interior circumference of the external piston, wherein the piston pin passes through the slot of the internal piston and the external piston, a latching pin passing through the piston pin and selectively sliding therein, variable sliders disposed to selectively contact one of both ends of the latching pin, at both sides thereof to push the one of the both ends to the opposite side, and a support plate slidably supporting the variable sliders such that the variable sliders reciprocate in perpendicular direction to the length direction of the latching pin, wherein one end of a connecting arm selectively rotating may be connected to the variable slider and a sliding direction of the variable sliders may be controlled by rotation of the connecting arm.
[0012] An oil chamber may be formed between the inside of the external piston and the top of the internal piston so as to selectively store oil therein to generate hydraulic pressure, wherein an oil supply channel may be formed in the connecting rod to supply oil to the oil chamber.
[0013] A control channel may be formed in the latching pin to receive oil from the oil supply channel formed in the connecting rod and oil in the control channel may be selectively supplied into the oil chamber by reciprocation of the latching pin.
[0014] Protrusions may be formed on an inner side of the variable sliders to correspond to the both ends of the latching pin, and the protrusions do not face each other in movement direction therebetween.
[0015] The rotary shaft and the variable slider may be connected by the connecting arm, wherein an adaptor integrally rotating with the rotary shaft may be mounted on an external circumferential surface of the rotary shaft, the rotary shaft and the connecting arm may be connected by a first hinge portion of the adaptor, and the connecting arm may be connected with the variable slider by a second hinge portion, such that as the rotary shaft selectively rotates in one direction, the connecting arm reciprocates straight by means of the first hinge portion and the second hinge portion.
[0016] A guide rail that guides the variable sliders reciprocating forward/backward may be formed on one side of a fixing block wherein the fixing block fixes the support plate and slidably supports the variable sliders.
[0017] The rotary shaft may be operated by a separate vacuum actuator.
[0018] An oil supply line may be formed on one side in the internal piston and an oil discharge line may be formed on the other side thereof, wherein an oil discharge hole may be formed through the other side of the internal piston to communicate with an oil chamber through the oil discharge line.
[0019] An oil supply hole may be formed through the one side of the internal piston to selectively communicate with a control channel of the latching pin, wherein a first check valve may be disposed in the oil supply line to selectively connect the control channel of the latching pin to the oil chamber and a second check valves may be disposed in the oil discharge line to selectively discharge the oil from the oil chamber to the outside, wherein a sliding pin may be disposed in the oil supply line to slide therein to open the oil supply line such that the control channel fluid-communicates with the oil chamber, when oil may be supplied to a side of the sliding pin.
[0020] An elastic member may be disposed at one end of the sliding pin to elastically support the end such that the oil supply line may be closed by the elastic member, when oil may be not supplied to the side of the sliding pin.
[0021] Locking protrusions formed to the sliding pin protrude from an external circumferential surface thereof in perpendicular direction to a motion direction of the sliding pin and integrally moves by a motion of the sliding pin, wherein an operational groove may be formed on the external circumferential surface of the internal piston and the locking protrusions protrude through operational holes formed through the operational groove.
[0022] A plurality of support protrusions may be formed downwards on the operation grooves in the internal piston and an operational ring having protrusions corresponding to the support protrusions on the interior circumference thereof may be inserted in the operation grooves, wherein the locking protrusions of the sliding pin and the protrusions of the operational ring may be engaged such that, as the sliding pin reciprocates, the operational ring selectively rotates in both directions by the protrusions of the sliding pin and the protrusions of the operational ring may be selectively engaged with the support protrusions in accordance with reciprocating direction of the operational ring.
[0023] According to the exemplary embodiment of the present invention, since hydraulic pressure may be selectively released or supplied through the oil chamber formed between the external piston and the internal piston, such that it may be possible to achieve a stable and efficient variable compression ratio.
[0024] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view showing a variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0026] FIG. 2 is a perspective view showing a driving part of the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0027] FIG. 3 is an exploded perspective view of FIG. 2 .
[0028] FIG. 4 is an exploded perspective view showing an operation unit of the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0029] FIG. 5 is a cross-sectional view showing a connecting rod used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0030] FIG. 6 is a perspective view showing a piston pin used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0031] FIG. 7 is a cross-sectional view showing when a latching pin has moved to one side from the combination position shown in FIG. 6 .
[0032] FIG. 8 is a cross-sectional view when the latching pin has moved to the other side from the combination position shown in FIG. 6 .
[0033] FIG. 9 is a view when the operation unit of the variable compression ratio apparatus according to an exemplary embodiment of the present invention operates at a high compression ratio and a low compression ratio.
[0034] FIG. 10 is a cross-sectional view when the operation unit of FIG. 9 is at a high compression ratio and a low compression ratio.
[0035] FIG. 11 is a cross-sectional view showing a sliding pin at a high compression ratio and a low compression ratio.
[0036] FIG. 12 is a perspective view showing a piston used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0037] FIG. 13 is a cross-sectional view showing the front and rear sides of the piston used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0038] FIG. 14 is a horizontal cross-sectional view showing the piston used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0039] FIG. 15 is a front view of FIG. 14 .
[0040] FIG. 16 is a perspective view showing a variable slider used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0041] It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.
[0042] In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION OF THE INVENTION
[0043] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0044] An exemplary embodiment of the present invention will hereinafter be described in detail with reference to the accompanying drawings.
[0045] FIG. 1 is a perspective view showing a variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0046] FIG. 2 is a perspective view showing a driving part of the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0047] FIG. 3 is an exploded perspective view of FIG. 2 .
[0048] FIG. 4 is an exploded perspective view showing an operation unit of the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0049] FIG. 5 is a cross-sectional view showing a connecting rod used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0050] FIG. 6 is a perspective view showing a piston pin used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0051] FIG. 7 is a cross-sectional view showing when a latching pin has moved to one side from the combination position shown in FIG. 6 .
[0052] FIG. 8 is a cross-sectional view when the latching pin has moved to the other side from the combination position shown in FIG. 6 .
[0053] FIG. 9 is a view when the operation unit of the variable compression ratio apparatus according to an exemplary embodiment of the present invention operates at a high compression ratio and a low compression ratio.
[0054] FIG. 10 is a cross-sectional view when the operation unit of FIG. 9 is at a high compression ratio and a low compression ratio.
[0055] FIG. 11 is a sliding pin at a high compression ratio and a low compression ratio.
[0056] FIG. 12 is a perspective view showing a piston used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0057] FIG. 13 is a cross-sectional view showing the front and rear sides of the piston used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0058] FIG. 14 is a horizontal cross-sectional view showing the piston used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0059] FIG. 15 is a front view of FIG. 14 .
[0060] FIG. 16 is a perspective view showing a variable slider used in the variable compression ratio apparatus according to an exemplary embodiment of the present invention.
[0061] Referring to FIG. 1 to FIG. 4 , a variable compression ratio apparatus according to the exemplary embodiment of the present invention includes a driving part P composed of a rotary shaft 100 , a connecting arm 110 , and a variable slider 120 , and an operation unit F composed of an external piton 200 reciprocating by means of explosion of fuel in a cylinder of an engine and an internal piston 210 sliding in the external piston 200 , wherein the internal piston 210 includes a slot 150 and the piston pin 230 passes through the slot 150 . The slot 150 is larger than the diameter of a piston pin 230 to allow a sliding motion of the internal piston 210 in the external piston 200 .
[0062] The rotary shaft 100 is selectively rotated in both directions by an actuator 300 separately disposed outside a cylinder block (not provided with reference numeral).
[0063] The actuator 300 may be any device that can operate the rotary shaft 100 , such as a vacuum actuator.
[0064] In this configuration, the external piston 200 mounted in the cylinder block is disposed to reciprocate along the inner wall of the cylinder and operated by a crankshaft 400 operating with the external piston 200 , and the external piston 200 and the connecting rod 220 are connected by the piston pin 230 at the upper end of the connecting rod 220 .
[0065] Further, a latching pin 240 vertically reciprocating in the piston pin 230 is provided.
[0066] Further, a space is defined between the external piston 200 and the internal piston 210 .
[0067] That is, the internal piston 210 is disposed to vertically reciprocate in close contact to the inner circumference of the external piston 200 and an oil chamber 212 temporarily storing oil and generating pressure is formed in the space that is defined when the internal piston 210 moves down.
[0068] Referring to FIG. 5 , a separate oil supply channel 221 may be formed in the connecting rod 220 to supply oil into the oil chamber 212 through a control channel 242 of the latching pin 240 .
[0069] That is, the oil supplied through the oil supply channel 221 selectively communicates with the oil chamber 212 by selectively opening the control channel 241 of the latching pin 240 , in accordance with reciprocation of the latching pin 240 , as explained hereinafter.
[0070] That is, as shown in FIG. 7 and FIG. 8 , the control channel 241 is formed in the latching pin 240 , communicates with the oil supply channel 221 and selectively communicates with the oil chamber 212 in accordance with left-right reciprocation of the latching pin 240 , such that the oil flows into the oil chamber 212 .
[0071] The latching pin 240 includes check valves 215 and 315 and inner surface of the piston pin 230 includes locking grooves 255 such that check valves 215 and 315 are selectively open by being alternatively engaged into the locking grooves 255 in accordance with left-right reciprocation of the latching pin 240 .
[0072] In FIG. 7 , the check valve 215 is configured to control an oil flow of oil supply line 213 such that when the latching pin 240 moves in the left direction, a ball of the check valve 215 is locked to the locking groove 255 and thus the oil supply line 213 opens to supply oil to the oil chamber 212 through oil supply hole 228 formed in the internal piston 210 .
[0073] In contrast, in FIG. 8 , the check valve 315 is configured to control an oil flow of oil discharge line 214 such that when the latching pin 240 moves in the right direction, a ball of the check valve 315 is locked to the locking groove 255 and thus the oil discharge line 214 opens to discharge oil from the oil chamber 212 through oil discharge hole 227 formed in the internal piston 210 .
[0074] In this operation, the rotary shaft 100 is rotated about the axis by the separate actuator 300 . The actuator 300 may be a vacuum actuator, as described above.
[0075] Referring to FIG. 2 and FIG. 3 , two adaptors 101 may be attached to the outer circumferential surface of the rotary shaft 100 .
[0076] The pair of adaptors 101 connects a pair of connecting arms 110 with a pair of variable sliders 120 to integrally operate in accordance with rotation of the rotary shaft 100 .
[0077] A first hinge portion 102 is formed at one end of each of the adaptors 101 .
[0078] The adaptor 101 and the rotary shaft 100 are connected by the first hinge portion 102 , and the connecting arm 110 and the variable slider 120 are connected by a second hinge portion 103 formed at the other ends of the connecting arms 110 .
[0079] That is, as the rotary shaft 100 is rotated by the actuator 300 , the connecting arm 110 rotated by the first hinge portion 102 of the adaptor 101 reciprocates straight.
[0080] Therefore, the variable slider 120 hinged to the second hinge portion 103 of the connecting arm 110 also reciprocates straight.
[0081] In this configuration, the variable slider 120 has a support plate 122 with a guide rail, which assists straight motion, on the outer side.
[0082] Further, as shown in FIG. 16 , protrusions 123 are formed on the opposite inner sides of the variable slider 120 .
[0083] The protrusions 123 is disposed to correspond to both ends of the latching pin 240 .
[0084] Further, both protrusions 123 are positioned without overlapping each other in the front-rear direction.
[0085] That is, when both variable sliders 120 are on the same vertical line, opposite to each other, the protrusions 123 are not positioned on the same vertical line, such that as the variable sliders 120 selectively moves forward and backward, the protrusion 123 of any one of the variable sliders 120 presses any one end 242 of the latching pin 240 .
[0086] The support plate 122 may have a plate shape that is wide such that ensure a movement distance while guiding the variable slider 120 moving straight along the guide rail.
[0087] Further, a fixing block 124 is formed at the lower portion of the support plate 122 to slidably support the variable slider 120 and to fix the support plate 122 .
[0088] The fixing block 124 is provided to firmly fix the variable slider 120 and the support plate 122 in the cylinder block, using a connecting member.
[0089] The fixing block 124 includes a guide rail 144 such that the variable slider 120 slides thereon.
[0090] Referring to FIG. 9 to FIG. 12 , oil flow at a high compression ratio and a low compression ratio in the variable compression ratio apparatus according to the exemplary embodiment of the present invention can be seen.
[0091] FIG. 10A and FIG. 12 A show a low compression ratio, where the oil discharge line 214 formed in the internal piston 210 is opened by the check valve 315 and the oil supply line 213 is closed by the check valve 214 by right motion of the latching pin 240 .
[0092] That is, since the check valve 315 in the oil discharge line 214 of the internal piston 210 is opened and the check valve 215 in the oil supply line 213 is closed, the oil in the oil chamber 212 is discharged through a discharge hole 232 formed through one side of the internal piston 210 .
[0093] In an exemplary embodiment of the present invention, a sliding pin 216 is slidably disposed in the oil supply line 213 and elastically biased by an elastic member 225 . Accordingly, in the low compression ratio, the sliding pin 216 in the oil supply line 213 is moved in the left direction by the elastic member 225 since hydraulic pressure is not supplied in the oil supply line 213 .
[0094] Simultaneously, the hydraulic pressure generated in the oil chamber 212 is removed, such that the external piston 200 moves down.
[0095] FIG. 10B and FIG. 11B show a high compression ratio, where the oil supply line 213 formed in the internal piston 210 is open by the latching pin 240 .
[0096] That is, while the oil is supplied from the oil supply line 213 of the internal piston 210 , the oil discharge line 214 at the other side is closed by the check valve 315 , such that hydraulic pressure is generated in the oil chamber 212 .
[0097] In an exemplary embodiment of the present invention, a sliding pin 216 is slidably disposed in the oil supply line 213 and elastically biased by an elastic member 225 . Accordingly, in the high compression ratio, the sliding pin 216 in the oil supply line 213 is moved in the right direction while hydraulic pressure is supplied in the oil supply line 213 as shown in FIG. 11B .
[0098] Further, as shown in FIG. 14 and FIG. 15 , an operational protrusion 217 formed to the sliding pin 216 protrudes vertically outward with the motion direction of the sliding pin from the external circumferential surface, surrounding the external circumferential surface of the sliding pin 216 .
[0099] Further, an operational groove 218 is formed on the external circumferential surface of the internal piston 210 .
[0100] The operational groove 218 has an operational hole 219 formed radially outward through the groove.
[0101] In this configuration, the operational protrusion 217 protrudes outside the internal piston 210 through the operational hole 219 and operates with a plurality of locking protrusions 223 formed on the inner circumference of an operational ring 222 , which is described below.
[0102] The operational ring 222 is fitted on the external circumferential surface of the internal piston 210 .
[0103] Since the operational ring 222 has a ring shape and has the locking protrusions 223 substantially symmetric at both sides, on the interior circumference, as described above.
[0104] The locking protrusions 223 selectively rotate in both directions by engaging with each other in accordance with reciprocation of the operational protrusion 217 of the sliding pin 216 .
[0105] In this configuration, a support protrusion 224 protruding downward is formed above the operational groove 218 .
[0106] That is, as shown in FIG. 16 , as the operational ring 222 is rotated by the operational protrusion 217 of the sliding pin 216 , the locking protrusions 223 of the operational ring 222 are selectively supported by the support protrusions 224 of the operational groove 218 , or engaged with each other in the up-down direction. Therefore, the height changes by the distance ‘d’, such that the compression ratio changes.
[0107] According to the variable compression ratio apparatus according to the exemplary embodiment of the present invention, it is possible to stably carry combustion load at a high compression ratio in comparison to the structures of the related art, such that is it possible to stably achieve a compression ratio.
[0108] For convenience in explanation and accurate definition in the appended claims, the terms “upper”, “lower”, “inner” and “outer” are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures.
[0109] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the claims appended hereto and their equivalents.
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A variable compression ratio apparatus may include an external piston, a piston pin mounted in the external piston and a connecting rod, including an internal piston including a slot and sliding in an interior circumference of the external piston, wherein the piston pin passes through the internal piston and the external piston, a latching pin passing through the piston pin and selectively sliding therein, variable sliders disposed to selectively contact one of both ends of the latching pin, at both sides thereof to push the one of the both ends to the opposite side, and a support plate slidably supporting the variable sliders such that the variable sliders reciprocate perpendicular to length direction of the latching pin, wherein one end of a connecting arm selectively rotating may be connected to the variable slider and a sliding direction of the variable sliders may be controlled by rotation of the connecting arm.
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BACKGROUND OF THE INVENTION
This application relates generally to photography and, more specifically, to diffusion transfer photographic systems including products and processes.
Diffusion transfer photographic systems wherein images are formed in color by the use of image dye-providing materials such as dye developers are well known in the art. Generally, multicolor transfer images are formed by processing an exposed multicolor photosensitive silver halide element with an aqueous alkaline processing composition distributed between two sheet-like elements, one of these elements including an image receiving layer. The processing composition is so applied and confined within and between the two sheet-like elements as not to contact or wet outer surfaces of the two superposed elements, thus providing a film unit whose external surfaces are dry. The processing composition preferably is distributed in viscous form from a pressure rupturable container.
It is known in the art to carry out development in the presence of development restrainers whereby development of exposed silver halide is continued for a period of time sufficient to form an imagewise distribution of diffusible unoxidized dye developers in undeveloped areas of the silver halide emulsion layer(s) with the unoxidized dye developers being transferred by diffusion to a superposed image receiving element and, after the predetermined development period, restraining further development of exposed silver halide by means of the development restrainer. See, for example, U.S. Pat. No. 3,265,498. Various development restrainers which are useful for such purposes are known including mercaptoazoles such as 1-phenyl-5-mercaptotetrazole. However, the use of such development restrainers is subject to certain limitations. For example, U.S. Pat. No. 3,260,597 discloses that mercaptoazole development restrainers or "arrestors", such as 1-phenyl-5-mercaptotetrazole, can not be used in the aqueous alkaline processing compositon in any appreciable amount because development of exposed silver halide will be stopped prematurely particularly in the outer blue and green sensitive emulsion layers of a multicolor system.
It is also known in the art to use blocked development restrainers which are designed to provide a timed release of a development restrainer during the development process. See, for example, U.S. Pat. No. 3,698,898 which discloses the use of quinone- or naphthoquinone-methide precursors which release a photographic reagent such as 1-phenyl-5-mercaptotetrazole in the presence of alkali; U.S. Pat. No. 4,009,029 which discloses a class of cyanoethyl-containing blocked development restrainers; German Offenlegungsschrift No. 2,427,183 which discloses various blocked development restrainers, and U.S. Pat. Nos. 3,260,597 and 3,265,498, referred to above, which disclose hydrolyzable blocked restrainers.
The use of phenylmercaptetrazole compounds which are substituted on the phenyl ring as development inhibitors in certain conventional photographic systems is also known. See, for example, Research Disclosure, July 1974, page 12, and U.S. Pat. No. 3,295,976.
SUMMARY OF THE INVENTION
The present application relates to a diffusion transfer photographic system wherein the development process is carried out in the presence of phenylmercaptoazoles which are substituted on the phenyl ring.
It is therefore an object of this invention to provide a novel diffusion transfer photographic system.
It is another object to provide a diffusion transfer photographic system wherein development of an exposed photosensitive element is carried out in the presence of phenylmercaptoazole compounds which are substituted on the phenyl ring.
It is a further object to provide such a diffusion transfer photographic system wherein the compounds utilized include a blocking group designed to provide a timed release of the substituted phenylmercaptoazoles during the development process.
Yet another object is to provide a diffusion transfer photographic process wherein the pH of the processing composition initially is substantially equal to or greater than the pKa of the substituent on the phenyl ring of the phenylmercaptoazole compound and subsequently, during development, the pH is lowered below the pKa.
Still another object is to provide a diffusion transfer photographic system wherein the substituted phenylmercaptoazole compounds may be incorporated in the aqueous alkaline processing composition.
A further object is to provide a diffusion transfer photographic system wherein the substituted phenylmercaptotetrazole compounds may be incorporated in the photosensitive element.
Yet another object is to provide a diffusion transfer photographic system wherein the photographic speed of one or more silver halide emulsions may be increased.
A still further object is to provide a diffusion transfer photographic system wherein fog development may be decreased.
Another object is to provide novel color diffusion transfer photographic products and process.
BRIEF SUMMARY OF THE INVENTION
These and other objects and advantages are accomplished in accordance with the invention by providing a diffusion transfer photographic system wherein development of an exposed photosensitive element with an aqueous alkaline processing composition is carried out in the presence of compounds which are represented by the formula ##STR2## wherein X represents the nonmetallic atoms necessary to form a nucleus which completes a 5- or 6-membered heterocyclic moiety on said structure including substituted rings and fused rings; R is H, an alkali metal or a group which is cleavable in a photographic aqueous alkaline processing composition; and R 1 is either a group which has a pKa of from about 7 to about 14 which is ionizable to an anion, preferably about 8.5 or above, whereby the silver salt of the mercaptan (resulting from cleavage or ionization of --SR) is rendered more soluble in the pH range within which R 1 is ionized to an anion than it is below that pH range, or a precursor of such a group.
The compounds which are useful according to the invention are generally phenylmercaptoazoles wherein the substituted phenyl moiety is attached to either a nitrogen atom or a carbon atom of the azole moiety. Accordingly, the compounds may be represented by either of the following formulas which are both within generic Formula A. ##STR3##
The heterocyclic moieties formed by X preferably include those wherein the heterocyclic atoms (i.e., atoms other than carbon) are members of a single heterocyclic ring as contrasted with compounds containing fused or condensed heterocyclic rings in which the heterocyclic atoms are members of more than one heterocyclic ring. Typical suitable compounds include monoazoles such as benzoxazoles, benzothiazoles, etc.; diazoles such as benzimidazoles; triazoles such as 1,2,4-triazoles, etc.; tetrazoles and pyrimidines. In a preferred embodiment of the invention the compounds include a tetrazole nucleus.
The substituent (R 1 ) on the phenyl moiety may be either any suitable substituent which has a pKa of from about 7 to about 14 which is ionizable to an anion whereby the silver salt of the mercaptan (resulting from cleavage or ionization of --SR) is rendered more soluble in the pH range within which R 1 is ionized to an anion than it is below that pH range, or a precursor of such a substituent. Typical suitable substituents are: ##STR4## where Z is H, alkyl having from 1 to 10 carbon atoms, aralkyl such as benzyl or phenethyl, phenyl or substituted phenyl.
The compounds within generic formula A wherein R 1 is ##STR5## are novel compounds and are disclosed and claimed in our copending patent application Serial No. 222,543, filed on even date herewith.
As stated previously, the compounds may include a mercaptan group attached to a carbon atom of the azole nucleus or may include a blocking group attached to the sulfur atom with the blocking group designed to cleave from the molecule in an aqueous alkaline medium to provide a timed release of the desired phenylmercaptoazole compound. Where R is a blocking group it may be any suitable blocking group such as, for example, those which cleave by hydrolysis; those which cleave by quinone methide elimination (e.g., R is ##STR6## such as disclosed in U.S. Pat. No. 3,698,898; those which cleave by hydrolysis followed by quinone methide elimination (e.g., R is ##STR7## and those which cleave by β-elimination (e.g., R is ##STR8## where R 2 is alkyl, and ##STR9## where R 3 and R 4 are H or alkyl). Typical suitable blocking groups include, for example, ##STR10## and succinimido groups which are substituted on the nitrogen atom with alkyl or aryl as disclosed in U.S. Pat. No. 3,888,677.
In a preferred embodiment of the invention, R is --CH 2 --CH 2 SO 2 R 5 where R 5 is alkyl, aryl or substituted aryl. Novel sulfone compounds within Formula A wherein R is --CH 2 --CH 2 SO 2 R 5 and their use in photographic applications are disclosed and claimed in copending patent application Ser. No. 222,504 of James R. Bartels-Keith and Alan L. Borror, filed on even date herewith.
Cleavage of the blocking group in aqueous alkaline medium releases, in a timed fashion during development, the substituted phenylmercaptoazole moiety. Cleavage of the blocking group occurs according to the following reaction sequence: ##STR11## where R' is R minus a proton. The rate of release of the substituted phenylmercaptoazole moiety is temperature dependent, that is, more is released as the temperature at which processing of the film unit is effected rises. Thus, more of the substituted phenylmercaptoazole moiety is made available at elevated temperatures, i.e., above room temperature, where more is typically desired, less is released at room temperature and even less below room temperature where lesser amounts are needed. Thus, these blocked compounds which are utilized according to the invention provide more uniform sensitometry for the film units of the invention over a wide temperature range of processing. In other words, the sensitometry of the film units which include such blocked compounds according to the invention is less temperature dependent than would otherwise be the case.
The compounds which are useful according to the invention have been found to modify and/or control the sensitometry when present during diffusion transfer processing of an exposed photosensitive element, particularly when such processing is carried out at elevated temperatures, e.g., at about 95° F. Such modification and/or control include a speed increase for one or more of the silver halide emulsions in a multicolor diffusion transfer photographic system and/or an increase in the D max of one or more of the individual colors due to control of fog development, as will be illustrated in detail below herein. The advantageous results obtained through the use of the mercaptoazole compounds according to the invention are not completely understood. However, to further aid those skilled in the art to understand and practice the invention, the proposed theoretical mechanism by which the advantageous results are thought to be effected will be discussed here. It should be understood, however, that the diffusion transfer photographic system has been proved to be operative and highly effective through extensive experimentation and the proposed theoretical mechanism is not to be construed as being limiting of the invention. It is theorized that the results obtained according to the invention are due to the compounds performing different functions at different stages of the development process, that is, as weak silver solvents and promoters of development at one stage of the development process and as development inhibitors, or restrainers, at another stage of the development process, and that the duel functions of these compounds within the diffusion transfer photographic system are pH dependent.
It is well known that in the diffusion transfer photographic development process the pH of any particular location within the film unit varies with time. Typically, the processing composition employed in the process has a very high pH, e.g., from about 13-14, and during the development process each layer of the multilayer film unit goes through a broad pH range which includes very high pH levels and relatively low pH levels. When the pH is substantially equal to or above the pKa of the substituent R 1 on the phenyl ring, the dianion is formed, for example, ##STR12## and acts as a weak silver solvent to form relatively soluble silver salts, thus promoting development. When the pH falls below the pKa of the substitutent R 1 , the monoanion is formed, for example, ##STR13## and the silver salt of the monoanion of the compound is very low in solubility resulting in a development restrainer action.
In the instances where certain substituted phenylmercaptotetrazole compounds were taught for use in specified photographic applications, i.e., the Research Disclosure article and U.S. Pat. No. 3,295,976, previously cited, the processes do not involve different pH at different stages of the development process. Thus, the pH-dependent dual functions of these compounds were not known or utilized in the processes disclosed in these references.
The compounds used according to the invention may be incorporated in various locations within the diffusion transfer film unit such as, for example, in the processing composition, in one or more layers within the photosensitive element or in one or more layers in the image-receiving element such as the image-receiving layer. In view of the foregoing discussion, it will be understood that, according to the invention, development of the exposed photosensitive element is carried out with a processing composition having an initial pH substantially equal to or above the pKa of R 1 , at least for some period of time after the processing composition comes into contact with the mercaptoazole compound so as to enable the substituent to ionize to form the dianion. In addition, at some point during the development process the pH of the environment where the compound is located is reduced below the pKa of R 1 so as to form the monoanion.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention as well as other objects and further features thereof, reference is made to the following detailed description of various preferred embodiments thereof taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a graphical illustration of the relative amount of silver developed with respect to time in exposed and unexposed areas for a control film unit and a film unit according to the invention, both processed at room temperature; and
FIG. 2 is a similar graphical illustration for the same film units processed at 95° F.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred compounds which are employed in accordance with the invention are represented by the formulas ##STR14##
The mercaptoazole compounds which are useful according to the invention may be prepared by reactions which are well known in the art. For example, 2-mercaptoimidazoles can be prepared by the reactions disclosed in The Chemistry of Heterocyclic Compounds Vol. 6: Imidazole and Its Derivatives, Part I, Hofmann, Interscience Publishers, Inc., New York, 1953, pages 77-85; Mercaptothiazoles and mercaptobenzothiazoles can be prepared according to the methods disclosed in The Chemistry of Heterocyclic Compounds Vol. 34: Thiazole and Its Derivatives, Part I, Metzger, John Wiley and Sons, 1979, pages 260-269; Part 2, pages 370-377; benzoxazolethiones can be prepared according to the methods disclosed in Heterocyclic Compounds, Vol. 5, Elderfield, John Wiley and Sons, 1957, pages 439-444; 5-mercapto-1,3,4-oxadiazoles can be prepared according to the methods disclosed in Heterocyclic Compounds, Vol. 7, Elderfield, John Wiley and Sons, 1961, page 352; mercapto-1,3,4-thiadiazoles, ibid, pages 587-612; and tetrazoles by the techniques disclosed in Heterocyclic Compounds, Vol. 8, Elderfield, John Wiley and Sons, 1967, pages 1-107. Mercapto-1,2,4-triazoles can be prepared by known literature techniques as described, for example, in Jour. Chem. Soc. E. Haggarth 1163 (1949). The compounds within Formulas A, B and C where R is a blocking group can be prepared also by known reactions such as by preforming the monosodium salt of the appropriate mercaptoazole derivative and carrying out a condensation reaction with the appropriate blocking group in a solvent such as acetone, ethanol, acetonitrile, etc., or by reacting the mercaptoazole derivative with the appropriate blocking group in a suitable solvent in the presence of one equivalent of sodium bicarbonate. Alternatively, the appropriate mercaptoazole derivative can be formed and the blocking group attached by means of a Michael addition with an appropriate olefin such as CH 2 ═CH--Y where Y is an electron withdrawing group such as cyano, etc., according to known teachings in the art.
The preparation of compound I is described in Pharmazie, 29(2), (1974), pp 95-99. The preparation of compound IV is described in Khim. Geterotsikl. Soedin., Sb.1: Azotsoderzhashchie Geterotsikl, 1967, pp 199-201. Compounds VI and VII can be prepared in accordance with the disclosure of U.S. Pat. No. 3,295,976.
Compound II is a per se novel compound and is one of the compounds claimed in our copending patent application, Ser. No. 222,543, filed on even date herewith. Compounds XII-XIX are per se novel compounds and are claimed in our copending patent application, Ser. No. 222,542, filed on even date herewith.
As stated previously, R 1 may also be a precursor of a substituent which has the requisite properties and the desired substituent may be formed in situ. For example, where it is desired to develop the exposed photosensitive element in the presence of a compound within Formula A which has a hydroxy group on the phenyl ring, it is possible to incorporate in the film unit as a precursor a compound within Formula A which has a hydrolyzable ester group on the phenyl ring and generate the desired hydroxy group in situ during photographic processing.
It should be noted here that the acetyl group which is substituted on the phenyl ring in compound XI does not ionize to any appreciable extent to form an anion in an aqueous alkaline photographic processing composition. However, it has been shown by experimentation that incorporating compound XI in a film unit according to the invention will provide advantageous results. Thus, it would appear that compound XI undergoes a change in aqueous alkaline processing composition and that the acetyl substituent is a precursor of a group which has the requisite properties described above which provide the desired results. It has also been found that when incorporated in the processing composition for a period of time, for example, about a week or more, prior to processing of the exposed photosensitive element, the compound does not provide the desired results, thus indicating that it has long term instability characteristics in the aqueous alkaline processing composition. It is therefore preferred to incorporate the compound elsewhere in the film unit, for example, in the photosensitive element.
Table I lists the pka of various substituents in certain of the compounds illustrated above.
TABLE I______________________________________COMPOUND pKa______________________________________I 10.10 ± 0.1II 11.4III 9.50 ± 0.1IV 9.95 ± 0.1V 11.55 ± 0.1VI 9.55 ± 0.1VII 8.65 ± 0.1IX 8.80 ± 0.1______________________________________
Solubility product measurements were made for the silver salt of phenylmercaptotetrazole (PMT) at pH 13.5 and for the silver salt of compound II at pH 7 and pH 13.5 (above and below the pka of the oxime substituent). The results are listed in Table II.
TABLE II______________________________________COMPOUND pH Ksp______________________________________PMT 7 3 × 10.sup.-16 * 13.5 4 × 10.sup.-16II 7 ˜1 × 10.sup.-16 13.5 2 × 10.sup.-15______________________________________ *Z. C. H. Tan, Photogr. Sci. Eng. 19, 17 (1975)
It is seen that while phenylmercaptotetrazole was relatively unaffected by pH the ionization of the oxime substituent increased the solubility of the silver salt of compound II by an order of magnitude.
The solubilities of the silver salts of PMT and compound II in the presence of excess amounts of their anions were measured at pH 7.0 and 13.5. Each solution was 4×10 -3 molar in silver. The results are shown in Table III wherein the solubility data is expressed in μmoles/liter of total silver.
TABLE III______________________________________ COMPOUND II PMTMolar Ratio pH pHCompound/Ag 7.0 13.5 7.0 13.5______________________________________1.25/1 <1 19 <1 11.75/1 <1 44 <1 22.13/1 <1 93 1 42.5/1 2 140 3 84.5/1 2 320 15 187.5/1 5 1400 58 63______________________________________
It can be seen that compound II is a weak to moderate silver solvent at high pH while PMT is not. Further, it is evident that when the oxime substituent is protonated it reverts to behavior which is similar to that of PMT. In fact, compound II forms an even less soluble salt in neutral solution than does PMT, thus giving it greater differentiation on the availability of silver in soluble form as the pH drops in the diffusion transfer development process.
As stated previously, the compounds which are employed according to the invention may be incorporated in any location in the film unit with the preferred location in any particular instance being dependent upon various factors such as the compound itself, the type of film unit and the results desired. The compounds generally may be incorporated in the film unit in any useful amount. Routine scoping tests may be used to ascertain the concentration appropriate for any given film unit and location. When the compounds are incorporated in the processing composition they are present preferably in an amount of from about 0.02 to about 0.07% by weight. When incorporated in a layer in the photosensitive element the compounds are typically present in a ratio of from about 1 mg/m 2 to about 3 mg/m 2 to about 3800 mg/m 2 of silver. It has been observed that, typically, where the compounds are incorporated in the photosensitive element, the total amount required per film unit to give a desired result is less than that required when the compound is incorporated in the processing composition. It has also been observed that too great an amount of the compounds can lead to reduced control of one or more of the image dye-providing materials which results in high D min values in the photographic reproduction or can lead to a loss in D max for one or more colors as will be apparent from the Examples.
In a preferred embodiment of the invention compounds according to the invention can be incorporated in more than one location in the diffusion transfer film unit. For example, part of the total quantity of the substituted phenylmercaptoazole compound can be incorporated in the processing composition and the remainder in the photosensitive element. Thus, during the initial stages of development, the quantity available can be appropriate to provide a speed increase for one or more silver halide emulsions (silver solvent effect) without providing any undesired premature development restraint and the additional quantity dissolved during processing could give a total concentration desired to prevent further development. This embodiment is particularly useful where R is H or an alkali metal for the compound incorporated in the processing composition and R is a cleavable group for the compound incorporated in the photosensitive element.
The compounds used in accordance with the invention may be used generally in association with any silver halide emulsion. It is preferred to use the compounds in a diffusion transfer photographic system which includes a negative silver halide emulsion, i.e., one which develops in the areas of exposure. The diffusion transfer photographic system of the invention may include any image dye-providing material in association with the silver halide emulsion(s).
The image dye-providing materials which can be utilized generally may be characterized as either (1) initially soluble or diffusible in the processing composition but which are selectively rendered nondiffusible imagewise as a function of development; or (2) initially insoluble or nondiffusible in the processing composition but which selectively provide a diffusible product imagewise as a function of development. The image dye-providing materials may be complete dyes or dye intermediates, e.g., color couplers. The requisite differential in mobility or solubility may be obtained, for example, by a chemical reaction such as a redox reaction, a coupling reaction or a cleavage reaction. In a particularly preferred embodiment of the invention the image dye-providing materials are dye developers which are initially diffusible materials. The dye developers contain, in the same molecule, both the chromophoric system of a dye and a silver halide developing function as is described in U.S. Pat. No. 2,983,606. Other image dye-providing materials which may be used include, for example, initially diffusible coupling dyes such as are useful in the diffusion transfer process described in U.S. Pat. No. 3,087,817 and which are rendered nondiffusible by coupling with the oxidation product of a color developer; initially nondiffusible dyes which release a diffusible dye following oxidation, sometimes referred to as "redox dye releaser" dyes, such as described in U.S. Pat. Nos. 3,725,062 and 4,076,529; initially nondiffusible image dye-providing materials which release a diffusible dye following oxidation and intramolecular ring closure as are described in U.S. Pat. No. 3,433,939 or undergo silver assisted cleavage to release a diffusible dye in accordance with the disclosure of U.S. Pat. No. 3,719,489; and initially nondiffusible image dye-providing materials which release a diffusible dye following coupling with an oxidized color developer as described in U.S. Pat. No. 3,227,550.
The compounds may be incorporated into the photographic elements by any suitable technique. In embodiments where the compounds are incorporated in a separate discrete layer or in a silver halide emulsion layer they are typically coated from a water dispersion and the layer includes a binder material such as gelatin or the like-
The diffusion transfer film units of the invention include those wherein the image receiving element is designed to be separated from the photosensitive element after processing and integral positive-negative diffusion transfer film units which are retained intact after processing. In a preferred embodiment the diffusion transfer film units of the invention utilize initially diffusible dye developers as the image dye-providing materials. As described in U.S. Pat. No. 2,983,606, a photosensitive element containing a dye developer and a silver halide emulsion in photoexposed and a processing composition applied thereto, for example, by immersion, coating, spraying, flowing, etc., in the dark. The exposed photosensitive element is superposed prior to, during, or after the processing composition is applied, on a sheet-like support element which may be utilized as an image-receiving element. In a preferred embodiment, the processing composition is applied to the exposed photosensitive element in a substantially uniform layer as the photosensitive element is brought into superposed relationship with the image-receiving layer. The processing composition, positioned intermediate the photosensitive element and the image-receiving layer, permeates the emulsion to initiate development of the latent image contained therein. The dye developer is immobilized or precipitated in exposed areas as a consequence of the development of the latent image. This immobilization is apparently, at least in part, due to a change in the solubility characteristics of the dye developer upon oxidation and expecially as regards its solubility in alkaline solutions. It may also be due in part to a tanning effect on the emulsion by oxidized developing agent, and in part to a localized exhaustion of alkali as a result of development. In unexposed and partially exposed areas of the emulsion, the dye developer is unreacted and diffusible and thus provides an imagewise distribution of unoxidized dye developer, diffusible in the processing composition, as a function of the point-to-point degree of exposure of the silver halide emulsion. At least part of this imagewise distribution of unoxidized dye developer is transferred, by imbibition, to a superposed image-receiving layer or element, said transfer substantially excluding oxidized dye developer. The image-receiving layer receives a depthwise diffusion, from the developed emulsion, of unoxidized dye developer without appreciably disturbing the imagewise distribution thereof to provide a reversed or positive color image of the developed image. The image-receiving element may contain agents adapted to mordant or otherwise fix the diffused, unoxidized dye developer. In a preferred embodiment of said U.S. Pat. No. 2,983,606 and in certain commercial applications thereof, the desired positive image is revealed by separating the image-receiving layer from the photosensitive element at the end of a suitable imbibition period. Alternatively, as also disclosed in said U.S. Pat. No. 2,983,606, the image-receiving layer need not be separated from its superposed contact with the photosensitive element, subsequent to transfer image formation, if the support for the image-receiving layer, as well as any other layers intermediate said support and image-receiving layer, is transparent and a processing composition containing a substance, e.g., a white pigment, effective to mask the developed silver halide emulsion or emulsions is applied between the image-receiving layer and said silver halide emulsion or emulsions.
Dye developers, as noted in said U.S. Pat. No. 2,983,606, are compounds which contain, in the same molecule, both the chromophoric system of a dye and also a silver halide developing function. By "a silver halide developing function" is meant a grouping adapted to develop exposed silver halide. A preferred silver halide development function is a hydroquinonyl group. In general, the development function includes a benzonoid developing function, that is, an aromatic developing group which forms quinonoid or quinone substances when oxidized.
Multicolor images may be obtained using dye developers in diffusion transfer processes by several techniques. One such technique contemplates obtaining multicolor transfer images utilizing dye developers by employment of an integral multilayer photosensitive element, such as is disclosed in the aforementioned U.S. Pat. No. 2,983,606 and in U.S. Pat. No. 3,345,163, wherein at least two selectively sensitized photosensitive strata, superposed on a single support, are processed, simultaneously and without separation, with a single common image-receiving layer. A suitable arrangement of this type comprises a support carrying a red-sensitive silver halide emulsion stratum, a green-sensitive silver halide emulsion stratum and a blue-sensitive silver halide emulsion stratum, said emulsions having associated therewith, respectively, for example, a cyan dye developer, a magenta dye developer and a yellow dye developer. The dye developer may be utilized in the silver halide emulsion stratum, for example in the form of particles, or it may be disposed in a stratum behind the appropriate silver halide emulsion strata. Each set of silver halide emulsion and associated dye developer stata may be separated from other sets by suitable interlayers, for example, by a layer or stratum of gelatin or polyvinyl alcohol. In certain instances, it may be desirable to incorporate a yellow filter in front of the green-sensitive emulsion and such yellow filter may be incorporated in an interlayer. However, where desirable, a yellow dye developer of the appropriate spectral characteristics and present in a state capable of functioning as a yellow filter may be so employed and a separate yellow filter omitted.
Particularly useful products for obtaining multicolor dye developer images are disclosed in U.S. Pat. No. 3,415,644. This patent discloses photographic products wherein a photosensitive element and an image-receiving element are maintained in fixed relationship prior to exposure, and this relationship is maintained as a laminate after processing and image formation. In these products, the final image is viewed through a transparent (support) element against a light-reflecting, i.e., white background. Photoexposure is made through said transparent element and application of the processing composition provides a layer of light-reflecting material to provide a white background. The light-reflecting material (referred to in said patent as an "opacifying agent") is preferably titanium dioxide, and it also performs an opacifying function, i.e., it is effective to mask the developed silver halide emulsions so that the transfer image may be viewed without interference therefrom, and it also acts to protect the photoexposed silver halide emulsions from postexposure fogging by light passing through said transparent layer if the photoexposed film unit is removed from the camera before image-formation is completed.
U.S. Pat. No. 3,647,437 is concerned with improvements in products and processes disclosed in said U.S. Pat. No. 3,415,644, and discloses the provision of light-absorbing materials to permit such processes to be performed, outside of the camera in which photoexposure is effected, under much more intense ambient light conditions. A light-absorbing material or reagent, preferably a pH-sensitive phthalein dye, is provided so positioned and/or constituted as not to interfere with photoexposure but so positioned between the photoexposed silver halide emulsions and the transparent support during processing after photoexposure as to absorb light which otherwise might fog the photoexposed emulsions. Furthermore, the light-absorbing material is so positioned and/or constituted after processing as not to interfere with viewing the desired image shortly after said image has been formed. In the preferred embodiments, the light-absorbing material, also sometimes referred to as an optical filter agent, is initially contained in the processing composition together with a light-reflecting material, e.g., titanium dioxide. The concentration of the light-absorbing dye is selected to provide the light transmission opacity required to perform the particular process under the selected light conditions.
In a particularly useful embodiment, the light-absorbing dye is highly colored at the pH of the processing composition, e.g., 13-14, but is substantially non-absorbing of visible light at a lower pH, e.g., less than 10-12. This pH reduction may be effected by an acid-reacting reagent appropriately positioned in the film unit, e.g., in a layer between the transparent support and the image-receiving layer.
The dye developers are preferably selected for their ability to provide colors that are useful in carrying out subtractive color photography, that is, the previously mentioned cyan, magenta and yellow. The dye developers employed may be incorporated in the respective silver halide emulsion or, in the preferred embodiment, in a separate layer behind the respective silver halide emulsion, and such a layer of dye developer may be applied by use of a coating solution containing the respective dye developer distributed, in a concentration calculated to give the desired coverage of dye developer per unit area, in a film-forming natural, or synthetic, polymer, for example, gelatin, polyvinyl alcohol, and the like, adapted to be permeated by the processing composition.
Other diffusion transfer products and processes according to the invention are the types described in U.S. Pat. Nos. 3,573,043 and 3,594,165. For convenience, the entire disclosure of each of the six patents referred to immediately above is hereby incorporated by reference herein.
A particularly useful film unit according to the invention is one wherein the photosensitive element includes a light-reflecting layer between the silver halide layer and the image dye-providing layer (as described in Canadian Pat. No. 668,952), the substrate of the photosensitive element carries the polymeric acid neutralizing layer which in turn carries the timing layer (as described in U.S. Pat. No. 3,573,043) and the processing composition includes an oximated polydiacetone acrylamine thickening agent (as described in U.S. Pat. No. 4,202,694.
The invention will now be described further in detail with respect to specific preferred embodiments by way of examples, it being understood that these are illustrative only and the invention is not intended to be limited to the materials, conditions process parameters, etc. which are recited therein. All parts and percentages are by weight unless otherwise indicated.
EXAMPLE I
As a control a film unit was prepared as follows: The photosenstive element comprised a subcoated transparent polyethylene terephthalate photographic film base having coated thereon the following layers in succession:
1. a layer of sodium cellulose sulfate coated at a coverage of about 27.6 mgs/m 2 ;
2. a layer of a cyan dye developer represented by the formula ##STR15## dispersed in gelatin and coated at a coverage of about 747 mgs/m 2 of the dye developer and about 1554 mgs/m 2 of gelatin and including about 68 mgs/m 2 of 4'-methylphenylhydroquinone and about 270 mgs/m 2 of 2-phenylbenzimidazole;
3. a red-sensitive silver iodobromide emulsion layer coated at a coverage of about 1280 mgs/m 2 of silver and about 768 mgs/m 2 of gelatin;
4. an interlayer comprising about 2505 mgs/m 2 of a 60-29-6-4-0.4 pentapolymer of butylacrylate, diacetone acrylamide, methacrylic acid, styrene and acrylic acid and about 78 mgs/m 2 of polyacrylamide;
5. A layer of a magenta dye developer represented by the formula ##STR16## dispersed in gelatin and coated at a coverage of about 646 mgs/m 2 of the dye developer, about 448 mgs/m 2 of gelatin and including about 229 mgs/m 2 of 2-phenylbenzimidazole;
6. a green-sensitive silver iodobromide layer coated at a coverage of about 1050 mgs/m 2 of silver and about 504 mgs/m 2 of gelatin;
7. a layer comprising about 215 mgs/m 2 of dodecylamino-reductone and about 215 mgs/m 2 of gelatin;
8. an interlayer comprising about 1366 mgs/m 2 of the pentapolymer described in layer 4, about 87 mgs/m 2 , about 78 mgs/m 2 of polyacrylamide and about 71 mgs/m 2 of succindialdehyde;
9. a layer of a yellow dye developer represented by the formula ##STR17## dispersed in gelatin and coated at a coverage of about 968 mgs/m 2 of dye developer and about 451 mgs/m 2 of gelatin and including about 208 mgs/m 2 of 2-phenylbenzimidazole;
10. a blue-sensitive silver iodobromide emulsion layer coated at a coverage of about 1280 mgs/m 2 of silver, about 775 mgs/m 2 of gelatin and about 306 mgs/m 2 of 4-methyl phenyl hydroquinone;
11. an overcoat layer coated at a coverage of about 461 mgs/m 2 of gelatin and about 21 mgs/m 2 of carbon black.
The image-receiving element comprised a transparent polyethylene terephthalate film base coated with the following layers in succession:
1. as a polymeric acid layer approximately 9 parts of a 1/2 butyl ester of polyethylene/maleic anhydride copolymer and 1 part of polyvinyl butyral coated at a coverage of about 2450 mgs/ft 2 (26,372 mgs/m 2 );
2. a timing layer containing about 425 mgs/ft 2 (4575 mgs/m 2 ) of a 60-30-4-6 tetrapolymer of butyacrylate, diacetone acrylamide, styrene and methacrylic acid and including 9% polyvinyl alcohol; and
3. a polymeric image receiving layer of: (a) 3 parts of a mixture of 2 parts polyvinyl alcohol and 1 part poly-4-vinyl pyridine and (b) 1 part of a graft copolymer comprised of 4-vinylpyridine (4VP) and vinylbenzyl trimethyl ammonium chloride (TMQ) grafted onto hydroxyethyl cellulose (HEC) at a ratio of HEC/4VP/TMQ of 2.2/2.2/1 coated at a coverage of about 300 mgs/ft 2 (3229 mgs/m 2 ).
The film unit was processed with an aqueous alkaline processing composition as follows:
______________________________________Titanium dioxide 38.05 g.Carboxymethyl hydroxyethyl cellulose 2.00 gPotassium hydroxide (45% aqueous solution) 11.11 g.Benzotriazole 0.28 g.6-methyl uracil 0.30 g.Nhydroxyethyl-N,N',N'tris-carboxymethyl ethylene diamine 0.75 g.Polyethylene glycol (MW 4000) 0.45 g.Bis(2-aminoethyl)sulfide 0.02 g.Colloidal silica (30% aqueous dispersion) 1.85 g.Nphenethyl-α-picolinium bromide(50% aqueous solution) 2.55 g.4-aminopyrazolo(3,4-d)pyrimidine 0.25 g. 0.30 g. ##STR18## 1.36 g. ##STR19##Water to make a total of 100. g.______________________________________
A film unit according to the invention was prepared identical to the control with the exception that the processing composition further included 0.05% of compound II.
The film units were processed at room temperature as follows: one half of each film unit was exposed through the transparent base of the image-receiving element to light from a Xenon source (100 meter candle seconds) which was passed in turn through an ultraviolet filter, neutral density filters to reduce the film plane light flux to 0.5 m c s, and a Wratten 47B blue filter; the other half of each film unit was not exposed. The film units were then processed by passing them through a pair of rollers at a gap spacing of 0.0030" and the relative amount of silver developed (a function of the infra-red light absorbed) was measured as a function of time for both the exposed and unexposed areas. The relative amount of developed silver vs time curves are shown in FIG. 1. It is seen that the presence of compound II reduced fog development (relative amount of developed silver in unexposed areas) in comparison to the control. It is also apparent that the difference between the relative amount of silver developed in exposed and unexposed regions in the presence of compound II is signficantly greater than the corresponding difference for the control.
The experiment was repeated with processing being carried out at 95° F. The relative amount of developed silver vs time curves as shown in FIG. 2. It is seen that fog development in the control increased significantly at the higher processing temperature, whereas the increase was only slight with compound II present. Further, at the higher processing temperature the presence of compound II greatly reduced fog development in comparison to the control without any appreciable change in the rate at which exposed silver halide was developed.
EXAMPLE II
As a control a film unit was prepared as follows: The photosensitive element comprised a subcoated opaque polyethylene terephthalate photographic film base having coated thereon the following layers in succession:
1. a cyan dye developer layer coated at a coverage of about 742 mgs/m 2 of the cyan dye developer described in Example I, about 1485 mgs/m 2 of gelatin, about 68 mgs/m 2 of 4'-methylphenylhydroquinone and about 270 mgs/m 2 of 2-phenylbenzimidazole;
2. a red-sensitive silver iodobromide emulsion layer coated at a coverage of about 1290 mgs/m 2 of silver and about 775 mgs/m 2 of gelatin;
3. an interlayer of a 60-30-4-6 terpolymer of butyl acrylate, diacetone acrylamide, styrene and methacrylic acid coated at a coverage of about 2582 mgs/m 2 of the tetrapolymer and about 68 mgs/m 2 of polyacrylamide; 4. a magenta dye developer layer coated at a coverage of about 646 mgs/m 2 of the magenta dye developer described in Example I, about 452 mgs/m 2 of gelatin, about 11 mgs/m 2 of carbon black and about 226 mgs/m 2 of 2-phenylbenzimidazole;
5. a green-sensitive silver iodobromide layer coated at a coverage of about 795 mgs/m 2 of silver and about 525 mgs/m 2 of gelatin;
6. an interlayer including about 1452 mgs/m 2 of the tetrapolymer described in layer 3, about 75 mgs/m 2 of polyacrylamide and about 71 mgs/m 2 of succindialdehyde;
7. a yellow dye developer layer coated at a coverage of about 968 mgs/m 2 of the yellow dye developer described in Example I, about 452 mgs/m 2 of gelatin, about 27 mgs/m 2 of carbon black and about 204 mgs/m 2 of 2-phenylbenzimidazole;
8. a blue-sensitive silver iodobromide emulsion layer coated at a coverage of about 1280 mgs/m 2 of silver, about 563 mgs/m 2 of gelatin and about 204 mgs/m 2 of 4'-methyl phenyl hydroquinone;
9. an overcoat layer coated at a coverage of about 484 mgs/m 2 of gelatin and about 43 mgs/m 2 of carbon black.
The image-receiving element was identical to that described in Example I.
The film unit was processed with a control aqueous alkaline processing composition which was the same as the control described in Example I with the exception that it included 0.55 g of benzotriazole and did not include any 4-aminopyrazolo (3,4-d)pyrimidine.
The film unit was exposed (0.5 meter-candle-seconds) on a sensitometer to a photographic test exposure scale, or step wedge, through the transparent support of the image-receiving element and processed at 75° F. with the processing composition by passing the film unit through a pair of pressure rollers set at a gap spacing of about 0.0030 inch. The film unit was retained intact and viewed through the transparent base. There was obtained a well developed image.
The neutral density column of the image was read on the densitometer to obtain the D max values for red, green and blue curves, respectively. In addition, the speed of the red, green and blue curves, respectively (defined as the negative log of the relative exposure required to give red, green and blue absorption in the neutral column a reflection density of 0.75) was measured. The values obtained are shown in Table IV.
The experiment was repeated with five additional film units (IIA-IIE) with the exception that the processing composition further included compound XI in the amounts shown in Table IV.
TABLE IV______________________________________Film % Comp'd Dmax Rel. SpeedUnit XI R G B R G B______________________________________Control -- 2.31 2.20 2.22 1.41 1.29 1.23IIA 0.013 2.36 2.23 2.31 1.45 1.42 1.45IIB 0.025 2.36 2.21 2.25 1.45 1.45 1.53IIC 0.05 2.37 2.17 2.18 1.45 1.49 1.50IID 0.075 2.36 2.18 2.24 1.43 1.45 1.27IIE 0.1 2.34 2.16 2.23 1.40 1.33 0.44______________________________________
It can be seen that the presence of compound XI provided a slight increase in the D max of the individual colors at certain concentrations and also provided an appreciable increase in the green and blue speeds at certain concentrations. Thus it is apparent that in this case about 0.025% of compound XI gave the optimum combination of speed increase and D max increase. The data also show that in a given film unit excessive concentrations of the compound for that film unit can lead to undesirable results; thus in Film Unit IIE the blue speed dropped considerably indicating premature inhibition of development of the blue-sensitive silver halide layer.
EXAMPLE III
The experiment described in Example II was repeated with six film units (IIIA-IIIF) which included compound II in the amounts shown in Table V. In addition, certain of the film units were also processed at 95° F. The room temperature data for the control film unit of Example II were used for comparison. In addition, a control film unit was processed at 95° F.
TABLE V__________________________________________________________________________Film % Comp'dUnit II R G B R G B__________________________________________________________________________ 75° F. Dmax Rel. SpeedControl -- 2.31 2.20 2.22 1.41 1.29 1.23IIIA 0.05 2.39 2.24 2.36 1.36 1.35 1.38IIIB 0.06 2.43 2.28 2.38 1.39 1.40 1.44IIIC 0.07 2.42 2.25 2.35 1.38 1.40 1.46IIID 0.08 2.36 1.97 2.13 1.35 1.41 1.48IIIE 0.09 2.35 1.91 2.04 1.40 1.48 1.55IIIF 0.10 2.32 1.81 1.88 1.40 1.52 1.60 95° F. ΔDmax ΔRel. SpeedControl -0.45 -0.28 -0.45 +0.10 +0.16 +0.08IIIA 0.05 -- -- -- -- -- --IIIB 0.06 -0.20 -0.05 -0.12 +0.05 +0.01 -0.08IIIC 0.07 -0.17 -0.02 -0.10 +0.04 +0.01 -0.08IIID 0.08 - 0.13 +0.26 +0.12 +0.07 +0.02 -0.06IIIE 0.09 -0.07 +0.33 +0.23 +0.02 -0.04 -0.10IIIF 0.10 -- -- -- -- -- --__________________________________________________________________________
The results show that at room temperature processing (75° F.) the presence of compound II provided an increase in the D max of the individual colors at concentrations up to 0.07% and an increase in the green and blue speeds in each film unit. When the film units were processed at 95° F. the presence of compound II provided a significant improvement over the control in D max since the D max of the individual colors went down considerably less, in comparison to the values obtained at 75° F., in most instances, and actually increased in others.
EXAMPLE IV
Two sets of film units, identical to those described in Example II except that the processing composition of one (IVA) contained 0.025% of compound XI and that of the other, (IVB) contained 0.05% of compound II were processed at 75° F. and 95° F. The data are shown in Table VI. The data for the control film unit of Example II were used for comparison.
TABLE VI______________________________________FilmUnit R G B R G B______________________________________75° F.Dmax Rel. SpeedControl 2.31 2.20 2.22 1.41 1.29 1.23IVA 2.36 2.21 2.25 1.45 1.45 1.53IVB 2.27 2.22 2.26 1.39 1.39 1.4295° F.ΔDmax ΔRel. SpeedControl -0.45 -0.28 -0.45 +0.10 +0.16 +0.08IVA -0.25 +0.01 -0.01 +0.04 -0.03 -0.12IVB -0.15 -0.01 +0.02 +0.08 +0.05 -0.04______________________________________
It can be seen that again the presence of compounds XI and II provided significant increases in the green and blue relative speeds at 75° F. and provided significant improvement in the red, green and blue D max at 95° F., with the relative speeds of these colors being desirably closer than in the control.
EXAMPLE V
A control film unit was prepared as follows: The photosensitive element comprised a subcoated opaque polyethylene terephthalate photographic film base having coated thereon in succession:
1. a layer of sodium cellulose sulfate coated at a coverage of about 14 mgs/m 2 ;
2. a cyan dye developer layer comprising about 747 mgs/m 2 of the cyan dye developer illustrated in Example I, about 1554 mgs/m 2 of gelatin, about 207 mgs/m 2 of 2-phenylbenzimidazole and about 68 mgs/m 2 of 4'-methyl phenyl hydroquinone;
3. a red-sensitive silver iodobromide emulsion layer coated at a coverage of about 1280 mgs/m 2 of silver and about 768 mgs/m 2 of gelatin;
4. an interlayer comprising about 1882 mgs/m 2 of the pentapolymer described in Example I and about 58 mgs/m 2 of polyacrylamide;
5. a magenta dye developer layer comprising about 545 mgs/m 2 of the magenta dye developer illustrated in Example I, about 382 mgs/m 2 of gelatin and about 230 mgs/m 2 of 2-phenylbenzimidazole;
6. a green-sensitive silver iodobromide emulsion layer coated at a coverage of about 560 mgs/m 2 of silver and about 246 mgs/m 2 of gelatin;
7. a green-sensitive silver iodobromide emulsion layer coated at a coverage of about 1050 mgs/m 2 of silver and about 504 mgs/m 2 of gelatin;
8. an interlayer comprising about 1598 mgs/m 2 of the pentapolymer described in Example I, about 102 mgs/m 2 of polyacrylamide and about 82.5 mgs/m 2 succindialdehyde;
9. a yellow dye developer layer comprising about 820 mgs/m 2 of the yellow dye developer illustrated in Example I, about 385 mgs/m 2 of gelatin and about 207 mgs/m 2 of 2-phenylbenzimidazole;
10. a blue-sensitive silver iodobromide emulsion layer coated at a coverage of about 1280 mgs/m 2 of silver, about 775 mgs/m 2 of gelatin and about 306 mgs/m 2 of 4'-methylphenyl hydroquinone; and
11. a topcoat layer of about 484 mgs/m 2 of gelatin.
The image-receiving element comprised a transparent subcoated polyethylene terephthalate film base on which the following layers were coated in succession:
1. as a polymeric acid layer approximately 9 parts of a 1/2 butyl ester of polyethylene/maleic anhydride copolymer and 1 part of polyvinyl butyral coated at a coverage of about 26,372 mgs/m 2 ;
2. a timing layer coated at a coverage of about 10,000 mgs/m 2 of a graft terpolymer of diacetone acrylamide, acrylamide, β-cyanoethylacrylate and 2-acrylamido-2-methane sulfonic acid on polyvinylalcohol;
3. a polymeric image receiving layer coated at a coverage of about 2200 mgs/m 2 of: (a) 3 parts of a mixture of 2 parts of polyvinyl alcohol and 1 part of poly-4-vinylpyridine and (b) 1 part of a graft copolymer comprised of 4-vinylpyridine (4VP) and vinyl benzyltrimethyl ammonium chloride (TMQ) grafted onto hydroxyethyl cellulose (HEC) at a ratio HEC/4VP/TMQ of 2.2/2.2/1; and about 74 mgs/m 2 of 1,4-butanediol diglycidyl ether;
4. a top coat layer comprising about 320 mgs/m 2 of polyvinyl alcohol.
The film unit was processed with the processing composition described in Example I as a control with the exception that it included 0.55 g of benzotriazole and 0.93 g of the aqueous colloidal silica dispersion.
Also four additional film units (VA-VD) were prepared and processed in the same manner with the exception that the processing composition further included compound I in the amounts shown in Table VII. An identical set of film units was also processed at 95° F.
TABLE VII__________________________________________________________________________Film % Comp'dUnit I R G B R G B__________________________________________________________________________ 75° F. Dmax Rel. SpeedControl -- 1.63 1.87 2.04 1.61 1.49 1.40VA 0.025 1.61 1.92 2.01 1.59 1.45 1.35VB 0.05 1.58 1.95 2.15 1.57 1.45 1.37VC 0.1 0.56 1.98 2.11 1.62 1.55 1.40VD 0.2 1.40 1.82 1.89 1.64 1.58 1.43 95° F. ΔDmax ΔRel. SpeedControl -- -0.58 -0.41 -0.45 0.00 -0.02 -0.06VA 0.025 -0.39 -0.33 -0.27 -0.06 -0.03 -0.05VB 0.05 -0.21 -0.19 -0.19 -0.05 -0.04 -0.07VC 0.1 -0.09 -0.21 -0.09 -0.10 -0.10 -0.03VD 0.2 -0.02 -0.08 +0.05 -0.05 +0.06 +0.13__________________________________________________________________________
It can be seen that at room temperature processing the presence of compound I provided an increase in the green and blue D max at concentrations up to 0.1% without any appreciable loss in relative speed. At 95° F. processing the presence of compound I gave a much smaller loss in D max for red, green and blue in comparison to the control, again without any significant change in the relative speeds.
EXAMPLE VI
This experiment represents a comparison of compounds I and II and phenylmercaptotetrazole (PMT) with a control at room temperature.
The control film unit comprised a subcoated opaque film base having the following layers coated thereon in succession:
1. a layer of sodium cellulose sulfate coated at a coverage of about 100 mgs/m 2 ;
2. a cyan dye developer layer coated at a coverage of about 635 mgs/m 2 of the cyan dye developer described in Example I, about 430 mgs/m 2 of gelatin, about 237 mgs/m 2 of N-dodecylaminopurine and about 128 mgs/m 2 of 4'-methyl phenyl hydroquinone;
3. a red sensitive silver iodobromide emulsion layer coated at a coverage of about 1500 mgs/m 2 of silver and about 900 mgs/m 2 of gelatin;
4. an interlayer comprising about 1264 mgs/m 2 of the pentapolymer described in Example I and about 67 mgs/m 2 of polyacrylamide;
5. a magenta dye developer layer coated at a coverage of about 646 mgs/m 2 of a magenta dye developer represented by the formula ##STR20## and about 323 mgs/m 2 of gelatin;
6. a green-sensitive silver iodobromide emulsion layer coated at a coverage of about 1300 mgs/m 2 of silver and about 596 mgs/m 2 of gelatin;
7. an interlayer comprising about 950 mgs/m 2 of the pentapolymer described in Example I and about 50 mgs/m 2 of polyacrylamide;
8. a yellow dye developer layer coated at a coverage of about 820 mgs/m 2 of the yellow dye developer described in Example I, and about 328 mgs/m 2 of gelatin;
9. a spacer layer comprising about 150 mgs/m 2 of N-dodecylaminopurine and about 150 mgs/m 2 of gelatin;
10. a blue sensitive silver iodobromide emulsion layer coated at a coverage of about 1200 mgs/m 2 of silver, about 421 mgs/m 2 of gelatin and about 320 mgs/m 2 of 4' methyl phenyl hydroquinone; and
11. a topcoat layer comprising about 484 mgs/m 2 of gelatin.
The image-receiving element comprises a transparent base having coated thereon in succession:
1. a polymeric acid layer as described in Example V.
2. a timing layer comprising about 2570 mgs/m 2 of the pentapolymer described in Example I and about 206 mgs/m 2 of polyacrylamide;
3. a polymeric image receiving layer as described in Example V with the exception that the coverages of the ether and the mixture of graft copolymer (PVA-P-4-VP) were 103 mgs/m 2 and 2990 mgs/m 2 respectively;
4. a topcoat layer comprising about 721 mgs/m 2 of a polyoxyethylene-polyoxypropylene block copolymer (Pluronic F-127, commercially available from BASF Wyandotte Co.) and about 309 mgs/m 2 of polyvinylalcohol.
The control film unit was processed with a processing composition as described in Example V.
Three additional film units (VIA-VIC) were prepared and processed in the same manner with the exception that the processing composition further included 0.05% of PMT, compound I and compound II respectively. The results are shown in Table VIII.
TABLE VIII______________________________________Film Dmax Dmin Rel. SpeedUnit R G B R G B R G B______________________________________Con- 1.80 2.24 1.65 0.21 0.21 0.18 1.41 1.37 1.64trolVI A 1.75 2.23 2.20 0.23 0.25 0.76 1.29 1.03 *VI B 1.75 2.24 1.98 0.22 0.20 0.18 1.39 1.38 1.44VI C 1.81 2.27 2.06 0.23 0.22 0.19 1.34 1.33 1.27______________________________________ * blue relative speed too slow to measure
It is seen that the presence of PMT caused a large increase in the blue D min and a very large decrease in the blue speed, thus indicating that the PMT restrained development of the blue sensitive silver halide emulsion prematurely. The presence of compounds I and II provided an increase in the blue D max without any increase in the blue D min .
EXAMPLE VII
As a control a film unit was prepared as follows: the photosensitive element comprised a subcoated transparent polyethylene terephthalate photographic film base having coated thereon the following layers in succession:
1. a layer of sodium cellulose sulfate coated at a coverage of about 14.4 mgs/m 2 ;
2. a cyan dye developer layer comprising about 747 mgs/m 2 of the cyan dye developer illustrated in Example I, about 1554 mgs/m 2 of gelatin, about 270 mgs/m 2 of 2-phenylbenzimidazole and about 68 mgs/m 2 of 4'-methylphenylhydroquinone;
3. a red-sensitive silver iodobromide emulsion layer coated at a coverage of about 1280 mgs/m 2 of silver and about 768 mgs/m 2 of gelatin;
4. an interlayer comprising about 2505 mgs/m 2 of the pentapolymer described in Example I and about 78 mgs/m 2 of polyacrylamide;
5. a magenta dye developer layer comprsing about 646 mgs/m 2 of the magenta dye developer described in Example I, about 452 mgs/m 2 of gelatin and about 229 mgs/m 2 of 2-phenylbenzimidazole;
6. a green-sensitive silver iodobromide emulsion layer coated at a coverage of about 510 mgs/m 2 of silver and about 224 mgs/m 2 of gelatin;
7. a spacer layer comprising about 1045 mgs/m 2 of polymethylmethacrylate and about 55 mgs/m 2 of polyacrylamide;
8. a green-sensitive silver iodobromide emulsion layer coated at a coverage of about 700 mgs/m 2 of silver and about 336 mgs/m 2 of gelatin;
9. an interlayer comprising about 1366 mgs/m 2 of the pentapolymer described in Example I and about 87 mgs/m 2 of polyacrylamide;
10. a yellow dye developer layer comprising about 820 mgs/m 2 of the yellow dye developer illustrated in Example I, about 384 mgs/m 2 of gelatin and about 208 mgs/m 2 of 2-phenyl-benzimidazole;
11. a blue-sensitive silver iodobromide emulsion layer coated at a coverage of about 1280 mgs/m 2 of silver, about 775 mgs/m 2 of gelatin and about 306 mgs/m 2 of 4'-methylphenylhydroquinone;
12. a top coat layer of about 484 mgs/m 2 of gelatin.
The image receiving element was identical to that described in Example V. The film unit was processed with a processing composition as described in Example V.
Six additional film units were prepared (VIIA-VIIF). Film Units VIIA-VIIC further included 1 mg/m 2 , 2 mgs/m 2 and 3 mgs/m 2 , respectively, of compound II in layer 5 of the photosensitive element and Film Units VIID-VIIF further included 1 mg/m 2 , 2 mgs/m 2 and 3 mgs/m 2 of compound XI in layer 5 of the photosensitive element. An identical set of film units was also processed at 95° F. The results are shown in Table IX.
TABLE IX__________________________________________________________________________75° F. 95° F.Film Dmax Rel. Speed Δ DmaxUnit R G B R G B R G B__________________________________________________________________________Control1.95 1.67 2.23 1.50 1.49 1.32 -0.56 -0.20 -0.18VIIA 2.03 1.75 2.25 1.52 1.46 1.33 -0.48 -0.19 -0.15VIIB 2.09 1.70 2.24 1.47 1.46 1.33 -0.27 -0.09 -0.11VIIC 2.14 1.78 2.28 1.41 1.39 1.29 -0.22 -0.06 -0.11VIID 2.01 1.71 2.23 1.56 1.48 1.35 -0.37 -0.12 -0.14VIIE 2.04 1.73 2.25 1.58 1.46 1.37 -0.27 -0.05 -0.11VIIF 2.08 1.71 2.23 1.57 1.43 1.39 -0.19 +0.06 -0.05__________________________________________________________________________
It can be seen that at room temperature the presence of compounds II and XI provided an increase in red and green D max . At 95° F. processing the presence of compounds II and XI gave smaller losses (varying with the coverages) of red, blue and green D max .
EXAMPLE VIII
PREPARATION OF COMPOUND XII
A catalyst was prepared by stirring a mixture of Celite® (10 g.) (diatomaceous earth available from Johns Manville) and potassium fluoride dihydrate (15 g.) in 250 ml. of distilled water for 30 minutes. The water was removed on a rotary evaporator and the solids dried overnight at room temperature under high vacuum. The catalyst was further dried in a vacuum oven at 58°-60° C. for about two days.
To a stirred solution of 1-(4-hydroxyphenyl)-5-mercaptotetrazole (5 g.) in dry tetrahydrofuran (50 ml.) at room temperature under nitrogen there were added methylvinylsulfone (2.8 g.) and the potassium fluoride/Celite catalyst (1 g.). The reaction mixture was stirred slowly for 24 hours. The solids were removed by filtration and the solvent was removed from the filtrate leaving behind a clear yellow-brown oil. The oil was dried under vacuum to give a tacky gum-like material. Recrystallization from methanol followed by drying to constant weight under vacuum gave a white, solid, compound XII, m.p. 139°-141° C.
The NMR spectrum of the material was consistent with compound XII. 13 C NMR (dmso-d 6 ); δ159.28, 153.69, 126.28, 124.05, 116.23, 53.01, 40.59, 25.29 ppm.
EXAMPLE IX
PREPARATION OF COMPOUND XIII
To a suspension of compound IV (2.166 g, 8.43 mmol) in methanol (10 ml) there were added, under nitrogen, 78% methyl vinyl sulfone (1.44 g, 8.42 mmol) and 0.25 ml of 40% benzyl trimethyl ammonium hydroxide in methanol and the reaction mixture refluxed for twenty-four hours. The cooled reaction mixture was filtered to collect the white crystals which had formed. Thin layer chromatography showed that some starting materials were present. The desired product, compound XIII, was separated by column chromatography followed by removal of the solvent, crystallization on standing and drying. The structure of the product was confirmed by UV and 13 C NMR spectra.
EXAMPLE X
PREPARATION OF COMPOUND XIV
A catalyst was prepared by stirring a mixture of 10 g of Celite® (diatomaceous earth available from Johns Manville) and 15 g of potassium fluoride in 250 ml of distilled water for about 30 minutes, removing the water on a rotary evaporator at 56° C. and drying the solid under vacuum at 58°-60° C. to calculated weight, 196 g. The catalyst (1 g) was added to a stirred solution of 5 g of compound I and 1.8 g of methyl vinyl ketone in 50 ml of dry tetrahydrofuran and the suspension was stirred under nitrogen at room temperature for three days. The solids were removed by filtering and the solvent removed from the filtrate to give about 7 g of a brown-yellow oil which was stirred briefly with 70 ml of ether at room temperature. The ether solution was decanted from the brown oily solid which had deposited, and the crystalline solid which formed in the ether on standing collected by filtration, washed and dried to give 4 g of white crystals (compound XIV), m.p. 118°-120° C. The structure of the product was confirmed by a 13 C NMR spectrum.
EXAMPLE XI
PREPARATION OF COMPOUND XV
A mixture of compound IV (257 mg., 1.0 mmol), methyl vinyl ketone (0.081 ml, 1.0 mmol) and 200 mg of potassium fluoride on Celite catalyst (6 mmol/g) in about 2 ml of pyridine was stirred overnight. The reaction mixture was poured into 5% hydrochloric acid and the solid collected by filtration. Thin layer chromatography showed two compounds. The desired product (compound XV) was separated by column chromatography, followed by removal of the solvent, crystallization on standing and drying. The structure of the product was confirmed by a proton NMR spectrum.
EXAMPLE XII
PREPARATION OF COMPOUND XVI
A stirred mixture of compound I (30.0 g, 0.154 m), 3-bromopropionitrile (20.72 g, 0.154 m) and sodium bicarbonate (12.98 g, 0.154 m) in 600 ml of dry acetonitrile was heated under nitrogen at 55° C. for 42 hours, then cooled in an ice bath and vacuum filtered. The filtrate was evaporated on a rotary evaporator at 25° C. The syrupy residue was taken up in 500 ml of ethyl acetate, washed with 400 ml of saturated NaHCO 3 solution and twice with 200 ml of water, dried over sodium sulfate and adsorptive activated carbon, and vacuum filtered through diatomaceous earth. The filtrate was evaporated on a rotary evaporator at 25° C. and the crystalline residue was taken up in 200 ml of ethyl acetate and 100 ml of hexane added to the solution. The solution was stored in a refrigerator overnight and 50 ml of hexane added. The crystalline material was collected by filtration, washed with two 50 ml volumes of hexane and dried under reduced pressure at ambient temperature to give 25 g (65.7% yield) of compound XVI.
EXAMPLE XIII
PREPARATION OF COMPOUND XVII
A mixture of compound II (11.647 g, 49.58 mmol), β-bromopropionitrile (6.626 g, 49.58 mmol) and sodium bicarbonate (4.17 g, 49.58 mmol) in 200 ml of dry acetonitrile was magnetically stirred in a 55° C. bath under nitrogen overnight. The reaction mixture was vacuum filtered and the filtrate was stripped of solvent by rotary evaporation giving an orange oily residue. The residue was taken up in ethyl acetate (75 ml) and to the solution there were added seed crystals and 150 ml of hexane. The mixture was scratched and stored overnight in a refrigerator. The crystals which formed were collected by filtration, washed twice with hexane and dried to give 12.74 g of compound XVII as light yellow crystals, in p. 111°-113° C. The structure of the product was confirmed by IR, UV and NMR spectra and thin layer chromatography.
EXAMPLE XII
PREPARATION OF COMPOUND XVIII
A mixture of compound I (4.14 g, 21.3 mmol), p-acetoxybenzyl chloride (3.94 g, 21.3 mmol) and sodium bicarbonate (1.79 g, 21.3 mmol) in 130 ml of dry acetonitrile was magnetically stirred under dry nitrogen at 55° C. overnight. The reaction mixture was cooled in an ice bath, the solids removed by vacuum filtration and the solvent stripped from the filtrate to give an oily residue. The oily residue was taken up in 100 ml. of ethyl acetate, washed with 80 ml of saturated sodium bicarbonate and twice with 80 ml of water, dried over sodium sulfate and activated charcoal and the mixture vacuum filtered through diatomaceous earth to give a light yellow solution. The solvent was stripped from the solution by rotary evaporation to give 12.5 g. of a light yellow oil. The oil was taken up in a mixture of 20 ml of ethyl acetate and 80 ml of hexane and the solution allowed to stand in a refrigerator overnight. The solvent was stripped by rotary evaporation to give an oily residue which was taken up in 100 ml of hexane and allowed to stand. The crystals which formed were collected by filtration, recrystallized from a mixture of 100 ml of hexane and 10 ml of ethyl acetate, washed with 20 ml of hexane and dried to give 6.17 g of the desired product (compound XVIII), m.p. 153°-154° C. (84.6% yield). The structure of the product was confirmed by IR, UV and NMR spectra and thin layer chromatography.
EXAMPLE XV
As a control a film unit was prepared as follows: the negative element comprised an opaque subcoated polyethylene terephthalate film base on which the following layers were coated in succession.
1. as a polymeric acid layer approximately 9 parts of a 1/2 butyl ester of polyethylene/maleic anhydride copolymer and 1 part of polyvinyl butyral coated at a coverage of about 26,460 mgs./m. 2 ;
2. a timing layer comprising about 97% of a 60-29-6-4-0.4 pentapolymer of butylacrylate, diacetone acrylamide, methacrylic acid, styrene and acrylic acid and about 3% polyvinylalcohol coated at a coverage of about 3000 mgs./m. 2 ;
3. a cyan dye developer layer comprising about 511 mgs./m. 2 of the cyan dye developer described in Example I, about 70 mgs./m. 2 of 4'methyl phenyl hydroquinone and about 317 mgs./m. 2 of gelatin;
4. a red-sensitive silver iodobromide emulsion layer comprising about 1378 mgs./m. 2 of silver and about 827 mgs./m. 2 of gelatin;
5. an interlayer comprising about 2090 mgs./m. 2 of the pentapolymer described in layer 2, about 110 mgs./m. 2 of polyacrylamide and about 44 mgs./m. 2 of succinaldehyde;
6. a magenta dye developer layer comprising about 460 mgs./m 2 of a magenta dye developer represented by the formula ##STR21## and about 210 mgs./m 2 of gelatin;
7. a green-sensitive silver iodobromide emulsion layer comprising about 723 mgs./m. 2 of silver and about 318 mgs./m. 2 of gelatin;
8. an interlayer comprising about 1881 mgs./m. 2 of the pentapolymer described in layer 2 and about 99 mgs./m. 2 of polyacrylamide;
9. a yellow dye developer layer comprising about 689 mgs./m. 2 of the yellow dye developer described in Example I and about 276 mgs./m. 2 of gelatin;
10. a blue-sensitive silver iodobromide emulsion layer comprising about 764 mgs./m. 2 of silver, about 499 mgs./m. 2 of gelatin, and about 265 mgs./m. 2 of 4'-methyl phenyl hydroquinone; and
11. a topcoat layer of about 400 mgs./m. 2 of gelatin.
The image receiving element comprised a transparent subcoated polyethylene terephthalate film base upon which there was coated an image receiving layer coated at a coverage of about 300 mgs./ft. 2 (3229 mgs./m 2 ) of: (a) 3 parts of a mixture of 2 parts polyvinyl alcohol and 1 part poly-4-vinylpyridine and (b) 1 part of a graft copolymer comprised of 4-vinylpyridine (4VP) and vinyl benzyl trimethyl ammonium chloride (TMQ) grafted onto hydroxyethyl cellulose (HEC) at a ratio HEC/4VP/TMQ of 2.2/2.2/1; and about 5 mgs./ft. 2 (53.8 mgs./m. 2 of 1,4-butanediol diglycidyl ether.
The film unit was processed with a processing composition made up as follows:
______________________________________Water 1632 ml.TiO.sub.2 2312.0 gramsOximated polydiacetoneacrylamide 32.0 "Potassium hydroxide (45% solution) 468.0 "Benzotriazole 22.0 "4-aminopyrazole-(3,4-d)pyrimidine 10.0 "6-methyl uracil 12.0 "Nhydroxyethyl-N,N',N'triscarboxymethylethylene diamine 30.0 "Polyethylene glycol (M.W. 4000) 18.0 "Bis(20 aminoethyl)sulfide 0.8 "Colloidal silica (30% solids) 37.0 "Nphenethyl-α-picolinium bromide(50% solids) 102.0 "Allopurinol 3.3 "2-methyl imidazole 23.8 "6-methyl-5-bromo azabenzimidazole 4.8 " ##STR22## 14.0 " ##STR23## 62.3 "______________________________________
The negative element was exposed (2 meter-candleseconds) on a sensitometer to a test exposure scale with white light, and then brought together with the image receiving element and processed at room temperature (24° C.) by passing the film unit through a pair of rollers set at a gap spacing of about 0.0026 inch. The film unit was kept intact and viewed through the base of the image receiving element.
An identical film unit was processed in the same manner at 35° C. The neutral density columns of the images were read on a densitometer to obtain the Dmax and Dmin values for red, green and blue, respectively. The values obtained are shown in Table IX.
Seven additional film units according to the invention (VIIIA-VIIIG) were prepared. These were identical to the control with the exception that the negatives also included a top coat layer comprising about 20 mg./ft. 2 (215 mgs./m. 2 ) of a blocked compound according to the invention (as shown in Table IX) and about 20 mg./ft. 2 of gelatin. The film units were processed as described above at 24° C. and at 35° C. The results are shown in Table X.
TABLE X______________________________________Film Com- Dmax DminUnit Pound R G B R G B______________________________________ 24° C.Control 1.81 1.60 1.31 0.15 0.16 0.24VIIIA XII 1.60 1.48 1.40 0.18 0.17 0.24VIIIB XIII 1.33 1.43 1.41 0.15 0.16 0.23VIIIC XIV 1.68 1.74 1.91 0.16 0.17 0.26VIIID XV 1.44 1.39 1.37 0.16 0.13 0.16VIIIE XVI 1.30 1.42 1.46 0.15 0.13 0.15VIIIF XVII 1.58 1.65 1.64 0.16 0.13 0.15VIIIG XVIII 1.48 1.83 1.88 0.14 0.15 0.23 35° C.Control -- 1.43 1.20 0.95 0.16 0.17 0.25VIIIA XII 1.32 1.23 1.12 0.16 0.17 0.24VIIIB XIII 1.07 1.13 1.11 0.16 0.17 0.25VIIIC XIV 1.65 1.67 1.62 0.16 0.17 0.26VIIID XV 1.28 1.24 1.14 0.16 0.14 0.17VIIIE XVI 1.24 1.27 1.24 0.17 0.14 0.17VIIIF XVII 1.40 1.35 1.34 0.16 0.14 0.17VIIIG XVIII 1.67 1.78 1.61 0.14 0.15 0.25______________________________________
It is seen that at both 24° C. and 35° C. the blue D max of Film Units VIIIA-VIIIG is higher than that of the Control and, in some instances much higher. At 24° C. the green D max of Film Units VIIC, VIIF and VIIG is higher than that of the Control while at 35° C. the green D max of all the Film Units except VIIIB is higher.
EXAMPLE XVI
PREPARATION OF COMPOUND XIX
A mixture of compound II (1.175 g, 5 mmol), sodium bicarbonate (420 mg., 5 mmol) and p-acetoxybenzyl chloride (925 mg., 5 mmol) in 30 ml of acetone was heated to boiling on a steam bath for 24 hours. The solution was vacuum filtered and the solvent was removed from the filtrate by rotary evaporation at 25° C. to give a light yellow oil. The oil was taken up in 30 ml. of methanol, the solution vacuum filtered and the filtrate allowed to stand overnight in a refrigerator. The light yellow crystals which formed were collected by filtration and dried under reduced pressure at room temperature to give 1.34 g (70% yield) of compound XIX, m.p. 126°-127° C.
C 18 H 17 N 5 O 3 S requires 56.38% C, 4.47% H, 18.27% N and 8.36% S. Elemental analysis found 56.50% C, 4.57% H, 18.27% N and 8.12% S.
Although the invention has been described with respect to specific preferred embodiments, it is not intended to be limited thereto but rather those skilled in the art will recognize that variations and modifications may be made within the spirit of the invention and the scope of the appended claims.
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There is disclosed a diffusion transfer photographic system wherein development of an exposed photosensitive element with an aqueous alkaline processing composition is effected in the presence of a compound represented by the formula ##STR1## wherein X represents the nonmetallic atoms necessary to form a nucleus which completes a 5- or 6-membered heterocyclic moiety on said structure including substituted rings and fused rings; R is H, an alkali metal or a group which is cleavable in a photographic aqueous alkaline processing composition; and R 1 is either a group which has a pKa of from about 7 to about 14 which is ionizable to an anion whereby the silver salt of the mercaptan (resulting from cleavage or ionization of --SR) is rendered more soluble in the pH range within which R 1 is ionized to an anion than it is below that pH range, or a precursor of such a group.
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BACKGROUND OF THE INVENTION
The present invention relates to arrowheads for hunting and the like and in particular to an improved arrowhead with retractable barbs useful for bowfishing.
Arrowheads for bowfishing may have radially extending barbs that swing rearward as the arrowhead passes through the fish, but then open to prevent the fish from slipping off of the arrow when the arrow is retrieved. In order to remove the fish from the arrow after the arrow is retrieved, the barbs may be folded forward over the arrow tip so that the arrow may be pulled backward through the fish. This forward folding of the barbs normally requires releasing a mechanical stop.
A first type of mechanical stop is released by, loosening the arrow shaft with respect to the arrowhead holding the barbs, for example, by relative rotation of a threaded coupling between the two. Separation of these components may withdraw a stop surface on the front of the arrow shaft from a stop on the barbs that normally operates to limit rotation of the barbs forward. An example of this type of stop system is shown in U.S. Pat. No. 4,819,360.
In a second type of mechanical stop, a threaded connection between the arrow head holding the barbs and the sharpened arrow tip is employed. This type of stop allows the arrowhead to be permanently attached to the arrow shaft. In this stop system, the rear of the arrow tip provides a stop surface that blocks forward rotation of the barbs. Removal of the tip allows the barbs to swing forward to extract the arrow from the fish. An example of this type of stop system is shown in U.S. Pat. No. 7,311,621.
In this latter design, the arrow tip, after being removed from the arrow, is subject to being dropped or misplaced as the fish is removed.
SUMMARY OF THE INVENTION
The present invention provides a barb design for a bowfishing arrowhead that allows the barbs to rotate forward to be extracted from the fish with only a minor loosening of the tip. In this way, the tip is always retained in connection with the arrowhead minimizing risk of loss of the tip during this process of removing the fish. The invention provides a shortened stop surface on the barb that allows the barb to rotate with only minor displacement of the tip together with an offset to the barb arm allowing the barb to swing around the diameter of the tip without interference from the tip when the tip is in place.
Specifically then the present invention provides an arrowhead with an arrowhead body extending along an arrow axis between a first and second end. The first end of the arrowhead body may attach to an arrow shaft that may extend rearwardly from the arrowhead body along the arrow axis and a second end may provide a threaded coupling extending along the arrow axis to receive an arrow tip. The arrow tip may be threaded onto the arrowhead body to be movable by rotation between a tightened and loosened position (both as attached to the arrowhead body), the loosened position displaced forwardly with respect to the tightened position. The arrowhead includes at least one arrow barb attached to the arrowhead body to pivot about a pivot axis perpendicular to the arrow axis. The barb may swing between a retracted rearward position extending rearwardly from the pivot axis along the arrow axis, through an extended position extending from pivot point in a direction perpendicular with respect to the arrow axis, and a retracted forward position extending forwardly from the pivot axis along the arrow axis.
The arrow barb may include an eye portion attached to an arm portion, the eye portion having a hole about which the arm portion pivots and the arm portion may extend from the eye portion at an offset from a line of radius of a center of the hole so that the arm portion is removed from interference with a rear edge of the arrow tip when the arm portion is in the retracted forward position and the arrow tip is in the loosened position.
It is thus a feature of at least one embodiment of the invention to allow removal of the fish from the arrow by moving the barbs to the forward retracted position without completely separating the tip from the arrowhead where it can be dropped or lost.
The offset may displace a front edge of the arm portion from the center of the hole by a distance at least equal to a radial distance between the rear edge of the arrow tip and the center of the hole measured perpendicular to the arrow axis.
It is thus a feature of at least one embodiment of the invention to allow the barbs to rest against the outer surface of the tip when the tip is loosened.
The eye may further include a stop surface abutting a rear end of the arrow tip when the barb is in the extended position and the arrow tip is in the tightened position to restrain pivoting of the barb from the extended position to the forwardly retracted position and removed from abutment with a rear end of the arrow tip when the barb pivots between the extended position and the forward retracted position and the arrow tip is in the loosened position.
It is thus a feature of at least one embodiment of the invention to prevent forward retraction of the barbs when the arrow and fish are being retrieved.
The stop surface may extend radially in a direction perpendicular to the arrow axis when abutting a rear end of the arrow tip by a distance less than a displacement of the rear edge of the arrow tip between the tightened and loosened positions.
It is thus a feature of at least one embodiment of the invention to permit disengagement of the stop surface without removal of the tip.
The loosened position may be displaced along the arrow axis by a distance substantially equal to a radial distance between the rear edge of the arrow tip and the center of the hole measured perpendicular to the arrow axis.
It is thus a feature of at least one embodiment of the invention to practically reduce the necessary loosening of the tip while providing a robust stop mechanism.
The arrow tip may provide a substantially cylindrical rear end and the rear edge of the arrow tip may be an edge defining the interface between a cylinder base defined by the rear end and a cylinder wall defined by surfaces of the arrow tip extending along the arrow axis.
It is thus a feature of at least one embodiment of the invention to provide a system that works with standard arrow tips.
These particular objects and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view in partial cross-section of an arrowhead and arrow tip of the prior art showing a stop surface provided by the rear face of the arrow tip against the leading edge of the barb when the tip is fully tightened onto the arrowhead;
FIG. 2 is a figure similar to that of FIG. 1 showing the arrow tip removed such as allows the barb to swing forward without interference;
FIG. 3 is a figure similar to that of FIG. 1 showing the present invention with the tip in the tightened position such as limits forward rotation of the barb in an extended position;
FIG. 4 is a figure similar to that of FIG. 3 showing rearward retraction of the barb with the tip in the tightened position when the arrow is in forward flight;
FIG. 5 is a figure similar to FIG. 3 with the tip in a loosened position but still retained on the arrowhead showing the ability of the barbs to rotate to a forward retracted position;
FIG. 6 is a fragmentary side elevational view of a simplified version of the barb and arrow tip showing dimensions allowing operation of the bath; and
FIG. 7 is a cross-sectional view along line 7 - 7 of FIG. 4 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Prior Art
Referring now to FIGS. 1 and 2 , a prior art arrowhead 10 may provide for an arrowhead body 12 that can attach to an arrow tip 14 by means of the threaded boss 16 . The threaded boss 16 may project along an arrow axis 18 from the front end of the arrowhead body 12 and be received by a threaded bore 20 opening axially into a rear end of the arrow tip 14 .
One or more slots 26 extending along the axis 18 may be cut radially into a front end of the arrowhead body 12 each to receive proximal ends of barbs 22 . Within the slots 26 , the barbs 22 are held by roll pins 24 passing through holes in the proximal ends of the barbs 22 .
The barbs 22 may pivot about roll pins 24 so as to extend in a direction generally perpendicular to the axis 18 (an extended position) shown in FIG. 1 where a distal tip 27 of the barb 22 is distant from the arrowhead body 12 . This position may be reached from a rearward retracted position (not shown) where a distal tip 27 of the barb 22 lies adjacent to the outer surface of the rear end of the arrowhead body 12 . Forward pivoting of the barbs 22 from the position shown in FIG. 1 , with a distal tip 27 extending forward, is prevented by interference between a rear edge 30 of the arrow tip 14 and a stop surface 32 being a front edge of the barb 22 .
As shown in FIG. 2 , with full removal of the tip 14 , barb 22 may swing forward within an exposed extension of the slot 26 passing into the threaded boss 16 until stopped by interference between the stop surface 32 and a rising wall of the slot 26 . This forward retracted position allows removal of the fish from the arrow.
The Present invention
Referring now to FIG. 3 , the present invention provides an arrowhead 36 providing an arrowhead body 38 having a rear end 40 that may be attached to an arrow shaft 42 , for example, by means of the cylindrical tendon 44 extending forward from the arrow shaft 42 received by a corresponding cylindrical bore 46 opening axially at a rear end 40 of the arrowhead body 38 . The arrowhead body 38 may be constructed of a metal material such as stainless steel to be resistant from the corrosive effects of water, and in one embodiment may be substantially cylindrical. A suitable material for an arrow shaft 42 may be a composite plastic such as a pultruded fiberglass or other composite material of a type known in the art.
An arrow tip 14 may attach at a front end 50 of the arrowhead body 38 , for example, by threading onto a threaded stud 52 extending forward from the arrowhead body 38 . This threaded stud 52 may be received by a corresponding threaded bore 54 opening axially at the rear of the tip 14 . A rear end of the tip 14 may be generally cylindrical and have the same outer diameter as the arrowhead body 38 and may present a rear circular base through which the threaded bore 54 is formed. A rear edge 56 of the tip 14 is defined by an interface between at an outer periphery of the rear circular base of the tip and a cylindrical outer periphery of the rear end of the tip 14 .
The tip 14 may be in a tightened position, as shown in FIG. 3 , with a rear end (base) of the tip 14 abutting a front end of the arrowhead body 38 , the latter which may present a corresponding circular base from which the threaded stud 52 extends. This tightened position may be obtained by rotating the tip 14 clockwise about the axis 18 to tighten the threaded bore 54 about the stud 52 .
Alternatively, as shown in FIG. 5 , the tip 14 can be loosened slightly to be displaced away from a front end of the arrowhead body 38 by displacement distance 59 in a loosened position. This loosened position may be obtained by rotating the tip 14 in a counterclockwise direction about the axis 18 to loosen the threaded bore 54 about the stud 52 and to separate the basis of the arrowhead body 38 and the tip 14 .
The front end of the tip 14 may be sharpened to taper to a penetrating point 58 generally aligned with the arrow axis 18 . The tip may be constructed of a machined stainless steel material.
Referring now to FIGS. 3 and 7 , an outer periphery of the arrowhead body 38 may provide for one or more axial slots 60 radially cut into the arrowhead body 38 . One or more barbs 62 may be attached to the arrowhead body 12 by means of an eye portion 64 at a proximal end of the barb 62 having a hole 66 . A hole 66 of each barb 62 may be held in a slot 60 by a roll pin 68 passing through the holes 66 and extending along different axes 70 angularly equally spaced around the arrow axis 18 and perpendicular to the arrow axis 18 . The roll pins 68 may be retained by blind bores cut into the arrowhead body 38 .
During use of the arrowhead 36 , the eye portion 64 of a barb 62 may rotate about the roll pin 68 so that a distal end 72 of the barb 62 may fully extend along a perpendicular to arrow axis 18 to an extended position that operates to retain a fish on the arrow shaft 42 or rear end of arrowhead body 38 . When the tip 14 is in the tightened position shown in FIG. 3 , a stop surface 74 extending upward from the eye portion 64 abuts the rear edge 56 of the tip 14 preventing further forward movement of the distal end 72 .
Referring now to FIG. 4 , although forward motion of the distal end 72 is blocked when the tip 14 is in the tightened position, the barb 62 may rotate rearward so that the distal end 72 moves close to the periphery of the arrow shaft 42 or rear end of the arrowhead body 38 in a rearward retracted position that allows the arrowhead body 38 and barb 62 to pass with low resistance through the fish. In this configuration a proximal arm portion 76 of the barb 62 may lie partially within the slot 60 rearward of the eye portion 64 and be slightly angled with respect to arrow axis 18 , and a distal arm portion 77 may lie more closely parallel to the arrow axis 18 against the outer surface of the arrow shaft 42 or rear end of the arrowhead body 38 .
Referring now to FIG. 5 , when the tip 14 is in the loosened position displaced by distance 59 forward from the arrowhead body 38 on the stud 52 , the barb 62 may rotate to move the distal end 72 to a forward retracted position that allows removal of the fish in a forward direction over the barbs 62 . In this position, a front edge of the proximal arm portion 76 may lie against an outer periphery of a rear end of the tip 14 and the stop surface 74 may be removed from interference with the rear edge 56 so as to allow pivoting of the eye portion 64 forward from the extended position shown in FIG. 3 to a forward retracted position shown in FIG. 5 .
Generally once the tip 14 has been loosened by at least the displacement distance 59 , it may continue to be loosened over an additional distance without further forward movement of the barbs 62 which are restrained only by contact between the arm portion 76 and the outer periphery of the tip 14 . Some additional forward movement of the barbs 62 may be possible when the tip 14 is fully removed; however, this removal of the tip 14 is not necessary for extraction of the fish over the barbs 62 which are substantially fully in the forward retracted position when the tip 14 is in the loosened position.
Referring now to FIG. 6 , generally the periphery of the eye portion 64 will, over a portion, follow a constant radius 80 about a center 82 of the hole 66 so as to avoid interference in rotation from a bottom of the slot 60 with rotation of the barb 62 from the rearward retracted position of FIG. 4 through the forward retracted position of FIG. 5 .
When the barb 62 is in the extended position, a stop surface 74 may project upward along a tangent of the constant radius 80 from the periphery of the eye portion 64 by a distance no greater than the displacement distance 59 . When the tip 14 is in the tightened position, the stop surface 74 may be parallel to and abutting a rear face of the tip 14 . In particular, the furthest upward extent of the stop surface 74 may contact the edge 56 to best resist rotation of the barb 62 . When the tip 14 is in the loosened position, stop surface 74 may rotate within a second radius 84 to remain clear from a rear surface of the tip 14 and the rear edge 56 , both being displaced from the first radius 80 by less than the distance 59 .
A front edge 86 of the proximal arm portion 76 extends in offset with respect to the eye portion 64 , for example, to extend upward from the eye portion 64 when the barb 62 is in the extended position of FIG. 3 , along a line displaced rearward along axis 18 from the center 82 of the hole 66 by an offset distance 88 . The offset distance 88 is greater in amount than a tip height 90 being measured perpendicular to the axis 18 from a center of the hole 66 to an outer peripheral edge of the tip 14 . In this way, the barb 62 when moved to the forward retracted position shown in FIG. 5 may be free from interference with the rear edge 56 of the tip 14 once the tip 14 is displaced by the displacement distance 59 . Front edge 86 may then provide the only contact between the barb 62 and the tip 14 and may touch an outer periphery 85 of the tip 14 well in front of the edge 56 so as to provide a constant limitation in the forward rotation of the barb 62 , even as the tip is further removed, than the displacement distance 59 to the point of removal of the tip entirely. Generally, the displacement distance 59 will be a small portion, for example, less than one quarter, of the length of the stud 52 , ensuring that at the displacement distance 59 and in the loosened position, the tip 14 is still securely held on the arrowhead body 38 by the threaded stud 52 .
Referring still to FIG. 6 anti-vibration features may be added to the tip 14 or to the threaded stud 52 in the form of a polymer insert 92 extending from the threads of the bore 54 to be deformed by the threads of the threaded stud 52 or by means of a slight distortion in the threads 94 of either element according to known locking techniques. Other forms of thread locking can also be employed.
Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “front”, “back”, “rear”, “bottom” and “side”, describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first”, “second” and other such numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context.
When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of such elements or features. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein and the claims should be understood to include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. All of the publications described herein, including patents and non-patent publications, are hereby incorporated herein by reference in their entireties.
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An arrowhead for bowfishing supports pivoting barbs that may refracted rearward to pass through a fish and then extended to retain the fish on the arrow. The barbs provide a truncated stop surface striking a rear of the arrow tip when the arrow tip is tightened on the arrowhead to prevent their forward motion from the extended position when the tip is tightened on the arrowhead and yet to allow such motion when the tip is slightly loosened but not removed. The barbs are offset with respect to their pivot point so that a slight loosening of the arrow tip also allows the barbs to pass forward over the arrow tip for retraction of the fish from the arrow while the tip is retained on the arrowhead.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to portable electronic devices and, particularly, to a portable electronic device with a free-standing supportability.
[0003] 2. Description of Related Art
[0004] Many portable electronic devices, e.g., mobile phones and personal digital assistants, are equipped with a video playing function. Due to their small size, a portable electronic device cannot be stably stood upright on a flat surface. Therefore, it is difficult to watch video images. In such case, users need to hold a portable electronic device in their hands to watch video image. However, the video image may shake and become blurry when users manually hold the portable electronic device. In addition, users may become tired if they are holding a portable electronic device for a long time.
[0005] Therefore, there is room for improvement within the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Many aspects of the portable electronic device can be better understood with reference to the following drawings. These drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present portable electronic device. Moreover, in the drawings like reference numerals designate corresponding sections throughout the several views.
[0007] FIG. 1 is an exploded, isometric view of the portable electronic device in accordance with an exemplary embodiment.
[0008] FIG. 2 is an exploded, isometric view of the support assembly shown in FIG 1 .
[0009] FIG. 3 is an assembled, isometric view of the portable electronic device shown in FIG. 1 .
[0010] FIG. 4 is a cross-sectional view of the portable electronic device shown in FIG. 3 taken along line IV-IV.
[0011] FIG. 5 is a cross-sectional view of the portable electronic device shown in FIG. 3 taken along line V-V.
DETAILED DESCRIPTION
[0012] The exemplary portable electronic device 100 shown in FIGS. 1 , 3 and 5 may be a mobile phone, a personal digital assistant (PDA), etc. The portable electronic device 100 includes a body member 10 , a cover member 20 and a support assembly 30 . The cover member 20 is mounted to the body member 10 . The support assembly 30 is mounted to the cover member 20 .
[0013] The cover member 20 may be a battery cover and mounted to the body member 10 by a typical means e.g., elastic latching means. The cover member 20 defines a receiving space 13 used to receive the support assembly 30 therein. The receiving space 13 is enclosed by a first wall 131 , a second wall 132 opposite to the first wall 131 , and two opposite side walls 133 . Each side walls 133 has a symmetric pivoting column 1331 protruding therefrom adjacent to the second wall 132 . The two symmetric pivoting columns 1331 are coaxial and face each other. A bottom wall of the receiving space 13 further defines a latching slot 134 adjacent to the pivoting columns 1331 . The latching slot 134 can be V-shaped (see FIG. 5 ). The latching slot 134 is configured to allow the support assembly 30 to rotate to a predetermined angle. A protrusion 137 protrudes from the first wall 131 , thus forming a clamping slot 1371 between the protrusion 137 and the bottom wall of the receiving space 13 (best seen in FIG. 6 ). The cover member 20 further defines an operation slot 15 adjacent to the first wall 131 . The operation slot 15 is used to facilitate a user's access to the support assembly 30 when it is received in the receiving space 13 .
[0014] Referring to FIG. 2 , the support assembly 30 includes a support board 31 , an elastic member 32 and two connecting sleeves 33 . The support board 31 is configured to be received in the receiving space 13 . The support board 31 includes a first end 311 and a second end 312 parallel and opposite to the first end 311 . The support board 31 includes a mounting cavity 3111 adjacent to the first end 311 , and a latching portion 3113 . In this exemplary embodiment, the mounting cavity 3111 has a semicircular cross-section. A bottom wall of the mounting cavity 3111 defines two mounting slits 3112 perpendicular with the cross-section of the mounting cavity 3111 . The latching portion 3113 is used to latch into the latching slot 134 . The connecting sleeve 33 includes a main portion 331 , a connecting block 332 protruding from an end surface of the main portion 331 , and a pivoting cavity 333 defined on the other end surface of the main portion 331 . The connecting sleeves 33 further define two mounting ribs 334 protruding from a peripheral wall of the main portion 331 corresponding to the mounting slits 3112 . The mounting ribs 334 are slidably received in the corresponding mounting slits 3112 so that the two connecting sleeves 33 are slidably mounted to the support board 31 with the connecting blocks 332 facing each other. The elastic member 32 is a coil spring received in the mounting cavity 3111 and sandwiched between the two connecting sleeves 33 . The connecting block 332 of one connecting sleeve 33 is received into an end of the elastic member 32 , and the connecting block 332 of the other connecting sleeve 33 is received into the other end of the elastic member 32 . The second end 312 has a clamp 3121 protruding from the middle portion. The clamp 3121 latches into the clamping slot 1371 to latch the support assembly 30 to the cover member 20 (see FIG. 6 ). An operation bar 3122 (see FIG. 6 ) also protrudes from the second end 312 corresponding to the operation slot 15 . The operation bar 3122 is exposed in the operation slot 15 and allows easy user access to the operation slot 15 .
[0015] Referring to FIG. 3 together, in assembly, the two connecting sleeves 33 are pushed towards each other, compressing the elastic member 32 . Then the first end 311 with the two connecting sleeves 33 and the elastic member 32 is inserted into the receiving space 13 and the pivoting cavities 333 are aligned with the pivoting columns 1331 . At this time, the connecting sleeves 33 are released and the elastic member 32 repells the connecting sleeves 33 to slide towards the pivoting columns 1331 until the pivoting columns 1331 are rotatably received in the corresponding pivoting cavities 333 . Then, the support board 31 is rotated around the pivoting columns 1331 towards the cover member 20 until the clamp 3121 latches into the clamping slot 1371 . At this time, the support assembly 30 have been retracted and received in the cover member 20 .
[0016] Referring to FIG. 4 to FIG. 7 , in use, a user can access the operation bar 3122 of the support board 31 by the operation slot 15 to make the clamp 3121 go over the protrusion 137 and out of the clamping slot 1371 . Then the support board 31 is rotated around the pivoting columns 1331 until the latching portion 3113 latches into the latching slot 134 . At this time, the latching portion 3113 abuts against a bottom wall of the latching slot 134 and the support board 31 can stably support the portable electronic device 100 upright. Thus, a user can easily enjoy the video images of the portable electronic device 100 without holding the portable electronic device 100 in his/her hands.
[0017] In alternative embodiments, the number of the mounting slits 3112 may be greater than two, and correspond to the number of mounting ribs.
[0018] In further alternative embodiments, a cavity can be defined on an end surface of the connecting sleeves 33 instead of the connecting block 332 . An end of the elastic member 32 is received in the hole.
[0019] It is to be understood that the shape of the latching slot 134 can be changed to allow the support board 31 rotate for different angles.
[0020] It is to be understood that the latching slot 132 can be defined on different portions of the cover member 20 .
[0021] In other alternative embodiments, the support assembly 30 may be directly mounted to the body member 10 .
[0022] It is to be understood, however, that even through numerous characteristics and advantages of the present disclosure have been set forth in the foregoing description, together with details of the structure and function of the disclosure, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of sections within the principles of the disclosure 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 free-standing portable electronic device is described. The portable electronic device includes a cover member, a body member and a support assembly rotatably mounted to the cover member and is used to stand the personal electronic device in an upright manner.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. Provisional Application Ser. No. 61/130,242 filed on May 29, 2008.
FIELD
[0002] This invention generally relates to optical metrology and more particularly relates to an apparatus and method for design and use of an aspheric lens to provide a spherical waveform in a Fizeau interferometer.
BACKGROUND
[0003] In interferometry, highly precise surface measurement is obtained for various types of optical components using interference fringes that are generated between light reflected from a reference surface and light from a surface under test. The Fizeau interferometer is one instrument of this type that is advantaged for measurement of various optical surfaces, particularly for spherical or planar surfaces having relatively large diameters.
[0004] The schematic block diagram of FIG. 1 shows components of a conventional Fizeau interferometer 10 . A laser 12 or other highly coherent light source directs light through a beamsplitter 14 and towards a test surface 20 , the sample surface to be measured, as well as toward a reference surface provided within Fizeau optics 18 . A collimator 16 and Fizeau optics 18 condition the path of light directed toward the target and reference surfaces and bend this light toward the proper angles for the surface being measured. The optical path of target and reference beams is identical through Fizeau optics 18 and collimator 16 . Beamsplitter 14 then redirects the returned light to an interference pattern imaging apparatus 24 for display and analysis.
[0005] Fizeau interferometry, using the overall pattern of FIG. 1 , is advantaged as a method for the interferometric surface inspection of precise spherical and nearly spherical surfaces because the Fizeau reference surface and the surface under test are within close proximity of each other. This reduces the likelihood of optical path disparities and helps to reduce retracing errors experienced by the light reflecting from the Fizeau reference surface and from the surface under test. Ideally, the interference that occurs during Fizeau interferometry only includes known errors on the Fizeau reference surface and errors on the surface under test, because all other sources of wavefront error are common to both paths.
[0006] The schematic diagram of FIG. 2 shows a function of Fizeau optics 18 for accurate surface measurement. Incoming light at L 1 is substantially planar, but must be redirected so that it arrives as spherical light at test surface 20 , a spherical surface. Under the desired conditions for interferometry, as shown at enlargements E 1 and E 2 , the light heading toward test surface 20 , traced along exemplary rays R 1 , R 2 , R 6 , and R 8 in FIG. 2 , has a specific angular relationship to a reference surface 22 . At any point along reference surface 22 , this light that is directed toward the sample surface-under-test, that is, toward test surface 20 , exits at a normal to surface 22 . Reference surface 22 is also termed the Fizeau reference surface. In addition, when test surface 20 has the proper shape, the returning light, as test light, follows the exact same path and is incident on reference surface 22 at a normal. Reference light L 2 that is reflected back from Fizeau reference surface 22 is also returned along the same path as the returning test light.
[0007] Fizeau objectives that deviate from perfect sphericity will cause the reference and test optical paths to vary slightly from one another upon return through the optical system, creating propagation errors. The greater the deviation of the wavefront from sphericity the greater the propagation error. Also, errors of larger slope, that is, of higher spatial frequency, will also cause similar propagation errors.
[0008] Complex optics designs are typically used to create a nearly perfect spherical wavefront from an incoming planar wavefront and to allow the spherical wavefront to be nearly perfectly normal to the Fizeau reference surface as described with reference to FIG. 2 . For example, to bend the light to an appropriate angle θ, as shown in FIG. 2 , a number of conventional designs provide Fizeau objectives with as many as 4 or 5 or more lens elements, often where the numerical aperture is 0.5 or greater. Conventional solutions have not provided Fizeau interferometry systems that feature reduced parts count, smaller size, lower weight, and reduced cost, at the same time. At best, conventional solutions typically address one of these factors at the expense of others. For example, the use of one or more diffractive optical elements (DOE) has been proposed as one way to simplify lens design and reduce parts count. However, due to the relatively high cost and complexity of DOE device design itself, little or no cost advantage is obtained using this approach. As is well known to those familiar with optics fabrication, the complex lens optics conventionally used for Fizeau interferometry require considerable expense and skill in manufacturing and assembly. Even the slightest errors in surface quality, thickness, radius, and alignment can have a significant effect on the measurement accuracy of these optical assemblies.
[0009] The use of an aspheric lens component is one solution that has been advanced for reducing the number of lens elements in the Fizeau optics. For example, commonly assigned U.S. Pat. No. 5,797,493 entitled “Interferometer with Catadioptric Imaging System Having Expanded Range of Numerical Aperture” to Vankerkhove disclosed the use of one or more aspheric lenses in the optical path of a Fizeau interferometer that has refractive elements and a curved reflective surface for beam direction. Similarly, U.S. Pat. No. 7,342,667 entitled “Method of Processing an Optical Element Using an Interferometer Having an Aspherical Lens That Transforms a First Spherical Beam Type into a Second Spherical Beam Type” to Freimann et al. discloses the use of one or more aspheric lenses in a Fizeau interferometer that uses refractive elements.
[0010] Although aspheric lenses are known to offer certain advantages, however, there can be practical hurdles that complicate their deployment or diminish their usefulness in various different applications. The need for precision fabrication, testing, and validation of the aspheric surface is a widely recognized problem to the optics designer and can present complex difficulties that are not easily or inexpensively addressed. In the '667 Freimann et al. patent, for example, a second interferometer apparatus is used in order to characterize or calibrate the aspheric lens for its use in a first interferometer apparatus. Design and use of a special-purpose second interferometer as a test fixture for using an aspheric lens in a first interferometer is a costly solution that adds time and complexity to interferometer manufacture, substantially eroding many of the potential advantages of using an aspheric lens in the first place.
[0011] Thus, it can be seen that there would be significant advantages to apparatus and methods for inexpensively testing and using an aspheric lens, thereby reducing parts count, size, and complexity of Fizeau interferometry optics.
SUMMARY
[0012] It is an object of the present invention to advance the art of optical measurement instrumentation. With this object in mind, the present invention provides an imaging system for obtaining interferometric measurements from a sample spherical surface, comprising:
[0013] a light source for providing an incident light beam;
[0014] a beamsplitter disposed to direct the incident light beam toward the sample spherical surface and to direct a test light reflected from the sample spherical surface and a reference light reflected from a reference spherical surface toward an interferometric imaging apparatus;
[0015] a lens assembly in the path of the incident light beam and comprising at least one lens element, wherein one of the at least one lens elements has an aspheric surface and wherein one of the at least one lens elements further provides the reference spherical surface facing the sample spherical surface; and
[0016] a reference plate that is temporarily disposed in the path of the incident light beam for measuring the aspheric surface itself and that is removable from the path of the incident light beam for obtaining interferometric measurements from the sample spherical surface.
[0017] It is a feature of the present invention that it employs an aspherical surface within the objective lens of Fizeau interferometer optics.
[0018] It is an advantage of the present invention that it provides interferometry optics solutions capable of having reduced parts count.
[0019] These and other aspects, objects, features and advantages of the present invention will be more clearly understood and appreciated from a review of the following detailed description of the preferred embodiments and appended claims, and by reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter of the present invention, it is believed that the invention will be better understood from the following description when taken in conjunction with the accompanying drawings, wherein:
[0021] FIG. 1 is a block diagram of a Fizeau interferometer;
[0022] FIG. 2 is a schematic block diagram that shows the path of light at the reference surface of Fizeau interferometer optics;
[0023] FIG. 3 is a block diagram showing a Fizeau optical assembly having aspheric and spherical lenses;
[0024] FIG. 4 is a block diagram showing a Fizeau optical assembly having a single aspheric lens;
[0025] FIG. 5A is a schematic diagram showing a test setup for measuring the aspheric Fizeau objective in a single-lens embodiment;
[0026] FIG. 5B is a schematic diagram showing a test setup for measuring the aspheric Fizeau objective in a multi-lens embodiment;
[0027] FIG. 6A is a close-up of optical elements in the test setup of FIG. 5A ;
[0028] FIG. 6B is a close-up of optical elements in the test setup of FIG. 5B ; and
[0029] FIG. 7 is a schematic block diagram showing a Fizeau interferometer according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0030] It is to be understood that elements not specifically shown or described may take various forms well known to those skilled in the art. For example, conventional interferometer beam-generating, beamsplitting, and collimation optics, and techniques for handling and interpreting the interference patterns obtained from test and reference light are well known to those skilled in the optical metrology art and, unless related to changes effected by methods and apparatus of the present invention, are not described herein.
[0031] Figures shown and described herein are provided in order to illustrate key principles of operation and component relationships along their respective optical paths according to the present invention and are not drawn with intent to show actual size or scale. Some exaggeration may be necessary in order to emphasize basic structural relationships or principles of operation. Some conventional components that would be needed for implementation of the described embodiments, such as various types of optical mounts, for example, are not shown in the drawings in order to simplify description of the invention itself. In the drawings and text that follow, like components are designated with like reference numerals, and similar descriptions concerning components and arrangement or interaction of components already described are omitted.
[0032] A distinction may be made between spherical and planar with respect to light provided in various embodiments and with respect to surface shapes of optical components. However, it is known that a planar light can be considered to be a type of spherical light, that is, spherical light having a radius of curvature that is considered to be at infinity.
[0033] The term “oblique angle”, as used in the present disclosure, describes an angle that is other than normal, that is, other than an integral multiple of 90 degrees.
[0034] Embodiments of the present invention provide the light bending (to angle θ, as shown in FIG. 2 ) that is required for Fizeau interferometry using a lens element that has an aspheric surface and a spherical surface, singly, or in combination with other lens elements. In addition, embodiments of the present invention provide a mechanism for facilitating testing and validation of the aspheric surface without requiring that a separate test fixture be designed and fabricated.
[0035] Referring to the schematic diagram of FIG. 3 , an embodiment of Fizeau optics 18 has a lens assembly that redirects an incident collimated light from collimator 16 toward a focal point, shown as target t, at angle θ. In this embodiment, a lens element 30 in the lens assembly has an aspherical surface at surface 38 and a surface 39 that is spherical. A spherical lens element 32 , has surfaces 31 and 33 . Lens element 33 provides the reference spherical surface that faces the sample spherical surface for Fizeau measurement. This embodiment uses only two optical elements and has a numerical aperture of 0.5, providing an f/1.0 Fizeau objective. It should be observed that there are other embodiments in which the aspherical surface is one of the other surfaces 31 or 39 of the lens assembly.
[0036] It can be appreciated that there would be advantages to embodiments that use a single aspheric lens, rather than using an aspheric lens in combination with one or more spherical lenses. The additional optics may be necessary, however, in order to increase the overall cone angle (shown in these figures as angle θ) when the desired angle cannot be achieved using a singlet solution.
[0037] There can be, however, applications in which a singlet solution is possible. FIG. 4 shows an alternative Fizeau optics arrangement using a single aspherical lens element 40 . Lens element 40 receives the collimated light at its aspheric surface 42 and directs the focused light from a spherical surface 44 toward the test target at the needed normal angle described earlier with reference to FIG. 2 . A single-element design of this type has a numerical aperture of 0.21 and provides an f/2.3 Fizeau objective.
[0038] The aspheric solutions shown in FIGS. 3 and 4 reduce the parts count, hence size and weight, of Fizeau optics and can provide improved performance over standard designs that use spherical lenses. However, as is well known to those skilled in the optical design arts, the jobs of testing and validation of an aspheric surface, at the accuracy needed, can present significant challenges. In conventional practice, for example, specially designed correction optics such as reflective, refractive, or diffractive “null” lenses or null correctors are typically used for asphere testing and a separate test fixture, such as a separate interferometer, is used. The development of specialized lenses and testing equipment, however, can add considerably to the time and expense required for asphere fabrication.
[0039] The apparatus and methods of the present invention address the problem of aspheric use and testing for an interferometer by providing a way to test the aspheric surface directly in the interferometer itself. That is, in embodiments of the present invention, components of the Fizeau objective can advantageously be used as the test fixture apparatus for test of the asphere surface of lens element 30 ( FIG. 3 ) or of lens element 40 ( FIG. 4 ). Moreover, this same test apparatus arrangement can also be used to measure other problems that exist in the optical path.
[0040] Referring to FIG. 5A , there is shown a test apparatus 50 that is formed by adding a planar reference plate 48 to the interferometer system described earlier. Components shown outside the dashed box are those parts of the interferometer that provide incident collimated light that is directed toward the test surface and read back the test and reference light signals in conventional use. A mount 54 is added to the interferometer components, provided for temporarily seating reference plate 48 in position as part of this test setup. Reference surface 48 , slightly wedge-shaped as shown in the enlarged view of FIG. 6A , is positioned between the aspheric lens element of Fizeau optics 18 and the source of collimated light from upstream optics in the interferometer. The wedge shape provides a slight tilt to a surface 51 , the first surface that receives incident collimated light, so that this surface is oblique to the incident light and deflects unwanted back-reflection from this surface away from the signal path; any detected back reflection from this surface could interfere with the signals of interest.
[0041] For measurement of aspheric surface 42 using test apparatus 50 in FIGS. 5A and 6A , an interference pattern is obtained by a combination of the reference reflected light (Ref) reflected back from a reference surface 52 with test reflected light (Test) that is reflected back from spherical surface 44 .
[0042] FIGS. 5B and 6B show the similar test apparatus 50 arrangement that is used for a more complex embodiment in which Fizeau lens 18 has one or more lens elements in addition to the aspherical lens, shown in these examples as lens 30 . It can be appreciated that this embodiment adds another level of testing capability, since the optical path of the test reflected light includes the additional lens surfaces and, therefore, allows correction or compensation for problems caused by imperfections in these surfaces or their materials. For example, the test setup of FIG. 6B can help to measure other optical factors in addition to aspheric curvature, such as inhomogeneity of the lens material for either lens, surface contour, lens radii, lens center thickness, and airspace errors between lens elements.
[0043] As with other interferometry methods, the arrangements shown in FIGS. 5A-6B eliminate the need to profile aspheric surface 42 or, for alternate embodiments, the appropriate aspheric surface 31 , 38 , or 39 directly, such as using contact profile methods. Instead, this measurement method uses the handling of light by lens element 18 and spherical waves as well as the support image processing components of the interferometer itself to ascertain surface shape and quality for the aspherical surface as it is being formed and finished. An iterative process of shaping and testing can then be followed to achieve the proper aspherical surface that is needed, including providing a surface that corrects for other defects in the Fizeau optics, as described with reference to the FIG. 5 B/ 6 B embodiment. Reference plate 48 can then be removed from mount 54 once Fizeau lens 18 is suitably formed and is ready for use in interferometry.
[0044] This straightforward method for aspheric testing can then be used in conjunction with any of a number of suitable techniques for asphere fabrication, including, for example, magnetorheological finishing (MRF), computer-controlled polishing, and ion beam figuring. These techniques, known to those skilled in the optical fabrication and metrology arts, allow deterministic forming and finishing of a high-quality aspheric surface.
[0045] Referring to FIG. 7 , the interferometer 10 apparatus of the present invention allows one or more aspheric lenses 30 , 40 to be used directly as the Fizeau lens 18 of the interferometer or at another suitable point along the optical path for measuring the sample spherical surface of test surface 20 . Embodiments of the present invention further allow testing of the aspheric surfaces of lenses 30 , 40 to help in surface fabrication.
[0046] Aspheric lens elements themselves can be formed from any suitable material, such as various types of glass or polymer. In general, high-index optical glasses are well suited for use as the aspheric lens.
[0047] Any of a number of suitable finishing techniques can be used in final surface preparation of the Fizeau optics of the present invention. For example, finishing processes can include polishing or application of a coating, such as a partially reflective coating, anti-reflective coating, or protective coating.
[0048] The interferometry apparatus of the present invention is capable of measurement for planar and spherical surfaces and is particularly well-suited for measurement applications of larger diameter lenses. As was noted earlier, the planar surface can be considered to be a special type of spherical surface, for the case in which the radius of curvature is effectively at infinity.
[0049] Unlike earlier solutions that require fabrication of a separate interferometer for testing and validating the aspheric surface, the method and apparatus of the present invention use the interferometer itself as the “test fixture” needed for aspheric surface testing. The only change required to interferometer components is the addition of reference plate 48 to the optical path, whether the reference plate is provided a temporary mounting bracket or fixture within the interferometer for this purpose, or whether an external mechanical device is temporarily provided for positioning the reference plate appropriately while the aspheric surface is checked. That is, the reference plate can be mechanically pivoted or otherwise disposed in place as needed, without the requirement for a separate mount 54 .
[0050] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the scope of the invention as described above, and as noted in the appended claims, by a person of ordinary skill in the art without departing from the scope of the invention. For example, light source 12 can be a laser or laser diode, other solid-state light source that provides an incident light beam. Collimator 16 is an optional component and can be formed from a single lens element or from multiple refractive or reflective optical components. Any of a number of different types of lens mounts or brackets could be used as mount 54 , including those that would allow reference plate 48 to be pivoted or otherwise temporarily moved into place in the optical path from outside the interferometer during device manufacture, so that no additional built-in fixture is needed in the interferometer hardware.
[0051] Thus, what is provided is an apparatus and method for design of an aspheric lens for providing a spherical waveform in a Fizeau interferometer.
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An imaging system for obtaining interferometric measurements from a sample spherical surface has a light source for providing an incident light beam, a beamsplitter disposed to direct the incident light beam toward the sample spherical surface and to direct a test light reflected from the sample spherical surface and a reference light reflected from a reference spherical surface toward an interferometric imaging apparatus. There is a lens assembly in the path of the incident light beam, with at least one lens element, wherein one of the at least one lens elements has an aspheric surface and wherein one of the at least one lens elements further provides the reference spherical surface facing the sample spherical surface. A reference plate is temporarily disposed in the path of the incident light beam for measuring the aspheric surface itself and is removable from the path of the incident light beam for obtaining interferometric measurements from the sample spherical surface.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to locking lug tools, and more particularly pertains to a new and improved locking lug removal tool wherein the same is arranged for the removal of locking lugs relative to a vehicular wheel.
2. Description of the Prior Art
Prior art locking lug structure is exemplified by the U.S. Pat. No. 4,869,633 to Hayashi wherein a locking lug member is formed with a uniquely configured side wall construction to be received within a complementarily configured cavity of an associated removal tool.
U.S. Pat. No. 4,825,669 to Herrera sets forth a wheel lug nut cover utilizing a key lock to secure the nut cover thereto.
U.S. Pat. No. 4,625,599 to Icard sets forth fixed lugs mounted to a first end of a tool to be received within recesses of a second tool to provide for extension of the tool structure.
As such, it may be appreciated that there continues to be a need for a new and improved locking lug removal tool as set forth by the instant invention which addresses both the problems of ease of use as well as effectiveness in construction and in this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of locking lug removal tools now present in the prior art, the present invention provides a locking lug removal tool wherein the same utilizes telescopingly mounted pins mounted within a locking lug removal tool to accommodate various recesses within a locking lug member relative to an associated vehicular wheel. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved locking lug removal tool which has all the advantages of the prior art removal tool apparatus and none of the disadvantages.
To attain this, the present invention provides a tool arranged with a first housing coaxially mounted in longitudinal alignment with a second housing, with a matrix of lock pins extending in a spring-biased relationship from the first housing into the second housing, wherein the lock pins are arranged for displacement and retraction into the first housing to accommodate various recesses relative to a locking lug as typically utilized with a vehicular wheel.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved locking lug removal tool which has all the advantages of the prior art locking lug apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved locking lug removal tool which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved locking lug removal tool which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved locking lug removal tool which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such locking lug removal tools economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved locking lug removal tool which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an orthographic cross-sectional illustration of the tool structure of the invention.
FIG. 2 is an orthographic top view of the instant invention.
FIG. 3 is an orthographic side view of the instant invention.
FIG. 4 is an orthographic bottom view of the instant invention.
FIG. 5 is an isometric illustration of the instant invention.
FIGS. 6, 8, 10, and 12 are bottom orthographic views of first cone inserts for utilization by the engaging pins of the invention.
FIGS. 7, 9, 11, and 13 are orthographic side views per the respective FIGS. 6, 8, 10, and 12.
FIGS. 14, 16, 18, and 20 are orthographic side views of second cone inserts for utilization by the invention.
FIGS. 15, 17, 19, and 21 are orthographic bottom views of the respective FIGS. 14, 16, 18, and 20.
FIG. 22 is an orthographic view, taken along the lines 22--22 of FIG. 12 in the direction indicated by the arrows.
FIG. 23 is an orthographic view, taken along the lines 23--23 of FIG. 21 in the direction indicated by the arrows.
FIG. 24 is an orthographic side view, taken in cross-section, of the cone inserts mounted to an engaging pin.
FIG. 25 is an orthographic side view of a first cone insert illustrative of mounting of the first cone insert relative to an engaging pin of the tool structure.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 25 thereof, a new and improved locking lug removal tool embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, the locking lug removal tool 10 of the instant invention, with specific reference to the FIGS. 1-5, includes a first coaxially aligned housing defined along an axis 11a fixedly secured at a longitudinal relationship to a second coaxially aligned housing 19 further defined along the axis 11a. A first housing top wall 12 is spaced from and parallel a first housing bottom wall 16. The first housing top wall 12 includes a top wall lug 13 positioned medially of the top wall 12, including a spring-biased detent 14 contained therewithin radially directed through the lug 13 for securement to a driving tool (not shown). A first housing side wall 15 is arranged coaxially defined about the axis 11a, with a matrix of bottom wall bores 17 projecting coaxially into the first housing 11 from the first housing bottom wall 16 extending to and in an orthogonal relationship relative to the top wall 12 but terminating in a spaced relationship relative to the top wall 12. Each of the bottom wall bores 17 includes a bore spring 18, with an engaging pin head 25 positioned at a forward distal end of each spring 18, wherein each spring biases each engaging pin head 25 longitudinally of and exteriorly of each bore. Each engaging pin head 25 includes an coaxially aligned engaging pin 24 extending below each engaging head to project therefrom, in a manner to be described in more detail below.
The second housing 19 includes a second housing top wall 20 in a contiguous and coextensive relationship relative to the bottom wall 16, with a second housing cavity 21 extending into the second housing from a second housing bottom wall 22. The second housing cavity 21 terminates in a cavity floor 28 arranged in a parallel spaced relationship relative to the second housing bottom wall 22. A fastener 23 coaxially aligned with the axis 11a is directed through the cavity floor 28 into the second housing through the second housing bottom wall 16. The engaging head 25 is mounted with and its forward travel limited by a second housing first bore 26 coaxially aligned with a respective bottom wall bore 17. A second housing second bore 27 extends coaxially of the first bore 26 orthogonally through the cavity floor 28, wherein each engaging pin head 25 is of a second diameter greater than a first diameter defined by each engaging pin 24 that in a fully extended orientation is arranged within the cavity 21.
In use of the tool, the tool is merely directed onto a loking lug (not shown) of any desired configuration and the pins 24 are received within a cavity formed within such a locking lug and those pins not utilized are merely retracted within each associated bore 17.
The FIGS. 6-13 and the FIGS. 14-21 illustrate respective first and second cone inserts 29 and 30. The first cone inserts 29 each include a first cone conical cavity 29a, wherein the second cone inserts 30 include a through-extending second cone bore 30a. The cones are arranged for adhering relative to the engaging pins 24 adjacent to the engaging pins' free distal ends spaced from the engaging pin heads 25 to accommodate various geometric configurations within a locking lug member and thereby permit tailoring of the engaging pins relative to such structure. An example of such securement is illustrated in the FIGS. 4 and 25, with the engaging pins received within the bores 30a and the cavities 29a as required. Further, the inserts 29 and 30 when adhered to the pins 24 control depth of retraction of the pins relative to the bottom wall bores 17.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A tool is arranged with a first housing coaxially mounted in longitudinal alignment with a second housing, with a matrix of block pins extending in a spring-biased relationship from the first housing into the second housing, wherein the lock pins are arranged for displacement and retraction into the first housing to accommodate various recesses relative to a locking lug as typically utilized with a vehicular wheel.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 60/583,885, filed Jun. 29, 2004, the disclosure of which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present application is generally directed to making pulp and is more specifically directed to screen assemblies for pulp digesters.
[0003] Continuous digesters are used in the paper and pulp industry to remove lignin from wood chips. The digesters generally include a series of tubular reactors that are arranged in a vertical orientation. The digester is made up of a plurality of reaction and extraction stages for carrying out the pulp-making process in a specific sequence. In certain stages, chemicals are introduced into the digester for chemically treating the woodchips. These chemicals may include hydrosulfide and sodium hydroxide, commonly referred to as liquor. In other stages, the chemicals are removed from the reactor through screens provided inside the digester.
[0004] FIGS. 1A and 1B show a conventional pulp digester 20 having a vessel wall 22 with an interior surface 24 and an exterior surface 26 . The vessel 22 has a step out section 28 and a straight section 30 located below the step out section. The step out section 28 diverges outwardly for expanding the diameter of the vessel 22 between an upstream section of the digester and a downstream section of the digester.
[0005] The digester 20 includes a bar screen 32 having an upper end 34 and a lower end 36 . The bar screen 32 includes a plurality of vertically extending, cylindrical bars 38 that are spaced from one another. The upper end 34 of the bar screen 32 is attached to the vessel via an upper support element 40 and the lower end 36 of the bar screen 32 is attached to the vessel via a lower support element 42 . The bar screen is permanently fixed to the vessel wall 22 , such as by welding the upper and lower ends 34 , 36 of the bar screen 32 to the upper and lower support elements 40 , 42 . The bar screen 32 has a diameter that remains substantially constant between the upper and lower ends 34 , 36 thereof.
[0006] The digester also includes an upper cover plate 44 having an upper end 46 and a lower end 48 . The upper end 46 of the upper cover plate 44 is secured to the interior surface 24 of the vessel at a location above the step out section 28 . The lower end 48 of the upper cover plate 44 is secured to the upper support element 40 . The digester also has a lower cover plate 50 having an upper end attached to lower support element 42 . The lower cover plate 50 extends downwardly from the bar screen 32 to a downstream section (not shown) of the digester. The digester has an outlet 52 for removing liquid from the vessel.
[0007] Permanently fixing the bar screen to the wall 22 involves a significant amount of work when assembling the digester. For example, when welding is used, the manufacturing process requires hundreds of welds to attach one bar screen to the vessel wall. For a vessel having many bar screens, the number of required welds may be in the thousands. The large number of welds increases the chances that one or more of the welds will crack, which may adversely affect operation of The digester or may require the digester to be taken off-line for repairs.
[0008] The production of quality pulp involves introducing and removing liquor from the digester at certain time periods. The liquor is typically removed from digesters by passing the liquor through screens in a radial direction. The radial removal of the liquor causes compression of the wood chips onto the screen. This may prevent the wood chips from continuing to move toward the bottom of the digester, which is critical for the proper treatment of the chips. Extreme radial compression may also limit the amount of liquor that can be removed from the digester. Both of these situations may adversely affect the quality of the pulp produced using the digester.
[0009] FIGS. 2A and 2B show a pulp digester having a diverging screen assembly. The digester 120 has a vessel wall 122 with an interior surface 124 and an exterior surface 126 . The vessel 122 has a step out section 128 and a straight section 130 located below the step out section. The step out section 128 diverges outwardly for expanding the diameter of the vessel 122 between an upstream stage and a downstream stage of the digester.
[0010] The digester 120 includes a diverging bar screen 132 having an upper end 134 and a lower end 136 . The bar screen 132 includes a plurality of vertically extending, cylindrical bars 138 that are spaced from one another. The upper end 134 of the bar screen 132 is attached to the vessel via an upper support element 140 and the lower end 136 of the bar screen 132 is attached to the vessel via a lower support element 142 . The bar screen continuously diverges between upper and lower ends thereof for reducing the compression loading of the wood chips on the screen. The digester also includes an upper cover plate 144 having an upper end 146 and a lower end 148 . The upper end 146 of the upper cover plate 144 is secured to the interior surface 124 of the vessel at a location above the step out section 128 . The lower end 148 of the upper cover plate 144 is secured to the upper support element 140 . The digester also has a lower cover plate 150 having an upper end attached to lower support element 142 . The lower cover plate 150 extends downwardly from the bar screen 132 to another downstream stage (not shown) of the digester. The digester has an outlet 152 for removing liquid from the vessel.
[0011] In spite of the above advances, there is a need to provide continuous digesters that more efficiently introduce and remove liquor from the digester vessel at various stages of the pulp making process. There also remains a need for simplified methods for building digesters. Specifically, there remains a need for simpler methods for assembling screen assemblies inside digesters that minimize the number of welds needed for securing the screen inside the digester. Further, there remains a need for screen assemblies that are less subject to breakage during digester operations.
SUMMARY OF THE INVENTION
[0012] In certain preferred embodiments of the present invention, a pulp digester includes a vessel having an inlet, an outlet and a wall extending between the inlet and the outlet, the wall of the vessel having a curved interior surface. The digester preferably includes a screen assembly positioned inside the vessel adjacent to the curved interior surface for removing liquid from pulp material. The screen assembly is desirably movable relative to the curved interior surface of the vessel wall. The digester also preferably includes at least one support element permanently attached to the vessel wall for limiting movement of the screen assembly relative to the curved interior surface of the vessel wall.
[0013] The at least one support element preferably supports a portion of the screen assembly. In certain preferred embodiments, the at least one support element supports a lower portion of the screen assembly. The at least one support element may include a ledge immovably attached to the vessel wall. The ledge may be welded to the vessel wall.
[0014] The at least one support element may also include at least one cover plate overlying the interior surface of the wall and being permanently attached to the wall, with the at least one cover plate being in contact with the screen assembly for limiting movement of the screen assembly over the curved interior surface of the vessel wall. In certain preferred embodiments, the at least one cover plate desirably includes an upper cover plate in contact with an upper end of the screen assembly and a lower cover plate in contact with a lower end of the screen assembly, the cover plates being permanently attached to the wall.
[0015] The at least one cover plate is preferably in contact with the screen assembly for limiting movement of the screen assembly relative to the curved interior surface of the vessel wall. The upper cover plate may diverge in a flow direction of the pulp material through the vessel. The digester may also include a pair of lateral cover plates in contact with respective sides of the screen assembly, the lateral cover plates extending between the upper and lower ends of the screen assembly and being permanently attached to the wall.
[0016] Although the present invention is not limited by any particular theory of operation, it is believed that providing screen assemblies that are movable relative to the vessel wall will solve a number of problems associated with digesters. First, the movable screen assembly of the present invention can better accommodate pressure changes within the vessel because the screen assembly can move in response to high-pressure areas within the vessel. Thus, the movable screen of the present invention enables pressure to be more evenly distributed throughout the vessel. Second, the ability of the screen assemblies of the present invention to move tends to minimize the formation of cracks in either the screen assembly or the welds used to position the screen assembly within the vessel. This feature overcomes problems found in prior art digesters that use thousands of welds to hold screens in place. These welds tend to crack under pressure or during long-term use, which results in maintenance problems or downtime for the digester. Third, the movable screen assemblies of the present invention can be used in a wide variety of digesters having different inner wall surfaces. As is well known to those skilled in the art, no two digesters are the same. This often makes it difficult to weld prior art screens to the vessel wall. However, this problem of matching the contour of the screen to the contour of the vessel wall is solved with the present invention because the screen floats and/or is movable relative to the vessel wall, thereby minimizing the need for providing exacting tolerances between the contour of the screen assembly and the contour of the vessel wall. The present invention also enables digesters to be assembled in less time and at lower cost. This is due, in part, to the fact that fewer welds are required for positioning the screens within a vessel. In many instances, the number of fewer welds may be in the hundreds or thousands.
[0017] In certain preferred embodiments of the present invention, the screen assemblies may be used to replace existing screens in a digester. In certain embodiments, the existing screen assemblies in a digester may be cut out and/or removed from the digester and replaced with one or more screen assemblies of the present invention. The newly installed one or more screen assemblies of the present invention may be held in place by cover plates that overlie the one or more edges of the screen assembly. The screen assembly of the present invention is preferably moveable relative to the vessel wall of the digester. As a result, the screen assembly is able to respond to high pressure areas within the digester. In certain preferred embodiments, the screen assemblies of the present invention are assembled outside of the digester. The screen assemblies are then secured inside the digesters in a manner so that the screen assemblies are moveable within a range or area relative to the vessel wall. Due to the moveable nature of the screen assemblies of the present invention, exact tolerances between the outer face of the screen assembly and the inner face of the vessel wall are not required.
[0018] In certain preferred embodiments, the screen assembly has an inner face that is concave in a horizontal direction. The screen assembly may also have an inner face that is convex in a vertical direction. In other preferred embodiments, the screen assembly may diverge in the flow direction of the pulp material.
[0019] The screen assembly desirably includes a plurality of bars extending in a generally vertical direction between the upper and lower ends of the screen assembly, whereby the bars are spaced from one another so as to define gaps between the spaced bars. In certain preferred embodiments, the bars are curved in the vertical direction. The size of the gaps between the spaced bars may remain constant between the upper and lower ends of the screen assembly. In other preferred embodiments, the size of the gaps between the spaced bars may change between the upper and lower ends of the screen assembly. In still other preferred embodiments, the vessel preferably has a longitudinal axis extending between upper and lower ends thereof and each of the bars of the screen assembly is curved relative to the longitudinal axis. The bars may be of any geometric shape in cross-section, such as cylindrical, circular, oval, square or rectangular. The exterior surface of the bars may be curved in one area and flat in another area.
[0020] In other preferred embodiments, the screen assembly may include one or more metal plates having one or more openings therethrough. The screen assembly may include a metal plate having a plurality of openings extending therethrough. The size and spacing of the openings may be constant or may change over the area of the plate. The openings may also be elongated in one or more directions such as slots. In further preferred embodiments, the screen assembly may include a plurality of metal plates that are assembled together with gaps or spaces between the metal plates. The size and shape of the gaps may be constant or may change.
[0021] In certain preferred embodiments, the screen assembly includes a top support arch, a bottom support arch spaced from the top support arch, and at least one intermediate support arch positioned between the top and bottom support arches. The screen assembly may also include at least one frame member attached to the support arches for maintaining the support arches in a fixed, spaced orientation relative to one another, and a plurality of spaced bars extending between the top and bottom support arches, the spaced bars having upper sections permanently attached to the top support arch, lower sections permanently attached to the bottom support arch and intermediate sections in contact with, but not permanently attached to, the at least one intermediate support arch.
[0022] The support arches may have inwardly extending fingers for engaging the bars. The fingers of the intermediate arch may be longer than the fingers of the top and bottom support arches for providing a curve to the bars between the top and bottom support arches. The screen assembly may include a plurality of intermediate support arches between the top and bottom support arches. The fingers of the intermediate arches near the center of the screen assembly are preferably longer than the fingers of the intermediate arches near the top and bottom support arches.
[0023] In other preferred embodiments of the present invention, a pulp digester includes a vessel having an inlet, an outlet and a wall extending between the inlet and the outlet, whereby the wall of the vessel has a curved interior surface. The digester may include a screen assembly for removing liquid from the pulp material, whereby the screen assembly has an inner face that is concave in a horizontal direction and convex in a vertical direction. In this embodiment, the screen assembly may be movable over the curved interior surface of the vessel wall, The digester further comprising at least one support element permanently attached to the vessel wall for limiting movement of the screen assembly over the curved interior surface of the vessel wall.
[0024] In other preferred embodiments of the present invention, a screen assembly for a pulp digester includes a top support arch, a bottom support arch spaced from the top support arch and at least one intermediate support arch positioned between the top and bottom support arches. The screen assembly desirably includes at least one frame member attached to the top support arch, the bottom support arch and the at least one intermediate support arch for maintaining the support arches is a fixed orientation relative to one another, and a plurality of spaced bars extending between the top and bottom support arches, the spaced bars having upper sections permanently attached to the top support arch, lower sections permanently attached to the bottom support arch and intermediate sections in contact with, but not permanently attached to, the at least one intermediate support arch. The bars are desirably curved between the upper and lower sections thereof.
[0025] In certain preferred embodiments, the screen assembly has an inner face that is concave in a horizontal direction. The inner face may be convex in a vertical direction.
[0026] Each of the support arches desirably has a convex outer face and a concave inner face having fingers that engage the respective bars. The fingers of the at least one intermediate support arch are preferably longer than the fingers of the top and bottom support arches for facilitating curving of the bars when the bars are in contact with the fingers. The inner ends of the fingers desirably have seating surfaces adapted to receive the bars. The bars have preferably have cylindrical exterior surfaces and the seating surfaces of said fingers are preferably concave for receiving the cylindrical exterior surfaces of the bars.
[0027] The support arches preferably extend in directions that are parallel to one another. At least one intermediate support arch preferably includes a plurality of intermediate support arches between the top support arch and the bottom support arch. The fingers of the intermediate support arches are progressively longer for the arches closer to the center of the screen assembly.
[0028] In another preferred embodiment of the present invention, a screen assembly for removing liquid from a pulp digester includes a top support arch having inwardly extending fingers, a bottom support arch spaced from the top support arch and having inwardly extending fingers, and at least one intermediate support arch positioned between the top and bottom support arches and having inwardly extending fingers. The screen assembly desirably includes at least one frame member attached to the top support arch, the bottom support arch and the at least one intermediate support arch for maintaining the support arches is a fixed orientation relative to one another, and a plurality of spaced bars extending between the top and bottom support arches, whereby each bar is in contact with one of the fingers of each support arch. The fingers of the at least one intermediate arch are preferably longer than the fingers of the top and bottom support arches for bending the bars between the top and bottom support arches.
[0029] The spaced bars may have upper sections permanently attached to the fingers of the top support arch, lower sections permanently attached to fingers of the bottom support arch and intermediate sections in contact with, but not permanently attached to, the fingers of the at least one intermediate support arch.
[0030] In other preferred embodiments of the present invention, a method of installing a screen assembly in a pulp digester includes providing a vessel having an inlet, an outlet and a wall extending between the inlet and the outlet, whereby the wall of the vessel has a curved interior surface. The method includes attaching a support element to the curved interior surface of the vessel wall, and installing a screen assembly inside the vessel adjacent the curved interior surface so that the screen assembly is movable relative to the curved interior surface, whereby the support element engages a portion of the screen assembly for limiting downward movement of the screen assembly through the vessel. The attaching step may include permanently securing the support element to the curved interior surface, such as by welding.
[0031] In another preferred embodiment of the present invention, a method of installing a screen assembly in a pulp digester includes providing a vessel having an inlet, an outlet and a wall extending between the inlet and the outlet, whereby the wall of the vessel has a curved interior surface, and installing a screen assembly inside the vessel adjacent the curved interior surface, the screen assembly having a horizontal cross-section that is concave and a vertical cross-section that is convex. The method may include attaching a support element to the curved interior surface of the vessel wall so that the screen assembly is movable relative to the curved interior surface, whereby the support element engages a portion of the screen assembly for limiting downward movement of the screen assembly through the vessel.
[0032] These and other preferred embodiments of the present invention will be described in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1A shows a cross-sectional view of a prior art pulp digester including a vessel and a cylindrical screen mounted in the vessel.
[0034] FIG. 1B shows a fragmentary front elevation view of the prior art pulp digester of FIG. 1A .
[0035] FIG. 2A shows a cross-sectional view of a prior art pulp digester including a vessel and a diverging screen mounted in the vessel.
[0036] FIG. 2B shows a fragmentary front elevation view of the prior art pulp digester of FIG. 2A .
[0037] FIG. 3A shows a cross-sectional view of a pulp digester including a vessel and a screen positioned inside the vessel, in accordance with certain preferred embodiments of the present invention.
[0038] FIG. 3B shows a fragmentary front elevation view of the vessel and the screen shown in FIG. 3A .
[0039] FIG. 4 shows another cross-sectional view of the pulp digester shown in FIG. 3A .
[0040] FIG. 5 shows an expanded view of an upper section of the screen shown in FIG. 4 .
[0041] FIG. 6 shows an expanded view of an intermediate section of the screen shown in FIG. 4 .
[0042] FIG. 7 shows an expanded view of a lower section of the screen shown in FIG. 4 .
[0043] FIG. 8 shows a top plan view of a portion of the vessel and the screen shown in FIG. 4 .
[0044] FIG. 9 shows an expanded view of a lateral section of the screen shown in FIG. 8 .
[0045] FIG. 10 shows an expanded view of an intermediate section of the screen shown in FIG. 8 .
[0046] FIG. 11A shows a bar screen having constant gaps between bars, in accordance with certain preferred embodiments of the present invention.
[0047] FIG. 11B shows a bar screen having gaps that increase in size between ends of the screen, in accordance with other preferred embodiments of the present invention.
[0048] FIG. 12 shows a graph comparing relative chip compaction for a right cylinder screen assembly, a diverging screen assembly and a screen assembly in accordance with certain preferred embodiments of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0049] FIGS. 3A and 3B show a pulp digester 220 in accordance with certain preferred embodiments of the present invention. The pulp digester 220 desirably includes a vessel wall 222 with an interior surface 224 facing the inside of the vessel and an exterior surface 226 facing the outside of the vessel. The vessel wall 222 has a step out section 228 that diverges outwardly from an upstream stage 229 of the digester. The vessel wall 222 also has a straight section 230 located below the step out section 228 . The vessel wall 222 has a longitudinal axis or centerline C-C, and the step out section 228 diverges outwardly from the centerline C-C for expanding the interior diameter of the vessel wall 222 between the upstream stage 229 and a downstream stage.
[0050] Referring to FIGS. 3A, 3B and 4 , the digester 220 preferably includes a bar screen 232 having an upper end 234 and a lower end 236 . The bar screen 232 desirably includes a plurality of vertically extending bars 238 that are spaced from one another. The bars 238 may be cylindrical in shape. The size of the gaps between the bars may be constant or may change over the area of the screen. The gaps between the bars 238 preferably allow fluid, such as liquor, to flow between the bars when treating pulp in the digester. The bar screen 232 preferably includes a series of support arches 260 that extend between the upper and lower ends of the screen.
[0051] In certain preferred embodiments, the upper end 234 of the bar screen 232 ( FIG. 3A ) may be located anywhere in the step out section 228 of the vessel wall 222 , with the lower end 236 of the bar screen being supported by the lower support element 242 .
[0052] Referring to FIGS. 3A, 4 and 5 , the uppermost end of bar screen 232 includes at least one bar 238 that is attached to a top support arch 260 A by weld 239 . Referring to FIGS. 4 and 7 , the lowermost end 226 of bar screen 232 includes at least one bar 238 that is attached to a bottom support arch 260 K by weld 235 . Referring to FIGS. 4 and 6 , bar screen 232 also has one or more intermediate support arches 260 between the top support arch 235 and the bottom support arch 237 . In the particular preferred embodiment shown in FIG. 6 , the round bar 238 is welded to intermediate support arch 260 by welding 262 . This welding with an intermediate arch is generally done when the screen 232 has a substantial height. Welding and even the provision of the intermediate arch may not be necessary for screens that do not have substantial height. Thus, in other preferred embodiments, the bar 238 merely engages and/or is supported by the intermediate support arch 260 and is not attached to the intermediate support arch 260 . Significantly, none of the support arches 260 A- 260 K is attached to the vessel wall 222 . As a result, the bar screen 232 is able to move relative to the vessel wall, within an area bordered by one or more supporting elements as will be described in more detail below.
[0053] Referring to FIGS. 3A, 3B , 4 and 5 , the digester also preferably includes an upper cover plate 244 having an upper end 246 and a lower end 248 . The upper end 246 of the upper cover plate 244 is secured to the interior surface 224 of the vessel wall 222 and the lower end 248 of the upper cover plate 244 is secured to an upper support element 240 . The upper support element 240 has an outer end that is attached to the inner wall 224 of the vessel wall 222 and an inner end that is attached to the upper cover plate 244 . Referring to FIGS. 4 and 5 , the above-referenced attachments may be formed by attaching the outer end of the upper support element 240 to the interior surface 224 of vessel wall 222 using welding seams 241 , and attaching the inner end of the upper support element 240 to the upper cover plate 244 using welding seam 243 . The upper cover plate 244 preferably diverges outwardly from centerline C-C between the upper and lower ends of the upper cover plate. As a result, the distance between the centerline and the upper end of the upper cover plate is less than the distance between the centerline and the lower end of the upper cover plate.
[0054] Referring to FIGS. 3A, 4 and 7 , the digester 220 also preferably has a lower cover plate 250 having an upper end attached to the lower support element 242 that is attached to the vessel wall 222 . The lower cover plate 250 extends downwardly from the lower end 236 of bar screen 232 to a downstream stage (not shown) of the digester. Referring to FIGS. 4 and 7 , the lower support element 242 has an outer end attached to vessel wall 222 by welding seam 245 and an inner end attached to lower cover plate 250 by welding seam 247 .
[0055] As noted above, the support arches 260 A- 260 K of the bar screen assembly 232 are not attached to the vessel wall 222 , but are bounded by and held in position by the one or more supporting elements such as the upper and lower cover plates 244 , 250 , the upper support element 240 or the lower support element 242 . As shown in FIGS. 4 and 5 , the upper cover plate 244 covers or overlaps the top support arch 260 A but is not attached thereto so that the upper end 234 of the bar screen is able to float freely in back of the upper cover plate. As shown in FIGS. 4 and 7 , the lower cover plate 250 covers or overlaps the bottom support arch 260 K but is not attached thereto so that the lower end 236 of the bar screen is able to float freely in back of the lower cover plate 250 . The lower support element 242 preferably supports the lower end of the screen assembly 232 and limits downward movement of the screen assembly relative to the vessel wall.
[0056] Referring to FIGS. 3A and 4 , the digester has at least one outlet 252 for removing fluid and/or liquid from the vessel wall 222 .
[0057] Referring to FIGS. 8-10 , digester 220 includes a first lateral support element 264 and a second lateral support element 266 that border the respective lateral sides of bar screen 232 . The first lateral support element 264 has an outer end that is attached to the interior surface 224 of vessel wall 222 by welding seams 268 and an inner end that is attached to a first lateral cover plate 270 by welding 272 . The second lateral support element 266 has an outer end that is attached to the interior surface 224 of vessel wall 222 by welding 274 and an inner end that is attached to a second lateral cover plate 276 by welding 278 .
[0058] The bar screen 232 includes a plurality of vertically extending bars 238 having gaps 280 between the bars. In certain preferred embodiments, the bars may be cylindrical and may extend in horizontal or diagonal directions. The bar screen also includes a series of support arches 260 A- 260 K that engage the vertically extending bars 238 . Each support arch 260 has a first end 282 , a second end 284 and a plurality of fingers 286 that engage the respective bars 238 . The fingers 286 define flow channels 288 therebetween that are in communication with the gaps 280 between the bars 238 .
[0059] The bar screen 232 also includes a first side frame 290 that is attached to the first end 282 of the support arch 260 by welding 292 and second side frame 294 that is attached to the second end 284 of the support arch 260 by welding (not shown). The side frames 290 , 294 may be attached to a plurality of the support arches for holding the support arches in a fixed orientation relative to one another. The inner ends of the fingers 286 desirably have grooves 296 formed therein for effectively seating the bars. In the particular embodiment shown, the grooves 296 are concave in shape.
[0060] Referring to FIG. 8 , the support arch 260 has an outer face 298 that defines an arch and a series of projections 300 extending from the outer face 298 . The inner surface 224 of the vessel wall 222 has a radius R 3 from centerline C (the position of centerline C is shown for simplicity only and is not to scale). The curvature of the support arch 260 preferably changes between the first and second ends of the arch 260 . As shown in FIG. 8 , the projections 300 A and 300 G adjacent the ends of the support arch are in contact with the inner surface 224 of vessel wall 222 . However, the gap 302 between the projections 300 and the inner surface 224 increases between the ends of the support arch and the center of the support arch 260 . As a result, the gap 302 between projection 300 D and inner surface 224 is greater than the gap between projections 300 C and 300 E and inner surface, which is greater than the gap between projections 300 B and 300 F and inner surface 224 . The radius of the support arch 260 is about R3 at the ends of the arch and is about R4 at an interior section of arch 260 , whereby R4<R3.
[0061] As shown in FIGS. 8 and 9 , the bar screen 232 is not permanently attached to the vessel wall 222 , but is able to move relative to the vessel wall 222 . As a result, the bar screen is able to move up and down between the upper and lower support elements 240 , 242 and laterally between the lateral support elements 264 , 266 .
[0062] Referring to FIGS. 3A and 8 , in certain preferred embodiments, the bar screen 232 is assembled by attaching the first and second side frames 290 , 294 to the first and second ends of support arches 260 . The support arches include top support arch 260 A, bottom support arch 260 K, and intermediate support arches 260 B- 260 J that lie between the top support arch and the bottom support arch. The support arches 260 A- 260 K extend in directions that are generally parallel to one another. In the particular embodiment shown in FIG. 3A , the support arches are parallel to one another and extend in substantially horizontal directions relative to the length of the digester.
[0063] Referring to FIGS. 3A, 8 and 10 , the length of the fingers 286 on a single support arch preferably remain the same, however, the finger length may vary between two or more arches. In other words, a first support arch may have fingers with a length x, and a second support arch may have fingers with a length x+1. Referring to FIG. 3A , in certain preferred embodiments, the fingers of support arch 260 F are longer than the fingers of support arches 260 E and 260 G, which are longer than the fingers of support arches 260 D and 260 H, which are longer than the fingers of support arches 260 C and 260 I, which are longer than the fingers of support arches 260 B and 260 J. As a result, when the vertically extending bars 238 are assembled with the support arches, the bars have a slight curve, with the center of the curve being located outside the vessel wall 222 . Referring to FIG. 4 , the bars 238 are curved about a center located outside the vessel wall and having a radius designated R 1 . As shown in FIG. 3A , the upper end of the bar screen 232 defines a diameter D 1 , and the lower end of the bar screen defines a diameter D 3 that is equal to D 1 . The center of the bar screen defines a diameter D 2 that is less than D 1 and D 3 . Thus, the inner face of the bar screen 232 has a decreasing diameter between the upper end 234 of the bar screen and a mid-point located between the upper and lower ends, and then has an increasing diameter between the mid-point of the bar screen and the lower end 236 thereof.
[0064] In certain preferred embodiments, the lower ends of the bars 238 are permanently attached to the fingers of the bottom support arch 260 K and the fingers of the top support arch 260 A, and are not permanently attached to the fingers of the intermediate arches 260 B- 260 J. This may be accomplished by seating a lower end of a bar 238 in one of the fingers of the bottom support arch 260 K and welding the bar to the finger. The bar is then seated in the fingers of the intermediate arches, starting first with arch 260 J and moving onto 260 B. The upper end of the bar is then seated in the groove of one of the fingers of top support arch 260 A and welded to the finger of the top support arch. The process is repeated for all of the vertically extending bars so that the lower ends of the bars are welded to the bottom support arch and the upper ends of the bars are welded to the top support arch. Due to the changing length of the fingers, the bars will have a slight curve between top and bottom support arches 260 A, 260 K. In certain preferred embodiments, the bars follow a curve having a center located outside the vessel wall, whereby the curve has a radius R 1 of between about 55-70 meters and more preferably about 60-65 meters. Thus, the bars 238 follow a curved path having an extremely large radius.
[0065] FIG. 11A shows bar screen 232 held in position by upper cover plate 244 , lateral cover plate 270 , and lower cover plate 250 . The bar screen is not permanently affixed to the vessel wall 222 so that the screen is able to float under the cover plates. The bar screen 232 includes a series of vertically extending bars 238 having gaps 280 therebetween. The size of the gaps 280 remains constant between the upper end 234 and the lower end 236 of the screen 232 .
[0066] FIG. 11B shows a bar screen 232 ′ held in position by upper cover plate 244 ′, lateral cover plate 276 ′ and lower cover plate 250 ′. Once again, the bar screen 232 ′ is not permanently affixed to the vessel wall 222 ′, but is able to move relative to vessel wall 222 ′. The bar screen 232 ′ includes a series of bars 238 ′ having gaps 280 ′ therebetween. The size of the gaps 280 ′ between the bars 238 ′ increases between the upper end 234 ′ and the lower end 236 ′ of the screen 232 ′.
[0067] FIG. 12 shows a graph comparing relative chip compaction in a pulp digester when using the standard, right cylinder screen assembly shown in FIG. 1A , the diverging screen assembly shown in FIG. 2A , and the screen assembly in accordance with certain preferred embodiments of the present invention shown in FIGS. 3A-11B . The results for the standard screen are depicted using a solid line, the results for the diverging screen are depicted using a dashed line having elongated dashes, and the results for the screen assembly of the present invention are depicted using a dashed line having shorter dashes. The X-axis in the graph represents the height of the screen assembly, starting 0.1 meter above the screen (wherein the cover plate is located). The Y-axis in the graph shows the relative compaction of the chip column. The chip columns in the three different systems (i.e. standard screen, diverging screen, screen of the present application) all have the same absolute starting value at 0.2 meter above the upper end of the screen. The graph shows that compaction for the standard screen and diverging screen increases at the transition between the cover plate and the screen. In contrast, the compaction level for the present invention actually decreases at the transition because the upper cover plate diverges. The peak value of the compaction is at the location where there is no axial flow vector at all. After peak value, the compaction is decreased rapidly by counter-current wash flow.
[0068] Thus, the graph of FIG. 12 shows that the screen assembly of the present invention provides the pressure relief where it is needed: at the top area of the screen. In contrast, the diverging screen has an integrating effect along the screen height. At the beginning there is no effect because of the diverging screen. At the end, where the effect of the diverging screen is greatest, the counter-current wash-flow dramatically reduces the compaction.
[0069] These and other variations and combinations of the features discussed above can be utilized without departing from the present invention. Thus, the foregoing description of the preferred embodiments should be taken by way of illustration rather than by way of limitation of the invention as defined by the claims.
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A pulp digester includes a vessel having an inlet, an outlet and a wall extending between the inlet and the outlet, the wall of the vessel having a curved interior surface. The digester includes a screen assembly positioned inside the vessel adjacent to the curved interior surface of the wall for removing liquid from pulp material. The screen assembly is movable relative to the curved interior surface of the vessel wall. The digester includes at least one support element permanently attached to the vessel wall for limiting movement of the screen assembly relative to the curved interior surface of the vessel wall. In certain embodiments, the at least one support, such as a ledge permanently attached to the vessel wall, supports a portion of the screen assembly. The screen assembly may have an inner face that is concave in a horizontal direction and convex in a vertical direction.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of the filing date of U. S. Provisional Patent Application No. 61/032,646, filed on Feb. 29, 2008, the contents of which are herein incorporated by reference.
FIELD OF INVENTION
[0002] The present invention generally relates to systems for measuring aberrations of the eye and more specifically to an ocular wavefront system adapted to measure aberrations of the eye for vision correction.
BACKGROUND INFORMATION
[0003] In the course of daily life, one typically regards objects located at different distances from the eye. To selectively focus on such objects, the focal length of the eye's lens must change. In a healthy eye, this is achieved through the contraction of a ciliary muscle that is mechanically coupled to the lens. To the extent that the ciliary muscle contracts, it deforms the lens. This deformation changes the focal length of the lens. By selectively deforming the lens in this manner, it becomes possible to focus on objects that are at different distances from the eye. This process of selectively focusing on objects at different distances is referred to as “accommodation.”
[0004] As a person ages, the lens loses plasticity. As a result, it becomes increasingly difficult to deform the lens sufficiently to focus on objects at different distances. This condition is known as presbyopia. Refractive errors caused by such conditions as hyperopia, myopia, as well as aberrations due to irregularities in the eye (e.g., in the cornea or in the natural crystalline lens) can also degrade one's ability to focus on an, object. To compensate for this loss of function, it is useful to provide different optical corrections for focusing on objects at different distances.
[0005] One approach to applying different optical corrections is to carry different pairs of glasses and to swap glasses as the need arises. For example, one might carry reading glasses for reading and a separate pair of distance glasses for driving.
[0006] In another approach, bifocal lenses assist accommodation by integrating two different optical corrections onto the same lens. The lower part of the lens is ground to provide a correction suitable for reading or other close-up work while the remainder of the lens is ground to provide a correction for distance vision. To regard an object, a wearer of a bifocal lens need only maneuver the head so that rays extending between the object-of-regard and the pupil pass through that portion of the bifocal lens having an optical correction appropriate for the range to that object.
[0007] Laser eye surgery techniques for improving focusing ability involve laser ablation of a portion of the eye. In Photorefractive Keratectomy (PRK) surgery, a surgeon uses an excimer laser to remove tissue from the surface of the cornea. In Laser-Assisted In Situ Keratomileusis (LASIK) surgery or Laser Epithelial Keratomileusis (LASEK) surgery, a surgeon removes tissue under the surface of the cornea by lifting a portion (a “flap”) of the cornea. Tissue is selectively removed to reshape the cornea so that less deformation of the lens is necessary for accommodation. Customized laser eye surgery based on measurements of a subject's eye can also compensate for some wavefront aberrations. During laser eye surgery, the cornea is reshaped to improve vision for a single distance of regard. Vision at other distances may remain degraded. For example, even after laser eye surgery, a subject may still need to use glasses to correct far vision. Therefore, there is a need in the art for a low-cost ocular wavefront system suitable for measuring the aberrations of the eye so that a clinician can use the information to evaluate of treat a patient's vision.
SUMMARY OF THE INVENTION
[0008] Thus, the present invention overcomes the disadvantages of the prior art, described above, by providing a low-cost ocular wavefront system that measures the aberrations of the eye so that a clinician can use the information to evaluate of treat a patient's vision.
[0009] Accordingly, it is an objective of the present invention to provide an ocular wavefront system that measures the aberrations of the eye.
[0010] It is a further objective of the instant invention to provide a method for providing multi-focal visual correction.
[0011] Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE FIGURES
[0012] FIG. 1 is a schematic illustrating one embodiment of the ocular wavefront system of the instant invention;
[0013] FIG. 2 is a schematic illustrating the sensor path details of the system illustrated in FIG. 1 ;
[0014] FIG. 3 is a front view illustrating a Hartman screen suitable for use with the instant invention;
[0015] FIG. 4 illustrates field of view at the eye's pupil.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiments illustrated.
[0017] Referring generally to FIG. 1 , an 830 nm super luminescent diode (SLD) 1 emits a beam which is directed toward pellicle beam splitter 2 . Some of the light from the SLD passes through the beam splitter and is absorbed and redirected by a beam dump 3 . The remainder of the light from the SLD is directed into the eye 4 . This light forms a diffuse source at the back of the eye. The SLD is preferably always on, and its output power is maintained at a level that is safe for continuous viewing. The wavefront exiting the patient's eye at the entrance pupil (about 3 mm inside the eye) passes back through the pellicle beam splitter and is refracted by a first lens 5 (L 1 ), redirected by penta prism 6 , and refracted by a second lens 7 (L 2 ) to make the wavefront available to the Hartman screen 8 . In a most preferred embodiment, L 1 5 and L 2 7 are equal focal length lenses. A penta prism 6 is utilized to redirect the light from the horizontal optical axis to the vertical optical axis so that the beam is rotated 90 degrees even if the penta prism is not exactly aligned and helps reduce the overall size of the system. The Hartmann screen (HS) aperture array serves to divide the incident wavefront into an array of spots that fall onto the sensor plane. The focal plane of the HS sensor is imaged on to a charge coupled device sensor (CCD sensor) 13 via a third lens 10 (L 3 ), an aperture 11 , and fourth lens 12 (L 4 ). As noted the penta prism 9 is used to redirect light through a 90 degree bend with the properties that it is insensitive to rotation errors and helps reduce the physical size of the system. To provide fine alignment of the system, the SLD 1 , L 1 5 , and CCD sensor 13 are mounted on adjustable fixtures. In operation, the patient observes the SLD 1 as a fixation source. This ensures that the SLD 1 light is properly positioned on the subject's retina.
[0018] Referring to FIG. 2 , the sensor path (straightened for ease of explanation) is illustrated. In the preferred embodiment, the focal lengths of lens 1 and lens 2 equal 100 mm and have 1:1 imaging at the hue saturation (HS) plane. This means d 1 =200 mm. For example, under these conditions, the following formula may be utilized.
[0000] 2 f 1 −d 0= d 2 (1)
[0019] Choosing d 0 =150 mm to give at least 50 mm working distance in front of the system gives d 2 =50 mm. The distance d 3 is set to a focal plane of the Hartmann screen. This focal plane distance is calculated using a well known relation from diffraction theory. This relation is given in equation (2) below.
[0000]
f
≈
R
2
λ
(
2
)
[0020] Equation (2) shows the focal distance for the aperture used as a lens. For a Hartmann screen with apertures spaced 0.25 mm apart having an aperture radius R=0.125 mm the resulting focal distance is about 4.7 mm. The Hartmann screen is illustrated in FIG. 3 . To compute the third lens and the fourth lens the vertical field of view at the pupil's entrance plane VFOV and the height of the CCD sensor H in is needed, preferably in mm. For example, if VFOV=8 mm and H=3.6 mm (1/3″ sensor). The required magnification is computed as 0.45 from:
[0000]
mag
=
H
VFOV
=
0.45
(
3
)
[0021] If L 3 is chosen to be 100 mm and L 4 is chosen to be 40 mm since they are commonly available lens focal lengths, selecting both L 3 and L 4 as achromats provides a high quality imaging system with only two lenses. The resulting magnification is 0.4 which is close enough to our desired magnification of 0.45. Thus, d 4 is 100 mm and d 5 is 40 mm.
[0022] For an f# =5 the aperture between lens 3 and lens 4 (shown as item 11 in FIG. 1 ) should be:
[0000]
D
=
xi
f
#
=
40
5
=
8
(
4
)
[0023] To compute the required clear aperture for lens 1 and lens 2 for no vignetting at the CCD proceed as follows. The vertical and horizontal FOV at the eye's pupil is illustrated with reference to FIG. 4 .
[0024] The ray height at the edge will be 13.33/2=6.67 mm. For a 10 diopter diverging wavefront at the pupil, the ray slope v may be calculated with the following formula (5):
[0000]
V
=
D
1000
=
10
1000
=
0.01
(
5
)
[0025] Now, system matrices are used for the S1=distance between eye's pupil and the first lens and S2 =S1+refraction at L 1 and the distance between L 1 and L 2 , to determine the ray height at the lenses L 1 and L 2 . The values r, S1 and S2 are determined by the following matrices (6)
[0000]
r
=
[
6.67
0.01
]
S
1
=
[
1
150
0
1
]
S
2
=
[
-
1
50
-
0.01
-
0.5
]
(
6
)
[0026] The matrix multiplication yields: 8.17 at L 1 and −6.17 at L 2 . Thus, 20 mm diameter optics at L 1 and L 2 are sufficient.
[0027] Traditional processing of the captured image follows the steps of:
[0028] 1. Find the centroids of the spots arrays.
[0029] 2. Find the deviation of each spot in x and y relative to a reference image for a plane wave.
[0030] 3. Calculate the wavefront derivative in x and y using the deviations found in step 2.
[0031] 4. Fit the wavefront derivatives to a Zernike polynomial to yield the desired ocular wavefront.
[0032] Instead of the traditional processing, in our preferred embodiment phase recovery techniques are used to obtain the wavefront slopes. Explaining the operation of the Fourier transform phase recovery technique first facilitates the explanation of the spatial demodulation technique to follow. Thus, we begin with a discussion of the Fourier transform technique. It is convenient to represent the irradiance distribution of the HS spot image for an incident plane wave as the infinite cosine function product g 0 (x,y) times a spatial domain aperture function that has a value of 1 inside the pupil and 0 outside. The function g 0 (x,y) is given by the following equation (7).
[0000]
g
0
(
x
,
y
)
=
[
1
2
+
1
2
cos
(
2
π
p
x
x
)
]
×
[
1
2
+
1
2
cos
(
2
π
p
y
y
)
]
(
7
)
[0033] In this equation, px and py are the period of the HS array spacing in the x and y directions. The corresponding Fourier transform G 0 (u,v) is a two-dimensional array of weighted delta functions:
[0000]
G
0
(
u
,
v
)
=
1
4
δ
(
0
,
0
)
+
1
8
[
δ
(
u
-
1
p
x
,
v
)
+
δ
(
u
+
1
p
y
,
v
)
]
…
(
8
)
[0034] For a sufficiently wide aperture the Fourier transform of the aperture function times the function g 0 is only slightly different from the simple delta functions of equation (8). When the local slope of the incident wavefront is not zero, the irradiance distribution can be thought of as being warped by a coordinate transformation. The value of delY (and similar for delX) is given by
[0000]
del
Y
=
-
W
(
y
)
y
×
f
(
9
)
[0035] The irradiance distribution for the aberrated incident wavefront is denoted g1(x,y) and is given by
[0000]
g
1
(
x
,
y
)
=
g
0
[
x
+
A
(
x
,
y
)
,
y
+
B
(
x
,
y
)
]
=
[
1
2
+
1
2
cos
(
2
π
p
x
(
x
+
A
(
x
,
y
)
)
)
]
×
[
1
2
+
1
2
cos
(
2
π
p
y
(
y
+
B
(
x
,
y
)
)
)
]
(
10
)
[0000] where A(x,y) and B (x,y) are proportional to the partial derivatives of the wavefront with respect to x and y. Now, writing the cosine functions as a sum of complex exponentials and taking the Fourier transform, we see that the function A(x,y) appears as the argument of a complex exponential shifted to the frequency 1/px along the u axis in the Fourier domain. Likewise, the function B(x,y) appears as the argument of a complex exponential shifted to the frequency 1/py along the v axis in the Fourier domain. Note that there are two regions that must be processed: one for wavefront derivatives with respect to x and the other for wavefront derivatives with respect to y. Now the top level steps used in the Fourier transform technique can be enumerated:
[0036] 1. Compute the Fourier transform of the HS image.
[0037] 2. Isolate the region of interest in the Fourier domain and shift the center of the region of interest to the origin.
[0038] 3. Compute the inverse Fourier transform and compute the complex angle to yield the wrapped phase.
[0039] Two additional steps are needed to complete the process.
[0040] 4. Unwrap the phase and normalize to yield the wavefront gradient; and
[0041] 5. Reconstruct the wavefront from the gradients.
[0042] In step 4, we need to unwrap the phase from the arrays (one for dW/dx and the other for dW/dy) computed in step 3 and then normalize the arrays to account for the micro lens focal length. Note that the normalization must be performed after the unwrapping. When there are no jump discontinuities (called residues) in the phase arrays, the unwrapping can be accomplished with a simple and fast algorithm. In this case, the unwrapping algorithm (in one dimension with U=unwrapped and W=wrapped) can be described as:
Set U(0)=W(0)
[0043] For n=1 to the end of the array do the following
[0000] D=W ( n )− W ( n− 1)
[0000] If D<−PI then D=D+ 2 Pi
[0000] If D>Pi then D=D− 2 Pi
[0000] U ( n )= U ( n− 1)+ D
[0044] This algorithm can be applied down the center of the array and then to the left and right to the edges of the arrays. Where there are phase discontinuities, more elaborate phase unwrapping techniques must be employed as are known to those skilled in the art. After unwrapping and normalizing to obtain the wavefront slopes in the x and y directions, the wavefront is constructed by fitting to a Zernike or Fourier expansion.
Spatial Demodulation
[0045] The previous processing using Fourier transforms can also be accomplished entirely in the spatial domain. In this method, the spots image is multiplied by a complex exponential to shift the desired neighborhood to the origin in the frequency domain. This operation can be described by the Fourier transform modulation relation shown in equation (11).
[0000]
-
j2π
ax
f
(
x
)
FT
F
(
s
+
a
)
(
11
)
[0046] One complex exponential is used to obtain the neighborhood for the wavefront slopes with respect to x and another is used to obtain the neighborhood for the wavefront slopes with respect to y. A low-pass filter is then used to isolate the desired frequency band. This produces the wrapped phase arrays as we obtained in the Fourier method. The remaining steps of unwrapping the phase and reconstruction the wavefront are the same as for the Fourier method. To be practical, the low-pass filter must be very efficient since it is computed in the spatial domain using convolution. One example of such a computationally efficient low-pass filter is the box filter in which all coefficients of the impulse response are equal. When implemented as a sliding sum, the filter is computed using only 2 adds and 2 subtracts per output sample. We use two passes of this filter to provide a triangle shaped impulse response which has much less energy in the side lobes of the filter's frequency response compared to the box filter. The main steps in the spatial demodulation technique are:
[0047] 1. Multiply the spots image by a complex exponential.
[0048] 2. Isolate the region of interest by applying a low-pass filter.
[0049] 3. Unwrap the phase and normalize to yield the wavefront gradient.
[0050] 4. Reconstruct the wavefront from the gradients.
Combination of Reconstruction Methods
[0051] To improve accuracy of the reconstructed ocular wavefront, we reconstruct the wavefront first using one method (for example the traditional method described above) and then another method (for example the spatial demodulation method described above). By averaging the two Zernike expansions representing the wavefronts, the accuracy of the measurements is increased. By evaluating the difference in the measurements provided by the two methods, we can determine how well the wavefront was likely obtained. That is, if the differences between the two methods is small, the resulting average is likely a good representation of the ocular wavefront. If the differences are large, one or more wavefront is likely in error and the ocular exam should be repeated to obtain a better (more accurate) measurement.
[0052] All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
[0053] It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification.
[0054] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. Any compounds, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.
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The present invention generally relates to systems for measuring aberrations of the eye and more specifically to an ocular wavefront system adapted to measure aberrations of the eye for vision correction.
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This application claims the priority benefit of the Korean Patent Application No. 10-2004-62814 filed on Aug. 10, 2004, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an organic light emitting diode (OLED) device, and more particularly, to a driving circuit of an OLED device and a method for driving the same, in which image data is processed by Frame Rate Control (FRC) and dithering, so that it is possible to decrease data processing capacity, area of drive IC, and power consumption.
2. Discussion of the Related Art
In general, a cathode ray tube (CRT), which is one type of flat display devices, has been widely used for monitors of a television, a measuring apparatus, and an information terminal. However, the CRT cannot satisfy the demands for compact size and lightweight due to the size and weight of the CRT itself. Thus, various display devices, for example, a liquid crystal display (LCD) device using electric field optical effect, a plasma display panel (PDP) using a gas discharge, a field emission display device, and an electroluminescence display (ELD) device using an electric field luminous effect, have been studied to substitute the CRT.
Among the various display devices, the ELD device is a display device of using electroluminescence (EL) phenomenon, wherein the EL phenomenon indicates the state of generating light when an electric field above a predetermined level is applied to a fluorescent substance. The ELD device is classified into an inorganic electroluminescence display device and an organic electroluminescence display (OELD) device.
The OELD device has attracted great attention as a high-picture quality device since the OELD device displays all colors of visible rays. Also, the OELD device realizes high luminance using a low driving voltage. In addition, the OELD device emits light in itself, whereby the OELD device has great contrast ratio, and the OELD device is suitable for realizing an ultra-thin display device. Also, since the OELD device has a simplified fabrication process, it may generate less environmental pollution. In the meantime, the OELD device has a rapid response time of several microseconds, whereby the OELD device is useful to obtain moving picture images. Furthermore, the OELD device has no limit to a viewing angle, and the OELD device is stably operated at a low temperature. Also, the OELD device can be operated at a high voltage between 5V and 15V. As a result, the OELD device has the simplified fabrication process and the simple design.
The OELD device is very similar in structure to the inorganic ELD device. However, the OELD device generates light by recombination of electron and hole, whereby the OELD device is referred to as an organic light emitting diode (OLED).
The OELD device emits light in itself, so that the OELD device has wide viewing angle and high contrast, as compared with the LCD device. Also, since the OELD device does not require a separate backlight unit, the OELD device can realize thin profile and low power consumption. In addition, the OELD device is driven at a low D.C. voltage, and the OELD device has a rapid response speed. Also, the OELD device is formed of a solid material. As a result, the OELD device can endure external forces, and the OELD device can be driven in a wide range of temperature. Furthermore, the OELD device has the advantage of low fabrication cost.
Unlike the LCD device or the PDP device, when fabricating the OELD device, it only requires equipment for deposition and encapsulation, thereby realizing the simplified fabrication process.
Especially, if the OELD device is driven in an active matrix method of having a thin film transistor of a switching device in each pixel region, it is possible to realize low power consumption, high resolution, and large size in the OELD device, even though a low current is applied to the OELD device.
In case of the active matrix type, a plurality of pixel regions are formed in the matrix type, and a thin film transistor is connected to each pixel region. This active matrix type is generally used for the flat display device. Hereinafter, an active matrix organic light emitting display (AMOLED) device, in which the active matrix type is applied to the OLED, will be described with reference to the accompanying drawings.
FIG. 1 is a circuit diagram illustrating an OELD device according to the related art. As shown in FIG. 1 , the OELD device according to the related art includes a gate line 1 , a data line 2 , a switching thin film transistor 4 , a driving thin film transistor 5 , a storage capacitor 6 , and a light emitting diode 7 . Although a single pixel unit is shown, it is known that the OELD device has a plurality of such pixel units in the matrix form.
At this time, a gate electrode of the switching thin film transistor 4 is connected with the gate line 1 , and a source electrode is connected with the data line 2 . Also, a drain electrode of the switching thin film transistor 4 is connected with a gate electrode of the driving thin film transistor 5 , and a drain electrode of the driving thin film transistor 5 is connected with an anode electrode of the light emitting diode 7 . Also, a source electrode of the driving thin film transistor 5 is connected with a power line 3 , and a cathode electrode of the light emitting diode 7 is grounded. Next, the storage capacitor 6 is connected with the gate and source electrodes of the driving thin film transistor 5 .
Accordingly, if a gate signal is applied through the gate line 1 , the switching thin film transistor 4 is turned on. Then, as a data signal of the data line 2 is transmitted to the gate electrode of the driving thin film transistor 5 through the switching thin film transistor 4 , the driving thin film transistor 5 is turned on, whereby light is emitted from the light-emitting diode 7 . At this time, when the switching thin film transistor 4 is turned off, the storage capacitor 6 stably maintains the gate voltage of the driving thin film transistor 5 .
FIG. 2 is a cross sectional view illustrating the driving thin film transistor and the light emitting diode of FIG. 1 .
FIG. 2 illustrates the related art OLED device. Referring to FIG. 2 , a buffer layer 11 of an insulating material, for example, silicon oxide SiO 2 is formed on the entire surface of a substrate 10 . Also, island-shaped polysilicon layers 21 , 22 and 23 are formed on predetermined portions of the buffer layer 11 . At this time, the polysilicon layers 21 , 22 and 23 are divided into an active layer 21 , and source and drain regions 22 and 23 , wherein the active layer 21 of the thin film transistor is not doped with impurity ions, and the source and drain regions 22 and 23 are doped with impurity ions. At this time, the polysilicon layers 21 , 22 and 23 are formed in a method of crystallizing an amorphous silicon layer.
Then, a gate insulating layer 30 is formed on the polysilicon layers 21 , 22 and 23 , wherein the polysilicon layers 21 , 22 and 23 are divided into the active layer 21 of the thin film transistor, and the source and drain regions 22 and 23 doped with the impurity ions. The gate insulating layer 30 is formed on the entire surface of the buffer layer 11 including the polysilicon layers 21 , 22 and 23 . Subsequently, a gate electrode 42 is formed on the gate insulating layer 30 above the active layer 21 .
Then, an insulating interlayer 50 is formed on the gate insulating layer 30 including the gate electrode 42 , wherein the insulating layer 50 has first and second contact holes 50 a and 50 b for exposing predetermined portions of the source and drain regions 22 and 23 of the polysilicon layers. At this time, the insulating interlayer 50 is formed of a dual-layered structure having first and second insulating interlayers 51 and 52 .
Next, a source electrode 62 and a drain electrode 63 are formed on predetermined portions of the insulating interlayer 50 and in the first and second contact holes 50 a and 50 b, wherein the source and drain electrodes 62 and 63 are formed of a conductive material such as metal. At this time, the source and drain electrodes 62 and 63 are respectively connected with the source and drain regions 22 and 23 of the polysilicon layers through the first and second contact holes 50 a and 50 b.
After that, a passivation layer 70 is formed on the entire surface of the insulating interlayer 50 and the source and drain electrodes 62 and 63 . At this time, the passivation layer 70 has a third contact hole 71 for exposing the drain electrode 63 in the second contact hole 50 b.
Then, a pixel electrode 81 is formed on predetermined portions of the passivation layer 70 and in the third contact hole 71 , wherein the pixel electrode 81 contacts the drain electrode 63 through the third contact hole 71 . At this time, the pixel electrode 81 is formed of a transparent conductive material. Also, the pixel electrode 81 serves as the anode electrode of the light emitting diode.
In the OLED device according to the related art, a drive IC for applying the data signal to the data line has linear output characteristics. Thus, in order to perform gamma correction, inputted data having a predetermined bit number is converted so that the converted data has a larger bit number than the predetermined bit number of the inputted data. As the bit number of data increases, the drive IC increases in size and power consumption.
FIG. 3 is a block diagram illustrating the related art OLED device. FIG. 4 is a graph illustrating the luminance characteristics by gray level before and after the gamma correction of FIG. 3 .
As shown in FIG. 3 and FIG. 4 , a driving circuit of the related art OLED device includes a gate drive unit 103 , a data drive unit 105 , and a timing controller 110 . At this time, the gate drive unit 103 and the data drive unit 105 respectively apply driving signals to gate and data lines formed on a panel 100 . The panel 100 includes a plurality of pixel units of FIGS. 1 and 2 as discussed above. Also, the timing controller 110 controls the gate drive unit 103 and the data drive unit 105 .
The timing controller 110 receives RGB image data of n-bit and synchronized signals HSYNC and VSYNC for displaying the corresponding RGB image data from a graphic source (not shown) of a system. Then, the timing controller 110 performs gamma correction and color compensation on the RGB image data, and outputs the compensated RGB data of m-bit to the data drive unit 105 .
In the meantime, the timing controller 110 further includes a data convert unit 111 for converting the gamma characteristic of RGB image data to a gamma 2.2 curve.
The data convert unit 111 receives the RGB image data of n-bit, and converts the gamma characteristics of the received original RGB image data to the gamma 2.2 curve shown in FIG. 4 . Then, the data convert unit 111 outputs the RGB image data of m-bit having the converted gamma characteristics. At this time, the data convert unit 111 performs the conversion of the gamma characteristics by LUT (Look-Up Table) or arithmetic of a numerical formula. For any pixel, the bit number of the RGB image data having the converted gamma characteristics is always larger by two than the bit number of the original RGB data.
FIG. 4 illustrates the gamma curve of the original RGB image data in comparison with the gamma 2.2 curve showing essential factors of the gamma characteristic in RGB color area. In FIG. 4 , the horizontal axis shows the gray level wherein a maximum value of the input RGB image is set to ‘1’, and the vertical axis shows the luminance level wherein a maximum value to the corresponding gray level is set to ‘1’. To satisfy the essential factors of the RGB color area, it is necessary to convert the gamma characteristics of the RGB data according to the gamma 2.2 curve.
However, the related art OLED device has the following disadvantages.
In case of the related art OLED device, in order to perform the gamma correction, the inputted data having the predetermined bit number is converted so that the converted data has a bit number larger (by two) than the predetermined bit number of the inputted data. In this state, the converted data is transmitted to the drive IC (data drive unit 105 ). That is, the data inputted to the timing controller has n-bit, and the data transmitted to the drive IC has m-bit, wherein m=n+2.
In this case, when the drive IC processes the data, the bit number of data is increased to m-bit, whereby the size of the drive IC and the power consumption increase.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a driving circuit of an OLED device (or OELD device) and a method for driving the same that substantially obviates one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a driving circuit of an OLED device (or OELD device) and a method for driving the same, to decrease the power consumption and size of the driving circuit.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, there is provided an organic light emitting diode (OLED) device comprising: a timing controller for performing a gamma correction of inputted image data for the OLED device, and then changing a bit number of the gamma-corrected image data to thereby output converted image data; and a data drive unit for outputting a data drive signal on the basis of the converted image data.
In accordance with another aspect of the present invention, there is provided a timing controller suitable for an organic light emitting diode (OLED) device, the timing controller comprising: a gamma correction unit to receive an n-bit data and convert the n-bit data to an m-bit data by a gamma correction process, where m>n; and a control unit to convert the m-bit data to an n′-bit data by a dithering process, where n′=n or n′=n+1.
In accordance with another aspect of the present invention, there is provided a method of driving an organic light emitting diode (OLED) device, the method comprising: performing a gamma correction of inputted image data for the OLED device; changing a bit number of the gamma-corrected image data and thereby outputting converted image data; and generating and outputting a data drive signal on the basis of the converted image data.
In accordance with another aspect of the present invention, there is provided a method of operating a timing controller suitable for an organic light emitting diode device, the timing controller including a gamma correction unit and a control unit, the method comprising: receiving, by the gamma correction unit, an n-bit data and converting the n-bit data to an m-bit data by a gamma correction process, where m>n; and converting, by the control unit, the m-bit data to an n′-bit data by a dithering process, where n′=n or n′=n+1.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a circuit diagram illustrating an organic ELD device according to the related art;
FIG. 2 is a cross sectional view illustrating a driving thin film transistor and an LED of FIG. 1 ;
FIG. 3 is a block diagram illustrating a driving unit of an organic ELD device according to the related art;
FIG. 4 is a graph illustrating the luminance characteristics by gray level before and after the gamma correction of FIG. 3 ;
FIG. 5 is a block diagram illustrating an OLED device according to the present invention;
FIG. 6 is a block diagram illustrating a data convert unit of FIG. 5 ;
FIG. 7 is a view of pixel data arrangement for illustrating a driving method of an OLED device according to a first example of the present invention; and
FIG. 8 is a view of pixel data arrangement for illustrating a driving method of an OLED device according to a second example of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
Hereinafter, an OLED device and a method for driving the same according to the preferred embodiments of the present invention will be described with reference to the accompanying drawings.
FIG. 5 is a block diagram illustrating an OLED (or OELD) device according to an embodiment of the present invention. FIG. 6 is a block diagram illustrating a data convert unit of FIG. 5 according to an embodiment of the present invention.
As shown in FIG. 5 and FIG. 6 , the OLED device according to the present invention includes an OLED (or OELD) panel 200 , a gate drive unit 203 , a data drive unit 205 , and a timing controller 210 , all operatively coupled. At this time, the gate drive unit 203 and the data drive unit 205 respectively apply driving signals to gate and data lines formed on the OLED panel 200 . Also, the timing controller 210 controls the gate drive unit 203 and the data drive unit 205 .
The timing controller 210 receives RGB image data of n-bit, and synchronized signals HSYNC and VSYNC and clock signals DE and MCLK for displaying the corresponding RGB image data from a graphic source, e.g., from an external system. Then, the timing controller 210 performs gamma correction, color compensation, FRC (Frame Rate Control), and dithering, and outputs the compensated RGB data of n′-bit (n′=n or n′=n+1) to the data drive unit 205 .
Particularly, the timing controller 210 includes a data convert unit 220 . As shown in FIG. 6 , the data convert unit 220 is provided with data correction units 221 a, 221 b and 221 c, and FRC and dithering units 222 a, 222 b and 222 c. At this time, the data correction units 221 a, 221 b and 221 c convert the gamma characteristics of inputted RGB image data according to a gamma 2.2 curve, and thereby outputs the gamma-corrected RGB data of m-bit where m=n+2. Then, the FRC and dithering units 222 a, 222 b and 222 c process the RGB data of m-bit by FRC and dithering and thereby outputs the RGB data of n′-bit, where n′=n or n′=n+1.
The data correction units 221 a, 221 b and 221 c alone function as a data convert unit provided in a timing controller of a related art OLED device (or OELD device) (e.g., as the data convert unit 111 of FIG. 3 ). That is, the data correction units 221 a, 221 b and 221 c convert the gamma characteristics of the inputted original RGB image data of n-bit according to the gamma 2.2 curve, e.g., shown in FIG. 4 , and outputs the RGB data of m-bit having the converted gamma characteristics in the same manner as the data convert unit 111 . In other words, the data correction units 221 a - 221 c perform the conversion of the gamma characteristics by LUT (Look-Up Table) or arithmetic of a numerical formula. For example, in case of using the LUT, when the RGB image data is inputted, RGB image data corresponding to the inputted RGB data is determined from the LUT and is outputted, wherein the LUT can be formed in a method of mapping the RGB image data having the converted gamma characteristics by each gray level of the original RGB image data. At this time, the bit number (m) in the RGB data of m-bit (m=n+2), having the converted gamma characteristics, is larger by two than the bit number (n) in the original RGB image data of n-bit, in order to improve accuracy in the conversion of the gamma characteristics.
According to the present invention, thereafter, the RGB image data of m-bit, converted by the data correction units 221 a, 221 b and 221 c, is transmitted respectively to the FRC and dithering units 222 a, 222 b and 222 c. Thus, the FRC and dithering units 222 a, 222 b and 222 c perform a dithering process by time and space and a FRC (Frame Rate Control) process to the RGB image data of m-bit, whereby the m-bit of the RGB data is decreased to n′-bit, where n′=n or n′=n+1.
Accordingly, the FRC and dithering units 222 a, 222 b and 222 c control the RGB image data of upper bit(s) in frequency and location by time and space, according to a predetermined lower bit(s) of the RGB image data outputted from the data correction units 221 a, 221 b and 221 c. That is, the FRC and dithering units 222 a, 222 b and 222 c decrease the bit number of the RGB image data. At this time, the bit number of the RGB image data outputted from the data correction units 221 a - 221 c is decreased by either 1 bit or 2 bits by the FRC and dithering units 222 a, 222 b and 222 c.
The dithering process by the FRC and dithering units 222 a - 222 c involves processing the inputted gray data having a predetermined gray level represented by a certain number of bits to have a lower bit number than the original gray-level bit number. As a result, it is possible to display a desired color by the lower bit number instead of the gray-level bit number. In comparison with a case of displaying the color by the original gray-level bit number, the dithering process is advantageous in that power consumption is decreased.
In the dithering process by the FRC and dithering units 222 a - 222 c for lowering the bit number of gray data, it is possible to select a reduction ratio of the lowered bit number to the original gray-level bit number. For example, according to the present invention, n′ can be selected to equal n or (n+1). In this case, as the reduction ratio is smaller, the gray data is displayed more similar to the color of the original gray-level data, so that it is possible to decrease deterioration in picture quality. In the meantime, in a display device, as the bit number becomes lower, a circuit is operated less, thereby decreasing power consumption.
The FRC (Frame Rate Control) process by the FRC and dithering units 222 a - 222 c is performed to prevent flicker, which is created when the same pixel is repetitively turned on and off. That is, in the FRC process, adjacent pixels in horizontal and vertical lines are differently turned on and off, so that it is possible to prevent the same pixel of sequential frames from being repetitively turned on and off.
Hereinafter, the FRC and dithering process according to the present invention will be described in detail.
FIGS. 7 and 8 illustrate two examples of a bit-number reduction process for explaining a driving method of the OLED device according to the present invention. These examples are implemented in the OLED device of FIG. 5 or other suitable display devices. FIG. 7 illustrates an example of processing an n-bit data where n=6 and FIG. 8 illustrates an example of processing an n-bit data where n=8.
As shown in FIG. 7 , in this first example, suppose that the original RGB image data has 6 bits (n=6) so that the bit number of the data corrected by and output from the data correction unit 221 a, 221 b or 221 c of the timing controller 220 is 8 (m=8).
After that, the data of 8 bits is processed by the FRC and dithering units 222 a - 222 c, whereby the 8-bit data may be converted to 6 bits. In this case, it may have flicker due to rapid response speed and great change in the luminance of the OLED device. To overcome these problems, in case the gamma corrected data has 8 bits, the lower 1 bit may be dropped such that the data becomes 7 bits.
Particularly, the data of 8 bits, outputted from the data correction units 221 a, 221 b and 221 c, is divided into data of high 7 bits and data of low 1 bit. Here, the ‘high 7 bits’ is referring to 7 most significant bits within the 8-bit data, and the ‘low 1 bit’ is referring to one least significant bit (the last bit within the 8-bit data). Similar meaning is to be applied whenever the terms ‘high x bit(s)’ and ‘low x bit(s)’ are used where x is an integer>0. The value of the low 1 bit is either ‘0’ or ‘1’. In FIG. 7 , ‘2g’ and ‘2g+1’ correspond to horizontal-direction gate lines formed in parallel, which show the order of the gate lines. Also, ‘2k’ and ‘2k+1’ correspond to vertical-direction data lines formed in parallel, which show the order of the data lines. In 2n-th frame and 2n+1-th frame, four adjacent pixels PXa˜PXd (defined by two adjacent gate lines and two adjacent lines) may be variously displayed according to whether the low 1 bit of the 8-bit data has a value of ‘0’ or ‘1’.
In order to display a case where the data (value) of the low 1 bit of the 8-bit data is ‘0’, four adjacent pixels display the data of the existing high 7 bits of the 8-bit data. This is indicated by the hatched lines (labeled ‘7 bit’) in FIG. 7 . That is, since the value of the low 1 bit (LSB) is ‘0’, this bit is dropped without any loss of data and only the existing high 7 bits of data are displayed by the pixels. To display a case where the value of the low 1 bit is ‘1’, the value of ‘1’ is added to the data of the existing high 7 bits and then the added value in 7 bits is displayed in the two pixels among the four adjacent pixels (2×2 pixels of horizontal and vertical lines), whereby the data ‘1’ of the low 1 bit is not lost even after the low 1 bit is dropped since it is applied to the other 7 bits in the two of the four adjacent pixels. This is indicated by a clear area (labeled ‘7’ bit+1’) in FIG. 7 .
At this time, to prevent the flicker, as shown in FIG. 7 , the location of the pixel corresponding to ‘7 bit+1’ is moved along the frames. For instance, at frame no. 2n, the pixels PXa and PXd are assigned to ‘7 bit+1’ data, whereas at frame no. 2n+1, ‘7 bit+1’ data is assigned to the pixels PXb and PXc.
Accordingly, in the example of FIG. 7 , the bit number of the data, reduced by the FRC and dithering process, is 1 bit, from 8 bits (m-bit) to 7 bits (n′-bit).
FIG. 8 displays a second example of the bit number reduction process by the FRC and dithering units according to the present invention. In this example, low 2 bits of m-bit data are dropped. As shown in FIG. 8 , in the driving method of the OLED device, original RGB image data, inputted from the external graphic source to the timing controller 210 , has 8 bits (n=8), and data outputted from the data correction units 221 a - 221 c has 10 bits (m=10). From the 10-bit image data, 8-bit data is produced by a method of dropping low 2 bits of the 10-bit data, whereby the resultant 8-bit data is transmitted to the data drive unit 205 from the FRC and dithering units 222 a - 222 c.
In this second example of the present invention, if a pixel is turned on and off by each 4 frame in the process of making the 8-bit data by the dithering process, it may have the flicker. Accordingly, in order to prevent the flicker, as shown in FIG. 8 , the FRC process is also performed by the units 222 a - 222 c, wherein the data is divided by each frame, so that it is possible to prevent the turning-on and off in the same position of the adjacent pixels during the sequential frames.
Referring to FIG. 8 , data of 10 bits (m=10) from the data correction units 221 a - 221 c is divided into data of high 8 bits (8 MSBs) and data of low 2 bits (2 LSBs), wherein the data of the low 2 bits will be ‘00’, ‘01’,‘10’ or ‘11’. At this time, to display a case where the data of the low 2 bits is ‘00’, the four adjacent pixels display the data of the existing high 8 bits of the 10-bit data while the low 2 bits of the 10-bit data are dropped. This is indicated by the hatched lines (labeled ‘8 bit’). In order to display a case where the data of the low 2 bits is ‘01’, one pixel among the four adjacent pixels displays 8-bit data, which is obtained by adding a value of ‘1’ to the existing high 8-bit data of the 10-bit data and displaying the added resultant data of 8-bits. This is indicated by the clear area (labeled ‘8 bit+1’) shown for that pixel and is also referred to below as ‘high 8-bit+1’. Accordingly, the dropped value ‘01’ is applied to the existing high 8-bit data such that the four pixels have on the average the low 2 bit of ‘01’.
In the case where the value of the low 2 bits is ‘10’, two pixels among the four adjacent pixels display the data of high 8-bit+1, while the other two pixels among the four adjacent pixels display the data of the existing high 8-bit.
In the case where the value of the low 2 bits is ‘11’, three pixels among the four adjacent pixels are displayed with the data of high 8-bit+1, while the remaining one pixel displays the data of the existing high 8-bit.
In all these cases, in order to prevent the flicker, the position of the pixel corresponding to high 8-bit+1 is moved along the frames in the same manner as in FIG. 7 . FIG. 8 shows the method of changing the position of the values for the pixels by the frames of ‘4n’, ‘4n+1’, ‘4n+2’ and ‘4n+3’.
In the OLED device and the method for driving the same according to the present invention, inputted original RGB data having a predetermined bit number (n) is converted to data having a bit number (m) larger by two than the predetermined bit number (n) of the original RGB by the gamma correction process. Then the converted data having the larger bit number (m) is converted again in the FRC and dithering process, whereby the bit number of the data inputted to the data drive IC is the same as that of the inputted original RGB data, or has a bit number corresponding to the value of adding ‘1’ to the bit number of the inputted gamma-corrected data, thereby decreasing the area of the data drive unit (drive IC) and the power consumption.
As mentioned above, the OLED device and the method for driving the same according to the present invention have the following advantages.
In the OLED device and the method for driving the same according to the present invention, the FRC and dithering process is performed for the gamma correction, whereby the data processing capacity and the area of the drive IC decrease, thereby decreasing the power consumption.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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An organic light emitting diode (OLED) device and a method of driving the OLED device are provided. The OLED device according to an embodiment includes a timing controller and a data drive unit. The timing controller performs a gamma correction of inputted image data for the OLED device, and then changes a bit number of the gamma-corrected image data to thereby output converted image data. The data drive unit outputs a data drive signal on the basis of the converted image data.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to:
U.S. Ser. No. 09/803,505 filed on Mar. 9, 2001 entitled: Opposing Spring Resilient Tension Suspension System.
U.S. Ser. No. 10/033,016 filed on Oct. 26, 2001 entitled: Opposing Spring Rebound Tension Suspension System.
U.S. Ser. No. 10/100,313 filed on Mar. 16, 2002 entitled: Method and Apparatus for Rebound Control.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to and, in particular, to improvements in the methods and apparatus for using a rebound spring carried on a shock absorber that is intended to utilize the unsprung weight of the wheel/axle system during rebound. More particularly, it is to resist rollover, sway, yaw and other chassis motion.
2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
In the past ten years the numbers of sport utility vehicles “SUV” and pickup trucks have increased dramatically to the point where those vehicles are more popular than the millions of passenger cars on the road. The SUV and trucks inherently have a higher center of gravity (CG) than normal passenger cars due to the need for higher ground clearance for bad weather travel (snow and ice), off-road use and/or for pickup truck payloads. Vehicles with a higher CG have a greater propensity to sway or even rollover during abrupt lane changes and evasive steering maneuvers than the lower normal passenger cars. One important arrangement of all these vehicles is the method of suspension used. Except for the use of hydraulic shock absorber damping resistance to rebound, all vehicle chassis and body loads are supported on the vehicle axles with various types of suspensions that have springs that resist primarily load and jounce of each wheel axle. No existing suspensions using coil springs, load leaf springs, air springs, torsion bars or rubber blocks suspensions have any other provision for rebound control of the forces due to inertia or gravity type negative suspension loads. Particularly, those rebound forces occurring at the inside wheel during hard cornering or if a wheel drops into a pothole. Typically, changes in suspension loads while driving straight along a road are caused generally by reactions to bumps, potholes, and roughness encountered by the vehicle wheels during their interaction with the road surface. Thus the suspension springs and associated shock absorbers quell the harshness and movements being transmitted to the body/chassis. The sway or side to side rolling motions that vehicles experience due to cornering forces, also cause vehicle springs to be loaded or unloaded, depending which way the vehicle is rolling during cornering. Many vehicles have an anti-sway/roll bar installed to help the vehicle body resist the rolling actions. These devices help the vehicle partially resist roll but only as it relates to the body lean, because they are fixed to the sprung mass and leaning with the body. Thus, they can actually reduce the load on the unloaded side of the vehicle. They use the body as a structure to support the torsion bar of the anti sway system transferring wheel jounce motion across to the opposite side. The disclosure herein will obviate the need for anti-sway bars, saving the cost of providing and installing them. Shock absorbers only dampen the bouncing movement of the vehicle wheels and suspension caused by the reaction to road surface, cornering and braking. Thus, the rate of sway may be affected only to a minor degree. A floating aluminum piston is placed between the fluid moving piston and the end of the shock body. The floating piston has nitrogen gas behind it that is at a preset pressure. This piston is used in racing shocks and other lift type shocks to do two things, first to pressurize the fluid at all times and second to raise the vehicle ride height. It is not practical to fill the entire shock body with fluid on both sides of the fluid piston. This ensures that as the fluid moving piston moves away from the end of the cavity as it would during extension or “rebound” travel, it does not permit a vacuum to form behind the fluid piston and sucking against the shock travel. It maintains a pressure front against the fluid to ensure that it is induced to pass the fluid piston during jounce travel. The fluid piston has holes in it to allow the fluid to pass by it and flexible shims on both sides of the fluid piston are adjusted in strength to set the resistance to flow through the piston during normal movement. Stiffer shims result in higher resistance to the fluid being compressed against them. All this and the use of nitrogen pressure against the piston are typical of existing shock absorber design. The basic tubular shock absorber is well known to skilled artisans, and is a commodity and is disclosed in numerous patents. The typical shock absorber is designed to dampen motion and with coil over springs adjust the ride height and/or spring stiffness.
U.S. Pat. No. 2,160,541 has a paired spring suspension connected in series to only support load and jounce with the added spring coupled in line with the main spring for increasing the effective spring constant at the extremes of suspension travel. The techniques disclosed in the various embodiments of '541 are in the nature of an overload spring that engages and changes the spring constant at the extremes of wheel travel. There is no spring in '541 connected to specifically resist rebound forces due to diverging motion of the sprung weight to unsprung weight. The disclosure of '541 specifically states that the higher spring constant results in less flex (on page 2 column 1 at lines 6 to 8), “ . . . which opposes any tendency of the vehicle to overturn laterally when negotiating a curve.” In each embodiment of '541 the springs act in unison to control primarily load and jounce and there is no teaching of a particular connection to directly apply rebound reaction of unsprung weight to one of the springs. The graph in '541 showing wheel travel verses spring forces verifies these conclusions. U.S. Pat. No. 5,263,695 discloses a refinement of the '541 teaching that includes a shock absorber for damping motion and an elastic block to ameliorate the transition between first and second springs for carrying the load. In addition to many disclosures in '695 of prior paired spring configurations there is a specific explanation in column 5, lines 1 through 5 as follows:
“The suspension according to the invention produces a comfort level which is higher the more the transition from one stiffness to the other takes place progressively (see the patents cited in the state of the art).”
The state of the art referred to includes prior patents of the same inventor and the acknowledgements of those prior patents clearly identifies the teachings as merely two springs of different stiffness in series. Even in FIG. 7 of '695 the springs are concentrically mounted but act in series, see column 4, lines 8 through 12. At best the structures for multiple springs shown in these patents have differing spring rates to give an allegedly more comfortable ride but do not specifically disclose rebound control.
U.S. Pat. No. 3,830,517 is a motorcycle rear wheel spring suspension wherein a top spring is longer and absorbs upward road shock and a bottom spring absorbs the rider's weight. Nothing is disclosed about resisting rebound with either the top or bottom spring and no attachment of the springs is shown or described that would operate to control rebound of the sprung weight.
U.S. Pat. No. 3,049,359 has a pair of coaxial coil springs designed to maintain ride height by automatic screw adjustment of the smaller and lighter inner tension coil spring. No disclosure of rebound control of sprung weight is made and the inner tension coil spring loadings are varied only in so far as the ride height is less or more than required as such the size and strength of the inner tension spring would be insufficient to transfer the unsprung weight to the chassis and resist rebound. Moreover the working travel of both springs appears to be the same; thus, no rebound control is possible. No existing suspension system suspends the chassis and/or body between opposing springs to counter load and jounce and reaction and rebound along different portions of the axle and wheel travel. An opposing spring suspension as disclosed herein can have little effect on the ride stiffness, but stabilizes cornering and evasive maneuvering sway by utilizing the unsprung weight of the axle system thus helping the vehicle to resist roll while maintaining the general ride quality.
U.S. Pat. No. 3,297,312 has a combination shock absorber and spring for automobile suspensions. Close examination reveals that a main rod connects between a top cap and a nut to bottom tube. It appears that the rod will bottom out against the tube end when the springs are compressed because rod is of set length and incompressible. The four springs stacked, as a unit, abut each other to act as one continuous variable rate spring. Specifically, the upper two springs have a disc that separates them that shifts up and down with the movement of the springs. The disc has valve holes in it to permit the movement of fluid to each side of the disc to act as a shock absorber. This appears to have minimal effect or use.
U.S. Pat. No. 5,183,285 has a suspension of a stiffness that is greater between the operating load position and the suspended wheels position than between the operating load position and the collapsed position. It is a suspension and a suspension process that uses a greater stiffness in the region of “rebound” than in the region of “bump” with means for smoothing the stiffness from the passage of one region to the other, and means for varying the reference position for “operating load” as a function of the number of persons and the load in the vehicle. A suspension wherein the stiffness is greater in the region between the position “operating load” and a position “suspended wheels” than in the range between the position “operating load” and a position “collapsed suspension” up to shock abutment. The suspension has stiffness greater in the region of “rebound” than in the region of “bump”; if these are graphically represented, a change of thickness represented by a break in the slope appears. FIGS. 13, 14 and 16 in U.S. Pat. No. 5,183,285 have a rebound spring around a shock positioned by a jack for varying the reference position for “operating load” as a function of the number of persons and the load in the vehicle. The jack varies the preload position so there is no gap between rebound and bump.
U.S. Pat. No. 6,273,441 has a load leaf spring suspension system with an elongated stabilizing spring mounted there above the axle. The added spring communicates roll resistance to the vehicle axle at its top center section. Force is concurrently applied at the ends of the stabilizing spring to the leaf spring of the vehicle by shackles. Adjustment of the device is achieved by use of a plurality of mounting apertures for the shackles located at varying distances from the center of the stabilizing spring thereby allowing for adjustment by the user for desired performance characteristics. Further force adjustment is achieved with one or a combination of an optional axle spacer located at the center section of the stabilizing spring to communicate with the axle. This stabilizer system does not employ opposing spring technology. An influence is delivered on the vehicle center of gravity by opposing spring. The center of gravity of the unsprung mass relative to the center of gravity of the sprung mass is affected during the cornering maneuvers. Without a tension or opposing spring to “tether” the sprung mass to the unsprung mass the unsprung mass does not initially help resist the movement upwards of the sprung mass. This resistance is best appreciated in a vehicle with very heavy unsprung mass relative to a lighter sprung mass during cornering versus a vehicle with light unsprung mass relative to a heavy sprung mass. The former is recognized as undesirable and the latter is greatly preferred and sought after in design of vehicles. Often the physical limits of the vehicle components determine the practical boundaries of the sprung weight to unsprung weight ratio. The disclosure herein has an approach to ameliorate the dynamics of that relationship.
U.S. Pat. 6,017,044 has as it's main thrust regulation of spring rebound and bound. Vertical downward jacking-force characteristics of the front suspension is set to be stronger relatively with respect to vertical downward jacking-force characteristics of the rear suspension during cornering. This is achieved by two means. The first is the use of a very strong bump rubber in FIG. 3 of U.S. Pat. No. 6,017,044 that comes into play at the extreme end of the front jounce travel. This bump rubber is not needed in our disclosure. Second, a short “spring” item in FIG. 4 of U.S. Pat. No. 6,017,044 is intended to help control “jack up” of the rear suspension occurring near the extreme end of the roll. The working distance traveled is very short.
U.S. Pat. No. 6,220,406 discloses a damper for reducing sway. It discloses background on various types of shock absorbers used in connection with motor vehicle suspension systems to absorb unwanted vibrations that occur during various driving conditions. To dampen the unwanted vibrations, shock absorbers are generally connected between the sprung portion (i.e., the vehicle body) and the unsprung portion (i.e., the suspension) of the vehicle. A piston assembly is located within the working chamber of the shock absorber and is connected to the body of the motor vehicle through a piston rod. Generally, the piston assembly includes a primary valve arranged to limit the flow of damping fluid within the working chamber when the shock absorber is compressed or extended. As such, the shock absorber is able to generate a damping force to smooth or dampen the vibrations transmitted from the suspension to the vehicle body. Typically, these vibrations occur from forces generated in a vertical direction between the vehicle body and the driving surface.
The greater the degree to which the flow of damping fluid within the working chamber is restricted across the piston assembly, the greater the damping forces that are generated by the shock absorber. It is also possible to implement a primary valve arrangement that produces one magnitude of damping on the compression stroke, and a second magnitude of damping on the rebound stroke. These different damping rates are typically constant as varying the sizes of the compression and rebound bypass orifices produces them. While these shock absorbers produce ride comfort levels ranging from “soft” to “firm,” few, if any, of the known shock absorbers produce varying degrees of damping in a passive manner. The shock absorber systems in use are capable of producing varying degrees of damping force; typically achieve this through the use of active control systems. These systems generally react to the vertically generated forces placed upon the vehicle suspension.
Accordingly, in '406 a shock absorber that includes a primary damping mechanism for counteracting the vertical forces placed upon the vehicle, and a secondary damping mechanism which is capable of providing varying damping in response to horizontal and lateral forces that are placed upon the vehicle suspension. Secondary and variable damping is provided in proportion to the lateral force encountered by a passive control or valves arranged to implement a passive anti-roll system for enhancing the control to the vehicle provided by the vehicle suspension. While such a passive damping system also eliminates the need for complicated and expensive controls to actively provide the varying degrees of damping, it is not easily adapted to the large variety of vehicles and their suspensions.
The problem of the lateral forces placed upon the vehicle suspension is they are generated during high-speed cornering. As the suspension and tires counteract these lateral forces, a rolling action on the vehicle body is produced. When these rolling forces exceed the limit for the vehicle, a rollover condition may be created wherein the vehicle is literally flipped over on its side. Accordingly, it is desirable to provide a shock absorber that provides increased resistance in response to these lateral and horizontal forces for counteracting or at least minimizing these rolling forces and the lift associated therewith.
BRIEF SUMMARY OF THE INVENTION
In the disclosed device and method, a rebound spring is placed to resist the lengthening of the shock absorber from a position that starts one inch into jounce travel from normal ride height to the full rebound suspension travel position. This rebound spring is opposing and resisting the forces that are generated when the suspension is unloading as for example during cornering. Namely the forces caused by the vehicle suspension spring trying to return to its free position and the centrifugal forces naturally resulting during cornering.
Using an additional coil spring mounted about the shock absorber to resist the rebound motion of the sprung weight applied by movement thereof away from the design height reduces chassis roll. The shock absorber thus reduces the initiation of rebound travel between the sprung and unsprung weights as the vehicle becomes lighter due to dynamic forces inducing roll or lift of the chassis and vehicle body.
The transitory effects of body roll during cornering flex the load springs on the side of the vehicle following the outside of the turn due to increased transfer weight to that side. Meanwhile the springs on the side of the vehicle, following the inside of the turn, unload extending toward their free position using the axle as a location for inducing lift of the sprung weight on that side resulting in increased body roll. Roll or sway during sudden cornering or evasive maneuvers rotates the vehicle and its center of gravity “CG” around the Roll Center axis.
The Roll Center axis is a function of the particular, vehicle's suspension geometry. Roll or sway is increased if the vehicle center of gravity is raised as in a SUV, four-wheel drive vehicle or truck. A sudden turn opposite the direction of vehicle travel can cause momentum to continue the sway of the vehicle forcing its center of gravity to move laterally past its maximum upright position, and so the vehicle continues on rolling and overturns.
The solution, as disclosed herein, may include an added rebound spring mounted coaxial about the shock absorber tube to act primarily to resist rebound of the suspension from the design height position and thereby apply resistive force to the chassis via the shock absorber to reduce lift. The coil rebound spring can also be added to a strut type suspension for exactly the same purpose. It is an advantage of the present invention that it can be easily and inexpensively added as an after market supplement to either the front or rear of an existing vehicle suspension with tubular shock absorbers. It is a further advantage of the present invention that the coil rebound spring has very little influence on ride height and/or ride stiffness.
The coil rebound spring works from one inch of jounce travel all the way to full rebound travel of the shock absorber. It works to prevent the onset of roll from the design height, rather than limiting the roll to a certain amount after it has rolled a certain amount. Limiting the roll from the design height position serves to reduce the momentum or inertial weight gain that occurs at the initiation of roll and continues after roll has begun. In other words, we seek to eliminate as much roll as possible from the outset. Rebound control overlaps the jounce control; therefore the disclosed system is truly bi-linear, a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view in cross section of a shock absorber having a coil rebound spring thereabout.
FIG. 2 is a schematic perspective view of a vehicle rounding a comer with roll depicted about its longitudinal axis A-A.
FIG. 3 is a side view in cross section of a typical combined shock absorber and strut type suspension unit, having a load spring but with the addition of the disclosed coil rebound spring thereabout.
FIG. 4 is a graph showing the travel relative to the jounce and rebound loads of the combined shock absorber and strut depicted in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a cross section view of a vehicle rebound control shock absorber 10 with a special suspension coil rebound spring 11 arrangement. It is to be used to replace a standard shock absorber installation independent of the vehicle spring system, as is commonly found in both vehicles with leaf type and coil type suspension spring systems. Commonly a shock absorber connects the sprung mass to the un-sprung mass and is used only to dampen unsprung mass oscillations induced by bumpy roads and sometimes with helper load springs for preloaded height and jounce improvement. The sprung mass is carried on vehicle chassis and body and herein after will be referred to structurally as chassis 16 . The unsprung weight is that which is not supported by the vehicle suspension spring system, i.e. axles 15 , wheels, tires, brake assemblies and suspension components that hang downwardly if the body is lifted. Typically, the passenger vehicle has four wheels with associated suspension with two at the front and two at the rear. The disclosure herein is to cover any number of axle 15 and wheel combinations so long as there is roll to be restrained.
FIG. 1 shows a coil spring mounted about a rebound control shock absorber 10 for exerting force to resist upper rebound control shock absorber 10 movement from the normal design height or preloaded ride position of chassis 16 . When both ends of the rebound control shock absorber 10 are pulled apart, as experienced by chassis 16 when it lifts during rebound of the axle 15 . It is called coil rebound spring 11 because it is intended to counter the lifting action of the vehicle suspension during roll due to cornering maneuvers. When a vehicle corners, its chassis 16 rolls about its longitudinal axis A-A in FIG. 2 relative to axles 15 . Load carrying coil springs 14 on the outside of chassis 16 become compressed as they assume jounce and the coil load springs 14 located on the inside of the turning chassis 16 during cornering become extended while experiencing rebound see FIG. 2 . Coil load springs 14 on the unloading inside side of the cornering vehicle are trying to return to their free state as they extend. Thus coil load springs 14 as they extend exert a lifting force to chassis 16 which is exacerbating the roll angle of the body mass. The lifting force is exactly what is not desired and is resisted by the coil rebound springs 11 herein disclosed. The whole purpose of using coil rebound springs 11 is to reduce chassis 16 roll at initiation of and during cornering because rebound movement at any axle 15 will likewise be resisted.
FIG. 3 shows another rebound control shock absorber 10 having coil rebound spring 11 thereabout, but with the addition of a compression type suspension coil load spring 14 . The additional compression coil load spring 14 carries the sprung weight and is intended to replace or supplement chassis 16 existing original equipment manufacturer suspension load spring 14 , if any. If load spring 14 is carried on the rebound control shock absorber 10 and no separate load spring 14 is used the vehicle suspension would be fully self-contained. Thus the rebound control shock absorber 10 with an integral coil load spring 14 as per FIG. 3 would be able to serve as a replacement assembly providing that the vehicle mounting points for such an assembly is sufficient to respond and carry the loadings expected. Typically, strut mountings that are prevalent on modern cars and trucks are adequate for operation with the assembly shown in FIG. 3 . It is important to note that coil rebound spring 11 seeks to control the sprung weight and the coil load spring 14 if original equipment manufacturer and/or on the rebound control shock absorber 10 as in FIG. 3 supports the sprung weight.
A rebound control shock absorber 10 for placement between axle 15 and chassis 16 is shown in FIGS. 1 , 2 and 3 . The rebound control shock absorber 10 is for additionally controlling the vehicle dynamics with increasing resistance under motion between a preloaded vehicle ride height position to a fully extended position of rebound control shock absorber 10 during rebound movement of chassis 16 away from axle 15 along an axis B-B through the rebound control shock absorber 10 . It is rebound control shock absorber 10 that applies the unsprung weight of the wheels, brake and axle 15 to chassis 16 through coil rebound spring 11 . The goal is not to lift the axle, wheel and its tire from the ground, if possible, during cornering but to apply the unsprung weight of those components at the lifting side of chassis 16 to resist roll of the chassis and body.
An axle mount 17 on axle 15 is provided to connect to rebound control shock absorber 10 . A chassis attachment 18 on chassis 16 of the vehicle connects to the depending rebound control shock absorber 10 so that it may operate along axis B-B between axle mount 17 and chassis attachment 18 . An elongated rod 19 has opposite ends 20 and 21 carried and aligned along the axis B-B. End 20 connects to chassis attachment 18 in FIG. 1 or 3 . While rebound control shock absorber 10 is shown with elongated rod 19 and end 20 at the top in FIGS. 1 and 3 , skilled artisans will understand that it can be inverted so that elongated rod 19 connects to axle mount 17 . A fluid displacement piston 22 is located on end 21 . If rebound control shock absorber 10 is inverted (not shown) then attention to how coil rebound spring 11 carries the unsprung weight must be addressed; again this is within the skill of artisans. Fluid displacement piston 22 is carried on the elongated rod 19 opposite its connection end 20 . Likewise a tube 23 is aligned along the axis B-B and connects to the axle mount 17 when the end 20 is connected to the chassis attachment 18 ; alternatively, the tube 23 connects to chassis attachment 18 when the end 20 is connected to the axle mount 17 .
Tube 23 has inside and outside cylindrical surfaces 24 and 25 . Inside cylindrical surface 24 is sized diametrically for surrounding the fluid displacement piston 22 for sliding sealing circumferential engagement there between with reciprocation along the axis B-B. A chamber 26 is defined by the inside cylindrical surface 24 and chamber 26 carries damping fluid (not shown) about fluid displacement piston 22 for controlled resistance to sliding reciprocal movement of the fluid displacement piston 22 within tube 23 against the inside cylindrical surface 24 and along the axis B-B.
Coil rebound spring 11 is carried about outside cylindrical surface 25 of tube 23 coaxial thereto and for expansion and contraction along the axis B-B as in FIGS. 1 and 3 . Coil rebound spring 11 is mounted to restrain expansion along the axis B-B of the rebound control shock absorber 10 between axle 15 and chassis 16 of the vehicle. Restraint is from at least the preloaded vehicle ride height position to the coil rebound spring 11 fully extended position during rebound motion of the axle 15 away from the chassis 16 as in FIG. 2 .
Tube 23 is elongated along the axis B-B with a top 27 and a bottom 28 separated from each other. A flanged retainer 29 affixes about the outside cylindrical surface 25 of tube 23 . Flanged retainer 29 is located between the top 27 and bottom 28 for applying axial rebound loads to tube 23 from rebound spring 11 during motion along axis B-B of the axle 15 away from chassis 16 . A tube cap 30 mounts in the top 27 and extends from tube 23 to a seat 31 overhanging tube cap radially from the outside cylindrical surface 25 as shown in FIGS. 1 and 3 .
A bore 32 positioned in and passing through tube cap 30 is coaxial with axis B-B and bore 32 allows elongated rod 19 to pass there through and reciprocate therein. Tube cap 30 connects axially to tube top 27 to capture coil rebound spring 11 between flanged retainer 29 and seat 31 . The coil rebound spring is thereby supported for coaxially circumscribing tube 23 between top 27 and bottom 28 thereof. Rebound is resisted during expansion of rebound control shock absorber 10 from its preloaded height to full extension along the axis B-B with motion of axle 15 away from chassis 16 .
A cylindrical housing 33 in FIGS. 1 and 3 is affixed to the end 20 connected to either chassis 16 or axle 15 depending on the orientation of rebound control shock absorber 10 . Cylindrical housing 33 extends from its affixed connection along the axis B-B to engage flanged retainer 29 . Cylindrical housing 33 has a circular cross section sized diametrically for surrounding coil rebound spring 11 with a clearance there between. In FIG. 3 the cylindrical housing 33 is shown with external threads. A fastener 34 on tube cap 30 adjacent seat 31 is shaped to retain coil rebound spring 11 to seat 31 during movement of coil rebound spring 11 along the axis B-B with motion of axle 15 away from chassis 16 . The coil rebound spring 11 is preloaded by the flanged retainer when the coil rebound spring is captured between flanged retainer 29 and seat 31 . During expansion of the rebound control shock absorber 10 from its preloaded position, the coil rebound spring resists expansion under motion of axle 15 away from chassis 16 .
Coil load spring 14 mounts co-axially about cylindrical housing 33 for carrying chassis 16 of the vehicle from the preloaded ride height position to a full jounce position compressing the coil load spring 14 as shown graphically in FIG. 2 . An upper collar 35 about cylindrical housing 33 is near connection end 20 and a lower collar 36 at tube bottom 28 capture coil load spring 14 so rebound spring 11 substantially resists expansion after coil load spring 14 substantially resists compression during rebound and jounce, respectively. The term, “after” is used in the preceding sentence because rebound spring 11 and coil load spring 14 operate independently to control (resist) different loads.
A method for rebound control by rebound control shock absorber 10 placed between axle 15 and chassis 16 of a vehicle is operable at least between a preloaded vehicle ride height position to a fully extended position during rebound movement of axle 15 away from chassis 16 along axis B-B. The method of rebound control has the steps of mounting rebound control shock absorber 10 to axle mount 17 , and attaching rebound control shock absorber 10 to chassis attachment 18 along axis B-B there between. Another step connects elongated rod 19 having opposite ends 20 and 21 so end 20 connects to either axle mount 17 or chassis attachment 18 . Locating piston 22 at the opposite end and connecting tube 23 to axle mount 17 if the elongated rod 19 is connected to chassis attachment 18 or connecting tube 23 to chassis attachment 18 if the elongated rod 19 is connected to the axle mount 17 are steps. The step of sizing tube 23 with a cross section to surround piston 22 for sliding sealing circumferential engagement within tube 23 due to motion of axle 15 away from chassis 16 is performed. Carrying damping fluid about piston 22 in chamber 26 defined by tube 23 is a step. The steps of controlling resistance to sliding reciprocal movement of piston 22 in tube 23 with the damping fluid, and carrying rebound spring 11 about tube 23 for restraining expansion of the rebound control shock absorber 10 . Restraining is between axle 15 and chassis 16 of the vehicle from the preloaded vehicle ride height position to the fully extend position along the axis B-B during rebound movement of axle 15 away from chassis 16 are followed.
The step of supporting rebound spring 11 coaxially circumscribing tube 23 so that rebound is resisted during expansion of rebound control shock absorber 10 from its preloaded height to full extension along the axis B-B with motion of axle 15 away from chassis 16 is done. The step of supporting load spring 14 relative to rebound spring 11 coaxial to one another and along the axis B-B with a clearance there between occurs. During expansion of rebound control shock absorber 10 from its preloaded vehicle height to full extension along the axis B-B there is motion of axle 15 away from chassis 16 load spring 14 and the rebound spring 11 operate substantially independent of one another to resist jounce and rebound, respectively. The method for rebound control by rebound control shock absorber 10 with the step of supporting rebound spring 11 and load spring 14 at the preloaded vehicle height so that the working force application travel there between is overlapping. Thus, about one inch of travel overlap during movement of the rebound spring 11 along the axis B-B with motion of axle 15 away from chassis 16 from the preloaded vehicle height is thus preformed. FIG. 4 shows in graphic form the resultant of overlap for rebound spring 11 and the load spring 14 combined. In the graph of FIG. 4 the load paths at a rate of 320 pound per inch compression jounce spring and a rate of 160 pounds per inch rebound counter spring are shown. The affect on the rebound travel spring of the suspension if engaged at one inch of jounce is no curve at the transition point.
The step of having the ratio of the spring constants of coil rebound spring 11 to the spring constant of load spring 14 be less than one. So that during expansion of rebound control shock absorber 10 from its preloaded position coil rebound spring 11 happens to resist expansion under motion of axle 15 away from chassis 16 to a lesser extent than load spring 14 resists jounce. The step of coil rebound spring 11 applying force to resist rebound of the axle 15 occurs.
The method for rebound control by rebound control shock absorber 10 has the step of locating coil rebound spring 11 to substantially resist expansion of rebound control shock absorber 10 . The step of co-axially positioning coil load spring 14 to substantially resist compression of rebound control shock absorber 10 during rebound and jounce is performed independently.
While the examples illustrating rebound control shock absorber 10 and rebound spring 11 are disclosed and described, skilled artisans will appreciate that many variations for the addition of rebound spring 11 will be possible. The specific examples should not be considered limiting and the particular arrangements shown in FIGS. 1 and 2 are merely for depiction of but some examples of form. In that regard, in the claims that follow the orientation of rebound control shock absorber 10 is either up or down and angled mounting thereof is also within the scope of the claims.
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A stabilizing apparatus and method that replaces the existing shock absorber of a road vehicle that works to resist the initiation of body roll during cornering. It seeks to counter act the forces being generated by the vehicle suspension springs that exacerbate the rollover propensity of vehicles during certain steering maneuvers.
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BACKGROUND OF THE INVENTION
The present invention relates to an ultraviolet ray absorbing agent (UV absorber) comprising a spiro compound specific in structure, as an active ingredient.
Up to now several benzophenone compounds and benzotriazole compounds have been disclosed as UV absorbers and some of them have been commercialized already.
However, these known UV absorbers involve such problems that some of them exhibit low UV absorption power, some are inferior in light resistance, some have colors which will result in color contamination of materials when incorporated thereinto for shielding, and some have low light stability, high sublimability, or low affinity for organic materials. Thus, satisfactory effect has not always been obtained with these UV absorbers.
SUMMARY OF THE INVENTION
Such being the case, the present inventors made intensive studies aiming at development of a UV absorber which will solve the above problems, and as a result were successful in developing spiro compounds of specific structure superior in UV absorptive power, of course, and specially in sublimation resistance (volatility resistance) and heat resistance, and have accomplished the present invention.
According to the invention, there is provided a UV absorber comprising as an active ingredient a spiro compound having a spiro ring structure in the molecule, said spiro compound being represented by the general formula, ##STR4## wherein, Y is ##STR5## A is ##STR6## R 1 is hydrogen, halogen, lower alkyl of 1 to 4 carbon atoms, lower alkoxyl of 1 to 4 carbon atoms, carboxyl, or sulfo, R 2 is hydrogen or alkyl of 1 to 12 carbon atoms, R 3 and R 4 are alkyls of 1 to 12 carbon atoms, X is methylene, oxygen, imino, sulfur, sulfinyl, or sulfonyl, and n is an integer of 1 to 12.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows results of measuring volatilities of different UV absorbers by using a thermobalance, with weight losses (%) as ordinate and heating temperatures as abscissa.
In the FIGURE, the numbers 1 to 4 mean the following compounds: 1: UVA compound No. 1, 2: UVA compound No. 2, 3: Known compound-1, 4: Known compound-2.
DETAILED DESCRIPTION OF THE INVENTION
The spiro compound of general formula (I) above specified according to the invention has the property of absorbing effectively ultraviolet rays of 200 to 400 nm wavelengths which degrade or break down organic substances while not absorbing rays of wavelengths exceeding 400 nm at all, and hence exhibits a strong ultraviolet-shielding action and remarkably less develops color. Thus the present spiro compound has the superior properties of not only being effective as a UV absorber even when used in a trace amount of about 0.001% by weight of the material to shield but also resulting in no color contamination of the material to shield when used in large amounts. Moreover the present spiro compound is excellent in heat stability (resistance to decomposition and sublimation). None of known benzophenone compounds and benzotriazole compounds surpass the present spiro compound in these properties.
The spiro compound specified according to the present invention can be readily obtained from 3,9-bis(1,1-dialkyl-2-hydroxyethyl)-2,4,8,10-tetraoxaspiro[5,5]undecane represented by the general formula, ##STR7## (wherein R 3 and R 4 have the same meaning as in formula (I)) and an acid derivative or ester derivative of benzophenone or benzotriazole compound represented by the general formula, ##STR8## (wherein A, R 2 , X, and n have the same meaning as in formula (I) and Z is hydroxyl, alkoxyl, or halogen) by reacting them in accordance with the normal esterification method.
Examples of the present spiro compound of general formula (I) are given in Tables I and II.
TABLE 1______________________________________ ##STR9##UVA No. R.sub.1 R.sub.2 X R.sub.3 R.sub.4 n______________________________________ 1 H H O CH.sub.3 CH.sub.3 1 2 H H O C.sub.2 H.sub.5 n-C.sub.4 H.sub.9 2 3 H H O CH.sub.3 CH.sub.3 3 4 H H O CH.sub.3 C.sub.2 H.sub.5 1 5 H H O C.sub.2 H.sub.5 n-C.sub.6 H.sub.13 1 6 4-Cl H O CH.sub.3 CH.sub.3 1 7 4-t-C.sub.4 H.sub.9 H O CH.sub.3 CH.sub.3 1 8 H H O CH.sub.3 CH.sub.3 0 9 H H O C.sub.2 H.sub.5 n-C.sub.4 H.sub.9 010 H H NH CH.sub.3 CH.sub.3 011 H H NH CH.sub.3 CH.sub.3 112 H H NH CH.sub.3 CH.sub.3 213 H H NH CH.sub.3 C.sub.2 H.sub.5 114 4-Cl H NH CH.sub.3 CH.sub.3 115 H H S CH.sub.3 CH.sub.3 116 H H SO.sub.2 C.sub.2 H.sub.5 n-C.sub.4 H.sub.9 117 H 3'-t-C.sub.4 H.sub.9 O CH.sub.3 CH.sub.3 118 H 5'-CH.sub.3 O CH.sub.3 CH.sub.3 119 4-Cl 5'-CH.sub.3 O CH.sub.3 CH.sub.3 120 4-Cl 3'-t-C.sub.4 H.sub.9 O C.sub.2 H.sub.5 n-C.sub.12 H.sub.25 121 4-SO.sub.3 H 5'-CH.sub.3 O CH.sub.3 CH.sub.3 1______________________________________
TABLE 2______________________________________ ##STR10##UVA No. R.sub.1 R.sub.2 X R.sub.3 R.sub.4 n______________________________________22 H H O CH.sub.3 CH.sub.3 123 H H O C.sub.2 H.sub.5 n-C.sub.4 H.sub.9 224 H H O CH.sub.3 CH.sub.3 325 H H O CH.sub.3 C.sub.2 H.sub.5 126 H H O C.sub.2 H.sub.5 n-C.sub.6 H.sub.13 127 4-Cl H O CH.sub.3 CH.sub.3 128 4-SO.sub.3 H H O CH.sub.3 CH.sub.3 129 4-t-C.sub.4 H.sub.9 H O CH.sub.3 CH.sub.3 130 H H O CH.sub.3 CH.sub.3 031 H H O C.sub.2 H.sub.5 n-C.sub.4 H.sub.9 032 H H NH CH.sub.3 CH.sub.3 033 H H NH CH.sub.3 CH.sub.3 134 H H NH CH.sub.3 C.sub.2 H.sub.5 135 4-Cl H NH CH.sub.3 CH.sub.3 136 H H S CH.sub.3 CH.sub.3 137 H H SO.sub.2 C.sub.2 H.sub.5 n-C.sub.4 H.sub.9 138 H 5'-CH.sub.3 O CH.sub.3 CH.sub.3 139 H 3'-t-C.sub.4 H.sub.9 O C.sub.2 H.sub.5 n-C.sub.4 H.sub.9 140 4-Cl 5'-CH.sub.3 O CH.sub.3 CH.sub.3 141 4-Cl 3'-t-C.sub.4 H.sub.9 O C.sub.2 H.sub.5 n-C.sub.12 H.sub.25 142 4-SO.sub.3 H 5'-CH.sub.3 O CH.sub.3 CH.sub.3 1______________________________________
The spiro compound specified according to the present invention is effective as a UV absorber for; various high molecular organic compounds including synthetic resins such as polyethylene, polypropylene, polystyrene, polyvinyl chloride, polyvinylidene chloride, MMA resin, ABS resin, polyacrylonitrile, acrylonitrile-styrene copolymer, polyamide, polyester, polyurethane, and polyacetal, synthetic rubbers such as butadiene rubber, isoprene rubber, isoprene-isobutylene rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, and ethylene-propylene-(diene) rubber, natural rubber, wool, silk, hemp, and cellulose; and other various organic materials including lubricating oil and other petroleum products, oil and fat, wax, and grease; particularly for high molecular organic compounds.
For using the spiro compound of the present invention as a UV absorber, methods of incorporating conventional UV absorbers are adaptable. Such methods include, for example; that of melt-mixing a powder of the spiro compound with an organic material powder before or during molding; that of blending the spiro compound into a feed monomer in advance of the polymerization thereof; that of adding the spiro compound to a polymer solution, followed by solvent removal; that of blending the spiro compound into an aqueous dispersion of a polymer; and that of impregnating a fibrous polymer with the spiro compound. Also other optional methods are applicable to use the present spiro compound.
When used, two or more of the present spiro compounds may be combined and if necessary, joint use of various common additives is possible which include a softening agent, antioxidant, heat stabilizer, pigment, etc.
When the present spiro compound is used as a UV absorber, its amount can be selected on the basis of of objective organic material, properties thereof, the application form and manner thereof, the kind of spiro compound used, etc. Generally speaking, however, the suitable amounts are from 0.001 to 10%, particularly from 0.05 to 5%, by weight based on the objective organic material. Even if used in excessive amounts, the present spiro compound does not produce such unfavorable effect as contamination or coloration of the objective organic material.
As stated above, the present spiro compound is such superior in heat stability (resistance to decomposition and volatility) as to be enough fit for use at high temperatures of 350° C. and higher. Therefore, the present spiro compound can be used advantageously even when organic polymers are processed at high temperatures.
The following examples illustrate the present invention.
PREPARATION EXAMPLE 1 UVA COMPOUND NO. 1
A mixture of 3.8 g (0.0124 mole) of 3,9-bis(1,1-dimethyl-2-hydroxyethyl)-2,4,8,10-tetraoxaspiro[5,5]undecane, 8 g (0.028 mole) of methyl 4-(4-benzoyl-3-hydroxyphenoxy)acetate, and 0.02 g (0.0009 mole) of catalyst lithiumamide was stirred under a nitrogen atmosphere at temperatures of 140°-150° C. for about 3 hours and subsequently under reduced pressures of 4-5 mmHg at the same temperatures for about 4 hours to complete the reaction. Then a suitable amount of toluene was added, the mixture was washed with water and dehydrated, and the toluene was expelled. Subsequent recrystallization from acetone gave a yellow-white powder of the objective compound, yield 8.2 g (81.5%), HPLC purity 99.0%, m.p. 169°-170.5° C.
______________________________________Anal. Calcd. (for C.sub.45 H.sub.48 O.sub.14) Found______________________________________C (%) 66.49 66.66H (%) 5.95 6.06______________________________________
PREPARATION EXAMPLE 2 UVA COMPOUND NO. 27
A mixture of 4 g (0.013 mole) of 3,9-bis(1,1-dimethyl-2-hydroxyethyl)-2,4,8,10-tetraoxaspiro[5,5]undecane, 9.6 g (0.029 mole) of 2-[2-hydroxy-4-(2'-methoxy-2'-one-ethoxy)phenyl]-5-chlorobenzotriazole, and 0.02 g (0.0009 mole) of catalyst lithiumamide was stirred under a nitrogen atmosphere at temperatures of 140°-150° C. for about 3 hours and subsequently under reduced pressures of 4-5 mmHg at the same temperatures for about 5 hours to complete the reaction. Then a suitable amount of toluene was added, the mixture was washed with water and dehydrated, and the toluene was expelled. Subsequent recrystallization from methyl ethyl ketone gave 9.2 of a yellow white crystalline powder of the objective compound, yield 78.0%, m.p. 217°-218° C.
______________________________________Anal. Calcd. (for C.sub.48 H.sub.44 O.sub.12 N.sub.6 Cl.sub.2) Found______________________________________C (%) 56.89 56.81H (%) 4.89 4.92N (%) 9.26 9.16Cl (%) 7.81 7.81______________________________________
EXAMPLE 1
(Thermal coloring test)
About 1.0 g of a UV absorber (UVA) sample is placed in a test tube and heated in an oil bath at 270±5° C. for 30 minutes. After allowing to cool, 500 mg of the sample is dissolved in 50 ml of dioxane (solution A). On the other hand, 500 mg of the untreated sample is dissolved in 50 ml of dioxane (solution B). Solutions A and B are measured for visible ray transmittance at wavelengths of 450, 500, and 550 nm. ##EQU1## at 450, 500, and 550 nm are regarded as percentage decreases in transmittance for these wavelengths. With these values, the UVA is evaluated for the degree of thermal degradative coloring. Results of the test are shown in Table 3.
Known compounds 1 and 2 used for comparison are both commercial UV absorbers having the following respective structures: ##STR11##
TABLE 3______________________________________Percentage decrease in transmittanceUVA No. T 450 nm T 500 nm T 550 nm Rating______________________________________1 10.1 5.4 2.5 +++2 10.4 5.3 2.4 +++4 11.1 5.9 2.9 +++5 11.3 6.0 3.1 +++6 10.8 5.7 2.7 +++11 20.8 9.6 6.5 ++14 21.9 10.2 7.8 ++22 11.2 6.8 2.8 +++23 11.5 6.8 2.7 +++25 12.0 7.0 3.2 +++27 12.1 7.1 3.2 +++28 13.8 8.4 5.0 +++32 23.1 11.5 8.0 ++35 23.5 11.7 8.5 ++37 10.2 5.2 2.5 +++Known 71.5 49.3 32.3 0compound 1Known 70.9 47.5 30.2 0compound 2______________________________________ Note: The larger number of + marks means the higher heat resistance.
EXAMPLE 2
(Volatility resistance test)
Volatilities of four compounds: UVA compound No. 1, UVA compound No. 2, known compound 1, and known compound 2 were measured by using a thermobalance.
Results of the measurements are shown in FIG. 1.
Measuring method:
Measuring instrument: Standard type of desk differential thermobalance (supplied by Rigaku Denki Co., Ltd.)
Measurement conditions
TGA sensitivity: 10 mg
Rate of heating: 10° C./min
Chart speed: 8 mm/min
Recorder sensitivity
Heating curve: 20 mV
Weight loss curve: 10 mV
EXAMPLE 3
Various UV absorbers were each dissolved in a 25% urethane dope (composed of 25 parts by weight of a polyurethane resin, 3.75 parts by weight of dimethylformamide, and 71.25 parts by weight of tetrahydrofuran) to a concentration as shown in Table 4. Each solution was applied on a nylon film and then dried in an oven at 45° C. for 1 hour to prepare a sheet (10 cm×5 cm). Light resistance tests on the prepared sheets were conducted by Fade-Ometer (supplied by Toyo Seiki Co., Ltd.) irradiation. The darkening degree of each sheet was judged by visual observation. Results thereof are shown in Table 4.
Figures in Table 4 represent darkening degrees of the sheets judged by visual observation on the basis of rating the shade of the unirradiated sheet as 0 and rating that of a thoroughly blackened sheet as 10 to grade the degrees into ten steps according to the blackened degrees.
TABLE 4______________________________________UV absorber Addi-UVA tion Degree of darkening by ir-Compound amount radiation for a period ofNo. (%) 0 hr 15 hr 30 hr 45 hr______________________________________Example ofpresentinvention 1 1.0 0 2 2-3 3 2.0 0 1 1-2 2 2 1.0 0 2 2-3 3 2.0 0 1 1-2 2 4 1.0 0 2 3 5 2.0 0 1 1-2 2-3 5 1.0 0 1 3 4 2.0 0 0-1 2 2-3 6 1.0 0 2 3 5 2.0 0 1 2 311 1.0 0 1 2 4 2.0 0 1 1-2 314 1.0 0 1 2-3 3-4 2.0 0 1 2 2-322 1.0 0 1 3 5 2.0 0 0-1 1-2 323 1.0 0 1 3 5 2.0 0 1 2 3-425 1.0 0 1 3 5 2.0 0 0-1 1-2 327 1.0 0 1 2-3 3-4 2.0 0 0-1 2 328 1.0 0 1 3 4-5 2.0 0 1 2-3 332 1.0 0 1 2-3 3-4 2.0 0 0-1 2 335 1.0 0 1 3 5 2.0 0 1 2-3 3ComparativeExampleKnown 1.0 0 3 5 6-7compound 1 2.0 0 2 4 5-6Known 1.0 0 3 5 7compound 2 2.0 0 2 5 6None -- 0 5-6 6-7 8______________________________________
EXAMPLE 4
A dry mixture of 50 parts by weight of an isotactic polypropylene and 0.25 part by weight each of different UVA's was compression-molded in the ordinary way at a temperature of about 204° C. and a pressure of 2,000 psi for 6 minutes to prepare 2.0-mm thick sheets, which were then cut into pieces of 5 cm square. These test pieces (and those similarly prepared without incorporating any UVA) were irradiated in a weather-ometer, and their discoloration degrees were examined. Results of the examination are shown in Table 5.
TABLE 5______________________________________ Irradiation periodUVA No. 500 hr 1000 hr 1500 hr______________________________________None Pale yellow Yellow Brown 1 Not dis- Not dis- Little colored colored discolored 9 Not dis- Not dis- Little colored colored discolored22 Not dis- Not dis- Little colored colored discolored33 Not dis- Not dis- Little colored colored discoloredKnown compound 1 Not dis- Pale Yellow colored yellowKnown compound 2 Not dis- Pale Yellow colored yellow______________________________________
The above polypropylene test sheet containing each of UVA Nos. 1, 9, 22, and 23, even after 1000 hour's exposure, gave no indication of embrittlement in a 180° C. bending test and showed neither fine surface cracks nor discoloration.
On the other hand, the sheet containing no UVA and the sheet containing each of known compounds 1 and 2 broke in the bending test after 300 to 400 hour's exposure and after 700 to 800 hour's exposure, respectively.
Tests similar to the above were conducted by using severally a polyethylene resin and a terephthalate resin in place of the polypropylene resin, giving nearly the same results.
EXAMPLE 5
______________________________________Polyvinyl chloride (P-1100) 100 parts by weightDioctyl phthalate 50 parts by weightKV-33K (Ca--Ba type stabilizer) 1.5 parts by weightCalcium stearate 0.6 part by weightBarium stearate 0.2 part by weightEach of different UVA's 0.1 part by weight______________________________________
Mixtures of the above compositions were each kneaded on a 6-inch roll mill at 150° C. for 5 minutes to form 0.5-mm thick sheets. These sheets (and those similarly prepared without incorporating any UVA) were exposed out of doors, and the discoloration-inhibiting effect of each UVA was evaluated by visual observation. Results of the evaluation are shown in Table 6.
TABLE 6______________________________________ Irradiation period 6 12 18 24 30UVA No. months months months months months______________________________________None Yellow Yellow Slight Slight Dark tinged tinged dark dark brown yellow brownKnown compound 1 Color- Color- Color- Yellow Yellow less less less tinged tingedKnown compound 2 Color- Color- Color- Yellow Yellow less less less tinged tinged 1 Color- Color- Color- Color- Color- less less less less less 9 Color- Color- Color- Color- Yellow less less less less tinged22 Color- Color- Color- Color- Color- less less less less less33 Color- Color- Color- Color- Yellow less less less less tinged______________________________________
EXAMPLE 6
A solution composed of 15 parts by weight of an acetylcellulose having an average 2.5 acetoxy groups per one unit of glucose, 0.3 part by weight of UVA No. 1, 2.0 parts by weight of dibutyl phthalate, and 82.7 parts by weight of acetone was spread on glass plates, and the solvent was removed to form films.
These 0.04-mm thick films (and those similarly prepared without incorporating any UVA) were exposed in a Fade-Ometer for 1000 hours, and their embrittlement degrees were examined. The results were as follows:
______________________________________UV absorber Flexural property of film______________________________________UVA No. 1 FlexibleNone Fragile______________________________________
EXAMPLE 7
A fine powder of UVA No. 22 was admixed with a disperse dye for polyester-purposes, to a concentration of 5% by weight, and a Tetron cloth was dyed with the resulting dye composition according to the normal method. The obtained dyeing was improved in light fastness by one or two classes over a dyeing similarly prepared without incorporating any UVA. The same effect is obtainable also by dispersing UVA No. 22 in water using a surfactant and adding the dispersion suitably to a dyeing bath at the time of dyeing. Dyeings of other synthetic fibers can also be improved in light fastness by applying the same or analogous method, that is, by mixing or using the present UV absorber jointly with various dyes or pigments at the time of dyeing the fibers.
EXAMPLE 8
Polyacrylonitrile fibers were treated with 0.03% by weight of UVA No. 29 in a bath ratio of 1:30 at temperatures of 95°-100° C. for 60 minutes, then soaped, rinsed with water, and dried. The light resistance of the fibers themselves was markedly enhanced by this treatment as compared with that of the untreated fibers. In this treatment, it is also possible to use jointly a dye, an optical whitening agent, or an oxidizing agent such as sodium chlorite, whereby the light fastness of the applied dye or optical whitening agent is also improved by one or two classes.
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An ultraviolet ray absorbing agent comprising as an active ingredient a spiro compound having a spiro ring structure in the molecule, said spiro compound being represented by the general formula ##STR1## wherein, Y is ##STR2## A is ##STR3## R 1 is hydrogen, halogen, lower alkyl of 1 to 4 carbon atoms, lower alkoxyl of 1 to 4 carbon atoms, carboxyl, or sulfo, R 2 is hydrogen or alkyl of 1 to 12 carbon atoms, R 3 and R 4 are alkyls of 1 to 12 carbon atoms, X is methylene, oxygen, imino, sulfur, sulfinyl, or sulfonyl, and n is an integer of 1 to 12.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a digital camera which employs an image pick-up device such as a CCD (charge-coupled device).
[0002] Recently, digital cameras which record image data on a medium such as a flash memory card, a smart card or the like have become widespread. A basic configuration of a digital camera is similar to a camera which uses a silver-salt film. That is, the digital camera includes components such as a photographing optical system for forming an image of an object on an image plane, and an aperture mechanism. In the digital camera, a CCD is provided instead of the photographing film on the Image plane.
[0003] [0003]FIG. 1 is a cross sectional view of a CCD 3 which is generally employed in a conventional digital camera. As shown in FIG. 1, on an upper portion of the CCD 3 , a plurality of photoreceptors (photo diodes) 32 and transistors for transferring charges (not shown) are formed.
[0004] Above the photodiodes 32 , apertures 33 a are formed, respectively. The apertures 33 a are covered with a plurality of micro-lenses 34 , respectively, which form an image on the photodiodes 32 (i.e., on a light-receptive surface of the CCD 3 ).
[0005] Since the micro-lenses 34 converge light on the light-receptive surface of the CCD 3 , the photographing optical system is required to form an image on the rear side of the light-receptive surface of the CCD 3 . For this purpose, the photographing optical system should be configured such that rays of light incident on the micro-lens 34 are substantially parallel. That is, the photographing optical system in the digital camera is required to be substantially telecentric.
[0006] In a camera utilizing the silver-salt film, by making use of depth of fields, it is possible to intentionally form a defocused (i.e., out-of-focus) portion In an image of the object For example, by fully opening the aperture, a central object is focused, while a background is defocused. In the case of the digital camera, since the photographing optical system has the telecentricity as described above, it is difficult to obtain an image whose background is sufficiently defocused. That is, because of the telecentricity, the depth-of-fields of the digital camera is deeper than that of the camera which uses the silver-salt film.
[0007] Therefore, in order to obtain an image whose background is appropriately defocused, the image data should be once transmitted to a computer and is retouched using a photo retouching software.
SUMMARY OF THE INVENTION
[0008] The present invention is advantageous in that it provides a digital camera which is capable of obtaining an image whose background is appropriately defocused.
[0009] According to an aspect of the invention, there is provided a digital camera, which is provided with an optical system which forms an image of an object, an image pick-up device which receives the object image and outputs an image signal corresponding to the received object image, and a filtering system which receives and processes the image signal so that a smoothing effect is applied to at least a portion of the object image.
[0010] With this configuration, an image whose background is appropriately defocused can be obtained. There is no necessity to retouch the image captured by the digital camera using a photo retouch software.
[0011] Optionally, the filtering system may calculate moving averages of pixel data in the image.
[0012] Further optionally, the digital camera may be further provided with a filter control system which is configured to change characteristics of the filtering system. With this configuration, the degree of smoothness of the image can be changed.
[0013] Preferably, the filter control system may change the characteristics of the filtering system corresponding to a distance between a first position which lies in the image and a second position at which a moving average is calculated.
[0014] In a particular case, the first position may be a center of the image.
[0015] Preferably, the digital camera is further provided with an automatic focusing system which drives the optical system to perform focusing. This automatic focusing system has at least one AF area in which the optical system focuses on the object, and is configured to manually or automatically select one of the at least one AF area. In this case, the first position corresponds to the one of the at least one AF area manually or automatically selected by the automatic focusing system.
[0016] With this configuration, the degree of smoothness (i.e. the degree of defocused condition) of the background of the image can be changed responsive to the distance between the selected AF area and the second position at which a moving average is calculated
[0017] In a particular case, the filter control system may change the characteristics of the filtering system such that the image includes at least one annular zone in which the degree of smoothness is uniform. In this case, the at least one annular zone may be arranged concentrically about the first position.
[0018] Alternatively, the rate of a change of the degree of smoothness of the image in a lateral direction of the image and the rate of a change of the degree of smoothness in a vertical direction of the image may be the same.
[0019] Alternatively, the rate of a change of the degree of smoothness of the image in a lateral direction of the image may be different from the rate of a change of the degree of smoothness of the image in a vertical direction of the image.
[0020] Optionally, the filter control system may change the characteristics of the filtering system corresponding to at least one of an object distance when the image is captured, an aperture diameter of an aperture which is provided in the optical system when the image is captured, and a focal length of said optical system in addition to the distance between the first position and the second position.
[0021] In a particular case, the optical system may be a zoom lens. In this case, the filter control system may change the characteristics of the filtering system responsive to a focal length of the zoom lens when the image is captured in addition to the distance between the first position and the second position.
[0022] Preferably, the digital camera may include a image processing system which processes the image signal to generate image data corresponding to the image formed by the optical system. In this case, the filtering system may be a digital filter which filters the image using the image data generated by the image processing system.
[0023] In a particular case, the digital camera may include an automatic aperture control system which calculates an f number to be used for capturing the image based on brightness information of the image to be captured and adjusts an aperture diameter of an aperture provided in the optical system according to the calculated f number In this case, the filter control system may change the characteristics of the filtering system responsive to the f number calculated by the automatic iris control system in addition to the distance between the first position and the second position.
[0024] According to another aspect of the invention, there is provided a digital camera, which is provided with an image capturing system that captures an image of an object within a predetermined area and outputs an image signal representing the captured Image; a processing system that processes the image signal, and a storage that stores the image signal processed by said processing system in the form of image data. In this case, the processing system includes a filtering system that defines at least one partial area in the predetermined area and coverts a part of the image signal representing an image segment included in the at least one partial area such that the image segment appears defocused.
[0025] In a particular case, the at least one partial area may include at least one annular area, respectively.
[0026] Optionally, the filtering system may define a plurality of annular areas centering around a predetermined point in the predetermined area, and the filtering system may vary a degree of defocused condition of image segments depending on the annular areas In which the image segments are included.
[0027] Still optionally, the degree of defocused condition of the Image segment may be greater for an image segment included in an outer annular area than an image segment included in an inner annular area.
[0028] In a particular case, the digital camera may further provided with a focusing condition detection system, and the predetermined point may correspond to a point at which the focusing condition detection system detects a focusing condition of the object.
[0029] Optionally, the focusing condition detection system may be capable of detecting a focusing condition of an object at a selected one of a plurality of points defined in the predetermined area, and the predetermined point may correspond to the selected one of the plurality of points.
[0030] Still optionally, the filtering system may change the degree of defocused condition for the plurality of annular zones at a first ratio along a longer side of the predetermined area, and at a second ratio along a shorter side of the predetermined area.
[0031] Still optionally, each of the first ratio and the second ratio is varied depending on at least one of an object distance, an aperture size of a photographing lens of the digital camera and a focal length of the photographing lens.
[0032] In a particular case, the first ratio and the second ratio may be different.
[0033] Alternatively, the first ratio and the second ratio may be substantially same.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0034] [0034]FIG. 1 is a cross sectional view of a CCD which is generally employed in a conventional digital camera;
[0035] [0035]FIG. 2 shows a cross sectional view of a digital camera according to an embodiment of the invention;
[0036] [0036]FIG. 3 schematically shows AF areas which are arranged in a finder field of the digital camera;
[0037] [0037]FIG. 4 shows a block diagram of a control system of the digital camera;
[0038] [0038]FIG. 5 shows a block diagram of the filtering unit provided in the digital camera;
[0039] [0039]FIG. 6A shows an example of an image data signal which is not smoothed:
[0040] [0040]FIG. 6B shows an image data signal which is smoothed by a filtering unit;
[0041] [0041]FIG. 6C shows an image data signal which is smoothed strongly in comparison with the image data signal shown In FIG. 6B;
[0042] [0042]FIG. 7 schematically shows an example of conditions used for performing a process for smoothing in a case where an AF area A 0 is selected;
[0043] [0043]FIG. 8A shows an example of the object which is to be processed;
[0044] [0044]FIG. 8B is a graph showing an example of a change of the coefficient for weighting in a vertical direction of an finder frame shown in FIG. 8A;
[0045] [0045]FIG. 8C Is a graph showing an example of a change of the coefficient for weighting in a lateral direction of the finder frame shown in FIG. 8A;
[0046] [0046]FIG. 9A shows another example of the object which is to be subjected to the process for blurring;
[0047] [0047]FIG. 9B is a graph showing an example of a change of the coefficient for weighting in the vertical direction of the finder frame shown in FIG. 9A;
[0048] [0048]FIG. 9C is a graph showing an example of a change of the coefficient for weighting in the lateral direction of the finder frame shown in FIG. 9A; and
[0049] [0049]FIG. 10 is a flowchart showing a process for filtering executed by the CPU in the digital camera.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0050] Hereinafter, a digital camera 10 according to an embodiment of the present invention will be described with reference to the accompanying drawings.
[0051] [0051]FIG. 2 shows a cross sectional view of the digital camera 10 . As shown in FIG. 2, the digital camera 10 is provided with a camera body 1 , to which a photographing lens 2 is detachably attached. The photographing lens 2 includes a lens barrel 21 which accommodates lenses 22 for forming an image of an object, and an aperture 23 .
[0052] on a rear side of the camera body 1 , a CCD 3 which converts an image formed thereon into an image signal is arranged to intersect with an optical axis of the photographing lens 2 . The structure of the CCD 3 is similar to the conventional one as shown In FIG. 1. That is, on the upper portion of the CCD 3 , a plurality of photoreceptors (photo diodes) 32 are formed in the form of a matrix. Above the photodiodes 32 , micro-lenses 34 are arranged, respectively. Further, in the digital camera 10 , an optical lowpass filter 35 is provided on the top surface of the CCD 3 as shown in FIG. 2.
[0053] In the digital camera 10 , the lenses 22 are driven by an AF (auto focusing) mechanism 15 , under control of a CPU 101 (FIG. 4), to focus on an object. The photographing lens 2 is configured to telecentrically form the object image on the CCD 3 .
[0054] The aperture 23 is configured such that the aperture size thereof is controllable, manually or electrically, so that the quantity of light passing through the photographing lens 2 is changed The aperture diameter is changed manually, or automatically through an aperture driving mechanism 16 under control of the CPU 101 .
[0055] A half mirror 4 is arranged in front of the CCD 3 . Part of light passed through the photographing lens 2 is reflected by the half mirror 4 and is directed to an upward direction. The remaining portion of the light is directed to the CCD 3 .
[0056] As shown In FIG. 2, a finder optical system 5 is arranged above the half mirror 4 . The finder optical system 5 includes a focusing plate 51 on which an image is formed by the photographing optical system 2 . Further, an AF frame LCD 52 is arranged on the focusing plate 51 . The camera body 1 further includes a pentagonal prism 53 which is arranged above the AF frame LCD 52 , an eyepiece lens 54 which is positioned at the rear of the pentagonal prism 53 , and a protection glass 55 which is arranged at the rear of the pentagonal prism 53 . On the rear side of the pentagonal prism 53 , a lens 56 , a filter 57 and a photometry device 58 are arranged at the upper rear potion of the camera body 1 .
[0057] The AF frame LCD 52 is driven by an LCD drive circuit 18 under control of the CPU 101 . As shown in FIG. 3, nine AF areas A 0 -A 8 are arranged in a finder field in the form of a three-by-three matrix. Patterns corresponding to the AF areas A 0 -A 8 are formed on the AF frame LCD 52 . When a user selects one of the AF areas A 0 -A 8 through an AF area setting button 12 , one of the patterns corresponding to the selected AF area is indicated on the finder field. Therefore, a user can identify the selected AF area In the finder field. Alternatively, the AF area may be automatically selected under control of the CPU 101 .
[0058] [0058]FIG. 4 shows a block diagram of a control system of the digital camera 10 . In FIG. 4, elements similar to those shown In FIG. 2 are given the same reference numbers as in FIG. 2.
[0059] As shown in FIG. 4, the CPU 101 is supplied with power through a DC-DC converter 102 , which converts a DC voltage of a battery 103 and output a converted DC voltage. To the CPU 101 , signals indicative of operation of a photometry switch 13 a and a release switch 13 b are input. When a release button 13 is depressed halfway, the photometry switch 13 a is ON, and when the release button 13 is fully depressed, the release switch 13 b is ON. Further, to the CPU 101 , an operation status of a mode setting button 14 is input The mode setting button 14 is used for setting defocused condition of the image captured by the digital camera 1 . Further, the CPU 101 receives a setting signal of the AF area setting button 12 indicative of one of the AF areas A 0 -A 8 .
[0060] The CCD 3 is driven by a CCD driver 105 which operates based on clock signals output by a clock generator 104 .
[0061] The CCD 3 converts an image formed on the light-receptive surface thereof to an image signal including a brightness component of the image. The image signal is amplified by an amplifier (AMP) 111 , and the amplified image signal is input to an A-D converter 112 which converts the image signal into a digital image signal. The digital image signal is input to an image processing unit 113 which applies predetermined processing to the digital image signal. As a result, the Image processing unit 113 generates an image data.
[0062] The image data generated by the image processing unit 113 is input to a data compression unit 114 which Is capable of performing image data compression. The data compression unit 114 can be switched between a mode in which image data compression is performed and a mode in which image data compression is not performed, i.e., the image data generated by the image processing unit 113 is directly input to an image memory 115 . Therefore, either the compressed image data or the image data which is not compressed is stored in the image memory 115 .
[0063] As shown in FIG. 4, the image data generated by the image processing unit 113 is also input to a filtering unit 116 which processes the image data so that a background of the image appears blurred (defocused). The filtering unit 116 is composed of a digital filter.
[0064] [0064]FIG. 5 shows a block diagram of the filtering unit 116 . As shown in FIG. 5, the filtering unit 116 Includes two delay circuits 121 , 122 for delaying pixel data input to an input terminal 116 a , multipliers 123 - 125 , and adders 126 , 127 . Each of the delay circuits 121 and 122 delays the pixel data which is sequentially input to the input terminal 116 a by a fixed time Interval Each of the multipliers 123 - 125 multiplies the pixel data by a coefficient for weighting. The adders 126 and 127 sum outputs of the multipliers 123 - 125 , which is output on an output terminal 116 b . Thus, the filtering unit 116 functions as a low pass filter which calculates moving averages of the image data.
[0065] In particular, since characteristics of the filtering unit 116 are controlled by the CPU 101 , they can be changed while the plurality of pieces of pixel data which constitute one image are sequentially input to the filtering unit 116 . Therefore, the moving averages are calculated while the CPU 101 changes the characteristics of the filtering unit.
[0066] The CPU 101 controls the characteristics of the filtering unit 116 by changing the number of pixels which are used for calculating the moving averages. This corresponds to changing the number of delay units and multipliers and values of the coefficients of the digital filter.
[0067] With this configuration, the degree of smoothness of the image can be changed by changing the characteristics of the filtering unit 116 .
[0068] As shown in FIG. 5, if the values of the coefficients are set at one third by the CPU 101 , a moving average is (a 1 +a 2 +a 3 )/3 where a 1 , a 2 and a 3 are three pieces of pixel data sequentially input to the filtering unit 116 .
[0069] When the photometry switch 13 a is switched to ON, intensity information output by the photometry device 58 and the brightness component of the image output by the CCD 3 are input to an exposure control unit 106 , and then the exposure control unit 106 determines an exposure value. Next, the exposure value determined by the exposure control unit 106 is inputted to the CPU 101 . Further, in a case where one of the AF areas A 0 -A 8 is selected through the use of the AF area setting button 12 , the CPU 101 controls the LCD drive circuit 18 to display the selected AF area on the AF frame LCD 52 , and controls the AF mechanism 15 to perform focusing. The CPU 101 displays various information as to photo shooting on an external display 7 .
[0070] When the release switch 13 b is switched to ON, the CPU 101 controls the aperture driving mechanism 16 and the CCD 3 to start accumulation of charges in the CCD 3 . The CPU 101 also controls a strobe control unit 19 to emit flashlight from strobe 6 in case of necessity.
[0071] The process of photo shooting using the digital camera 10 will be described. A user initially observes a finder image on which the AF areas A 0 -A 8 are overlaid. The user selects an AF area in which the object is positioned through the use of the AF area setting button 12 When the photometry switch 13 a is switched to ON, the CPU 101 controls the AF mechanism 15 to focus on the object in the selected AF area. Thus, the light passing though the photographing lens 2 is focused on the light-receptive surface of the CCD 3 . Further, the CPU 101 determines an aperture diameter (f number) of the aperture 23 based on the exposure value output by the exposure control unit 106 .
[0072] When the release switch 13 b is switched to ON, accumulation of charges in the CCD 3 on which the image is formed starts. Then, the charges accumulated in the CCD 3 is output as the image signal according to driving pulses output by the CCD driver 105 . The image processing unit 113 processes the image signal to generate Image data. Next, the compressed image data or the image data which is not compressed is stored in the image memory 115 . Since image processing for generating image data performed by the image processing unit 113 is generally known, a detailed description of image processing will be omitted.
[0073] If the mode setting button 14 is ON, the CPU 101 controls the filtering unit 116 to perform a process for blurring the background of the image. The filtering unit 116 calculates moving averages of a plurality of pieces of the pixel data which are sequentially input to the filtering unit 116 from the image processing unit 113 .
[0074] [0074]FIG. 6A shows an example of an Image data signal SG 0 corresponding to a horizontal line of the image. If the image data signal SG 0 Is input from the image processing unit 113 to the filtering unit 116 when the characteristics of the filtering unit 116 are controlled such that the degree of smoothness of the image becomes relatively low, an Image data signal SG 1 shown in FIG. 6B is output by the filtering unit 116 . As shown in FIG. 6B, the image data signal SG 1 is smoothed out.
[0075] [0075]FIG. 6C shows a case where the characteristics of the filtering unit 116 are controlled such that the degree of smoothness of the image becomes relatively high. As shown in FIG. 6C, an image data signal SG 2 is smoother than the image data signal SG 1 .
[0076] A detailed explanation of the filtering unit 116 will be described below. Before the CPU 101 performs the process for blurring the background of the image, the CPU 101 determines conditions which are used to perform the process for blurring based on information with regard to the selected AF area.
[0077] Assuming that the selected AF area is the area A 0 which is positioned at a center of the image. FIG. 7 shows an example of conditions used for performing the process for blurring In a case where the AF area A 0 is selected. As shown in FIG. 7, the CPU 101 divides the image which is to be processed into a plurality of annular zones (C 0 , C 1 , C 2 , C 3 , . . . ) concentrically arranged about the selected AF area A 0 . The CPU 101 understands one of the zones in which pixel data input from the image processing unit 113 to the filtering unit 116 is included. The CPU 101 sets different values of the coefficient for each zones (C 0 , C 1 , C 2 , C 3 , . . . ) so that the degree of smoothness is changed depending on a position of the pixel data in the image.
[0078] In this example, the degree of smoothness increases like a curve of a quadratic function as the distance from the AF area A 0 to a position at which a moving average of the pixel data is calculated increases.
[0079] With this configuration, the degree of the defocused condition in the annular zone (i.e., in the background of the image) can be increased as the distance from the AF area A 0 to the annular zone increases.
[0080] The degree of the defocused condition for the annular zones may be changed at a first ratio along a longer side of a finder frame and at a second ratio which is not equal to the first ratio along a shorter side of the finder frame. In this case, the first ratio and the second ratio represent the relationship between distance of the relative distances of the annular zones from the AF area A 0 and the corresponding degree of the defocused condition.
[0081] [0081]FIG. 8A shows an example of the object (a finder field) which is to be processed. If a user takes a picture of a flower shown in FIG. 8A, the user selects the AF area A 0 so that a pistil or a stamen of the flower comes into focus.
[0082] A solid line shown in FIG. 8B is a graph showing an example of a change of the degree of smoothness of the image in a vertical direction D 1 . A position 0 on a horizontal axis in FIG. 8B corresponds to the AF area A 0 . As shown in FIG. 8B, the degree of smoothness of the image increases as the distance from the AF area A 0 to a position at which a moving average of the pixel data is calculated increases.
[0083] A solid line shown in FIG. 8C is a graph showing an example of a change of the degree of smoothness of the image in a lateral direction D 0 . A position 0 on a horizontal axis in FIG. 8C corresponds to the AF area A 0 . As shown in FIG. 8C, the degree of smoothness increases as the distance form the AF area A 0 to a position at which a moving average of the pixel data is calculated increases.
[0084] Is should be appreciated that since changes of the degree of smoothness of the image in the vertical direction D 1 and in the lateral direction D 0 are the same, the degree of change of defocused condition in vertical direction D 1 and the degree of change of defocused condition in the lateral direction D 0 are the same. This means that, a zone in which the degree of defocused condition is uniform has the form of a circle. Accordingly, the background of the object (the flower) whose shape in the finder view is approximately circular can be well blurred.
[0085] The CPU 101 obtains an object distance and the size of the aperture 23 when an image Is captured. Therefore, the degree of smoothness of the image can be changed based on the aperture diameter (i.e., an f number) and/or the object distance when an image is captured as well as the distance from the AF area A 0 to a position at which a moving average is calculated. As shown dashed lines in FIGS. 8B or 8 C, the degree of smoothness may be increased as the aperture size increases Alternatively or additionally, the degree of smoothness may be increased as the object distance decreases.
[0086] If a digital camera 10 has an aperture driving mode, the degree of smoothness of the image may be changed based on the aperture diameter manually selected by the user.
[0087] In this case, the degree of defocus condition of the background of the image can be increased as the object distance decreases and/or as the aperture diameter increases. That is, the degree of the defocus condition of the background of the image can be changed depending on the aperture size and/or the object distance as in the case of the camera using a film.
[0088] [0088]FIG. 9A shows another example of the object (a finder field) which is to be processed. It should be noted that this example is a portrait, and therefore, a finder frame (i.e., the digital camera) is positioned such that the longer side of the finder frame is oriented In a vertical direction. In this case, the AF area A 2 which is positioned near the perimeter of the finder frame is selected to focus on an eye of the person.
[0089] [0089]FIGS. 9B and 9C are graphs showing changes of the degree of smoothness of the image.
[0090] A solid line In FIG. 9B is a graph showing a change of the degree of smoothness in the vertical direction D 1 . A position 0 on a horizontal axis in FIG. 9B corresponds to the AF area A 2 . As shown in FIG. 9B, the degree of smoothness of the image increases as the distance from the AF area A 2 to a position at which a moving average is calculated increases.
[0091] A solid line in FIG. 9C is a graph showing a change of the degree of smoothness of the image in a lateral direction D 0 . A position 0 on a horizontal axis in FIG. 9C corresponds to the AF area A 2 . As shown in FIG. 9C, the degree of smoothness increases as the distance form the AF area A 2 to a position at which a moving average Is calculated increases.
[0092] As can be seen from FIGS. 9B and 9C, the rate of the change of the degree of smoothness in the vertical direction D 1 is greater than the rate of the change of the degree of smoothness in the lateral direction D 0 . That is, the rate of increase of the degree of smoothness in the lateral direction D 0 is milder than the rate of increase of the degree of smoothness in the vertical direction D 1 . Therefore, in the image processed to appear defocused, the degree of the defocused condition increases gently in the lateral direction D 0 as the distance from the AF area A 2 to a position at which a moving average is calculated increases in comparison with an increase of the degree of the defocused condition in the vertical direction D 1 . This means that, a zone in which the degree of the defocused condition is uniform has the form of an ellipse.
[0093] Accordingly, in a case where a picture of a person such as the image shown in FIG. 9A is picked up by the digital camera 10 , it becomes possible to reduce the degree of the defocused condition in an area of the person's body, and to increase the degree of the defocused condition in the background of the image.
[0094] If the mode setting button 14 is OFF, the data compression unit 114 uses the image data directly transferred from the Image processing unit 113 , i.e., the process for blurring is not performed. This operation in which the process for blurring is not performed is advantageous in a case where a user takes a picture of a landscape because the entire region of this picture substantially comes into a focus.
[0095] Variations of the above-mentioned embodiment can be made. For example, alternative to or in addition to the use of the object distance and/or the aperture diameter, the CPU 101 may use a focus length of the photographing lens 2 for determining the degree of smoothness of the background of the image (i.e., the characteristics of the filtering unit 116 ) This is advantageous in a case where the digital camera 10 is capable of using a zoom lens or an interchangeable lens as the photographing lens 2 .
[0096] That Is, the CPU 101 increases the degree of smoothness when a long focal length is used. In this case, is becomes possible to increase the degree of the defocused condition when the long focal length is used, and to decrease the degree of the defocused condition when a short focal length is used.
[0097] Alternative to the filtering unit 116 which is configured to calculate moving averages, another type of digital filter which is capable of changing spatial frequencies of an image may be used.
[0098] Alternatively, the CPU 101 may be configured to perform a process for filtering according to a program stored in a ROM (not shown) incorporated in the CPU 101 . In this case, the filtering unit 116 can be omitted FIG. 10 is a flowchart showing a process for filtering executed by the CPU 101 . In FIG. 10, reference numbers (a 11 , a 12 , a 13 , . . . ) corresponding to pixels in an image are shown for reference purposes. Initially, the CPU 101 obtains pixel data all output by the image processing unit 113 , and multiplies all by one third, and then, stores the result (a 11 /3) into a variable b 1 (step S 1 ). Similarly, a 12 /3 and a 13 /3 are stored in variables b 2 and b 3 , respectively (S 2 , S 3 ). Next, the sum of b 1 , b 2 and b 3 is calculated, and then, the result ((a 11 +a 12 +a 13 )/3) is sent to the data compression unit 114 (S 5 ). This process is repeated until all the pixel data of one image are processed.
[0099] As described above, the digital camera can blur the background of the image based on the object distance, the aperture diameter of the photographing lens and/or the focal length of the photographing lens as in the case of the camera which uses the film. Therefore, there is no necessity to retouch the image picked up by the digital camera 10 using a photo retouch software.
[0100] The present disclosure relates to the subject matter contained in Japanese Patent Application No. 2001-286211, filed on Sep. 20, 2001, which is expressly incorporated herein by reference in its entirety.
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There is provided a digital camera, which is provided with an optical system which forms an image of an object, an image pick-up device which outputs an image signal corresponding to the image formed by said optical system, and a filtering system which filters the image to smooth at least a portion of the image based on the image signal outputted by the image pick-up device. The filtering system may calculate moving averages of pixels in the image. The digital camera may include a filter control system which is configured to change characteristics of the filtering system.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Japanese Patent Application No. 2012-072909 filed Mar. 28, 2012, the content of which is hereby incorporated herein by reference.
BACKGROUND
The present disclosure relates to a sewing machine that allows a clearance between a sewing needle and a hook point of a shuttle to be adjusted.
A known sewing machine mainly includes a bed, a pillar, an arm, and a head. The arm is provided with a drive shaft. The drive shaft may be driven by a sewing machine motor. The head is provided with a needle bar base. The needle bar base supports a needle bar. Due to the rotation of the drive shaft, the needle bar may be moved in the up-down direction. The bed is provided with a shuttle. The shuttle may be rotated in accordance with the rotation of a lower shaft, which may be rotated in conjunction with the drive shaft. An upper thread may be supplied to a sewing needle that is attached to the needle bar. A lower thread may be supplied from a bobbin that is housed in the shuttle. The upper thread and the lower thread may be interlaced by the needle bar and the shuttle working in cooperation with each other, thus forming a stitch on a work cloth.
A sewing machine is provided with a function to sew zigzag stitching. The zigzag stitching is sewing that is performed while the needle bar is swung left and right. An upper end portion of the needle bar base is swingably supported. The zigzag stitching is performed by moving a lower end portion of the needle bar base in the left-right direction.
In order to reliably form a stitch with a sewing machine, it is important to adjust a clearance between a sewing needle and a hook point of the shuttle. The clearance between the sewing needle and the hook point of the shuttle is hereinafter referred to as the needle gap. The needle gap may be adjusted for a left needle gap and a right needle gap. The left needle gap is a clearance between the sewing needle and the hook point when the sewing needle is in a left needle drop position (a left reference line position). The left reference line position is a leftmost needle drop position in the greatest zigzag width. The right needle gap is a clearance between the sewing needle and the hook point when the sewing needle is in a right needle drop position (a right reference line position). The right reference line position is a rightmost needle drop position in the greatest zigzag width. For example, in a known sewing machine, a plate is fixed to an arm by two screws. By displacing an attachment position of the plate in relation to the arm, it is possible to adjust the left and right needle drop positions. By adjusting the left and right needle drop positions, it is possible to adjust the needle gaps.
SUMMARY
In the above-described known sewing machine, a procedure when adjusting the needle gaps is as follows. First, the two screws fixing the plate to the arm may be loosened, such that the plate can be freely moved. The attachment position of the plate may be changed. The plate may be once more fixed to the arm by the screws. Thus, for example, in a case where the right needle gap is adjusted after the left needle gap has been adjusted, it is necessary to adjust the right needle gap while maintaining the adjusted left needle gap unchanged. As a result, an operation to adjust the needle gaps may be difficult.
Embodiments of the broad principles derived herein provide a sewing machine in which, after one of a left and a right needle gaps has been adjusted, the adjusted one of the needle gaps remains unchanged.
Embodiments provide a sewing machine that includes a needle bar, a needle bar base, a base frame, a guide member, and a fixing member. A sewing needle is attachable to a lower end portion of the needle bar. A needle bar base is configured to support the needle bar to allow the needle bar to be moved in an up-down direction. A first engagement portion is provided to a lower end portion of the needle bar base. A base frame is configured to swingably support an upper end portion of the needle bar base. A second engagement portion is provided to a lower end portion the base frame. A guide member includes a third engagement portion and a fourth engagement portion. The third engagement portion is configured to engage with the first engagement portion and guide movement of the first engagement portion in a predetermined direction. The fourth engagement portion is configured to engage with the second engagement portion. A fixing member is configured to fix the guide member to the base frame. When the needle bar base is in a reference position, a first reference line of the first engagement portion, a second reference line of the second engagement portion, and a third reference line of the fourth engagement portion are in a same straight line, and the guide member is configured to be swingable about the same straight line in a state in which fixing of the fixing member with respect to the base frame is loosened.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments will be described below in detail with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a sewing machine;
FIG. 2 is a perspective view showing an internal configuration of a left end portion of the sewing machine including a head;
FIG. 3 is a perspective view of a needle bar module;
FIG. 4 is an exploded perspective view of a needle bar support mechanism;
FIG. 5 is a perspective view of a base holder;
FIG. 6 is a perspective view of a needle bar base;
FIG. 7 is a perspective view of a lower side of a guide member, as seen from the front and right;
FIG. 8 is a perspective view of an upper side of the guide member, as seen from the front and right;
FIG. 9 is a diagram showing a state, as seen from above, of a relationship between the guide member and a left needle gap when the needle bar is positioned in a left reference line position; and
FIG. 10 is a diagram showing a state, as seen from above, of a relationship between the guide member and a right needle gap when the needle bar is positioned in a right reference line position.
DETAILED DESCRIPTION
Hereinafter, a sewing machine 1 according to an embodiment will be explained with reference to the drawings.
A configuration of the sewing machine 1 will be explained with reference to FIGS. 1 and 2 . In the following explanation, the lower right side, the upper left side, the lower left side, the upper right side, the upper side, and the lower side of FIG. 1 are respectively the front side, the rear side, the left side, the right side, the upper side, and the lower side of the sewing machine 1 . More specifically, a direction in which a pillar 3 , which is described below, extends is the up-down direction of the sewing machine 1 . A longitudinal direction of a bed 2 and an arm 4 is the left-right direction of the sewing machine 1 . An explanation of the structural members of the sewing machine 1 shown in FIGS. 3 to 10 is made with reference to the front-rear direction and the left-right direction when the structural members are attached to the sewing machine 1 .
As shown in FIG. 1 , the sewing machine 1 is provided with the bed 2 , the pillar 3 , the arm 4 , and a head 5 . The bed 2 extends in the left-right direction. A horizontal shuttle 8 (refer to FIG. 2 ) and the like are provided in the interior of the left portion of the bed 2 . The pillar 3 extends upward from the right end of the bed 2 . A sewing machine motor (not shown in the drawings) and the like are provided in the interior of the pillar 3 . The arm 4 extends to the left from the upper side of the pillar 3 such that the arm 4 faces the upper surface of the bed 2 . A drive shaft 51 (refer to FIG. 2 ) and the like are provided in the interior of the arm 4 . The head 5 is provided on the left side of the arm 4 . A needle bar module 10 (refer to FIG. 2 ) and the like are provided in the interior of the head 5 . The needle bar module 10 includes a needle bar support mechanism 100 , which will be described below. The needle bar support mechanism 100 includes a needle bar 110 that can be moved in the up-down direction. The needle bar 110 is exposed from the lower side of the head 5 , and extends downward. A sewing needle 101 may be attached to the lower end of the needle bar 110 .
As shown in FIG. 2 , a needle plate 11 is provided on the upper portion of the bed 2 . The needle plate 11 has a needle hole 12 that is positioned directly below the needle bar 110 . The sewing needle 101 that is attached to the needle bar 110 can be inserted through the needle hole 12 . The horizontal shuttle 8 is provided below the needle plate 11 . The horizontal shuttle 8 may house a bobbin (not shown in the drawings) on which a lower thread (not shown in the drawings) is wound. A lower shaft 21 may be rotated in conjunction with the drive shaft 51 . The horizontal shuttle 8 may be rotated in the horizontal direction in accordance with the rotation of the lower shaft 21 . The horizontal shuttle 8 includes a hook point 9 (refer to FIG. 9 ). The leading end portion of the hook point 9 faces a peripheral direction of the horizontal shuttle 8 . The hook point 9 may seize a loop of an upper thread. When the needle bar 110 is lowered by a needle bar drive mechanism 16 , the sewing needle 101 attached to the needle bar 110 may approach the hook point 9 of the horizontal shuttle 8 . A feed dog 13 is provided under the needle plate 11 . The feed dog 13 may move a work cloth by a predetermined feed distance.
A configuration of the needle bar module 10 , which is provided on the head 5 , will be explained with reference to FIGS. 2 to 8 . The needle bar module 10 shown in FIGS. 2 and 3 is a module that is formed by integrating the needle bar support mechanism 100 , the needle bar drive mechanism 16 , a thread take-up drive mechanism 17 , and a presser foot lifting mechanism 18 . The needle bar support mechanism 100 supports the needle bar 110 . The sewing needle 101 may be attached to the needle bar 110 . The needle bar drive mechanism 16 may drive the needle bar 110 to reciprocate in the up-down direction. The thread take-up drive mechanism 17 may drive a thread take-up lever 170 (refer to FIG. 3 ). The presser foot lifting mechanism 18 may raise and lower a presser bar 180 (refer to FIG. 3 ). The needle bar module 10 is fixed to a machine frame 6 inside the head 5 . The rotation of the drive shaft 51 may be transmitted to the needle bar drive mechanism 16 and the thread take-up drive mechanism 17 , so that the needle bar drive mechanism 16 and the thread take-up drive mechanism 17 may be driven.
As shown in FIG. 3 to FIG. 5 , a base holder 120 of the needle bar support mechanism 100 is formed of a metal plate that extends in the up-down direction. A support shaft 173 , which extends in the left-right direction, is fixed to the base holder 120 , slightly above the center of the base holder 120 in the up-down direction. The length of the support shaft 173 is longer than the length, in the left-right direction, of the base holder 120 . The support shaft 173 protrudes from the base holder 120 in the left and right directions. The left end portion of the support shaft 173 is fixed to the machine frame 6 by a presser plate 175 and a screw 174 (refer to FIG. 2 ). Although not shown in the drawings, the right end portion of the support shaft 173 is also fixed to the machine frame 6 in the same manner. Although not shown in the drawings, the lower end portion of the base holder 120 is fixed to the machine frame 6 such that an inclination (as seen from the side) of the base holder 120 can be adjusted. In a case where the screw 174 that fixes the support shaft 173 is slightly loosened, the base holder 120 may be swung with the support shaft 173 as the center of rotation, in the side view. Thus, the base holder 120 may be fixed to the machine frame 6 after the inclination of the base holder 120 , namely the posture of the base holder 120 in relation to the machine frame 6 , has been adjusted.
A support portion 122 is provided on the lower end portion of the base holder 120 . The support portion 122 is a portion that extends toward the front from the lower edge of the base holder 120 . A support hole 185 is formed in a position close to the right side of the support portion 122 . The support hole 185 penetrates the support portion 122 in the up-down direction. A boss portion 123 is provided in a position close to the front left side of the support portion 122 . The boss portion 123 is a portion that protrudes downward from the support portion 122 in a cylindrical shape. A central line of the boss portion 123 is denoted by Q. A screw hole 129 is formed in a position close to the rear left side of the support portion 122 . The screw hole 129 penetrates the support portion 122 in the up-down direction.
As shown in FIG. 3 , the presser bar 180 that extends in the up-down direction is inserted through the support hole 185 (refer to FIG. 4 ). A presser foot 181 is provided on the lower end portion of the presser bar 180 . A support piece 182 is attached to the upper portion of the base holder 120 . The upper end portion of the presser bar 180 is supported by the support piece 182 . In this manner, the presser bar 180 is supported on the base holder 120 such that the presser bar 180 can be moved in the up-down direction. A presser spring (not shown in the drawings) is provided around the presser bar 180 . The presser bar 180 is biased downward by the biasing force of the presser spring. A lever shaft 184 is provided on the lower right portion of the base holder 120 . The lever shaft 184 protrudes toward the front. A presser lever 183 is supported such that the presser lever 183 may be pivoted in relation to the lever shaft 184 . When the presser lever 183 is operated, the presser bar 180 and the presser foot 181 are raised and lowered. The presser foot lifting mechanism 18 includes the presser bar 180 , the presser spring, and the presser lever 183 , which are described above.
The thread take-up lever 170 and the thread take-up drive mechanism 17 are disposed at the right of the base holder 120 . The thread take-up lever 170 and the thread take-up drive mechanism 17 are known mechanisms and are briefly explained here. A thread take-up crank 52 is fixed to the left end portion of the drive shaft 51 . The thread take-up crank 52 may be rotated integrally with the drive shaft 51 . The thread take-up crank 52 may be rotated in accordance with the rotation of the drive shaft 51 , so that the thread take-up drive mechanism 17 may be driven. By the driving of the thread take-up drive mechanism 17 , the thread take-up lever 170 may be moved in the up-down direction in synchronization with the reciprocating motion in the up-down direction of the needle bar 110 .
As shown in FIGS. 4 and 5 , a support shaft 124 is provided on an upper end portion 118 of the base holder 120 . The support shaft 124 extends toward the front. The support shaft 124 pivotably supports a needle bar base 130 that will be described below. The support shaft 124 is provided with a base end portion 125 , a trunk portion 126 , and a leading end portion 127 . The trunk portion 126 is formed having a smaller diameter than that of the base end portion 125 . The trunk portion 126 extends longer in the front-rear direction. The leading end portion 127 is formed having a diameter that is smaller than a diameter of the trunk portion 126 . A male screw 128 is formed on the leading end portion 127 . The male screw 128 is a right-hand thread screw. Further, an attachment portion 119 is formed on the base holder 120 . The attachment portion 119 is a portion that extends toward the front from the upper left portion of the base holder 120 . A plate spring 150 , which will be described below, is fixed to the attachment portion 119 .
As shown in FIGS. 4 and 6 , the needle bar base 130 is formed of a metal plate that extends in the up-down direction. A through hole 131 is formed in an upper end portion 137 of the needle bar base 130 . The through hole 131 penetrates the upper end portion 137 in the front-rear direction. The inner diameter of the through hole 131 is slightly larger than the outer diameter of the trunk portion 126 of the support shaft 124 . The through hole 131 is formed in a tapered shape by chamfering, such that the through hole 131 becomes narrower from the front toward the rear. Further, the needle bar base 130 includes a pressing portion 132 . The pressing portion 132 is a portion that extends downward from the upper rear end portion of the needle bar base 130 . A groove 139 is formed in the pressing portion 132 . The groove 139 is generally an inverted U-shape. The width of the groove 139 in the left-right direction is slightly larger than the outer diameter of the trunk portion 126 of the support shaft 124 . The trunk portion 126 fits into the groove 139 .
The needle bar base 130 includes a support portion 133 . The support portion 133 is a portion that extends toward the rear from the lower edge of the needle bar base 130 . A hole 134 (refer to FIG. 3 ) is formed in a position toward the right side of the support portion 133 . The hole 134 penetrates the support portion 133 in the up-down direction. A left portion of the support portion 133 protrudes further to the rear than a right portion of the support portion 133 . A cylindrical pin 135 is provided on the rear end portion of the left portion of the support portion 133 . The pin 135 protrudes upward from the support portion 133 . A central line of the pin 135 is denoted by P. A direction in which the pin 135 extends is parallel to the needle bar 110 . The outer diameter of the pin 135 is generally the same as the size of a groove width of a long groove 191 that is provided in the guide member 190 , which will be described below.
The needle bar base 130 includes a bent portion 136 . The bent portion 136 is a portion that extends to the rear from a portion of the needle bar base 130 above the center of the needle bar base 130 in the up-down direction such that the bent portion 136 is parallel to the support portion 133 . A hole (not shown in the drawings) having a same inner diameter as a diameter of the hole 134 is formed in the bent portion 136 . As shown in FIG. 3 , the needle bar 110 is inserted into and supported by the hole 134 and the hole of the bent portion 136 , such that the needle bar 110 may be moved in the up-down direction. An attachment portion 111 is provided on the lower end portion of the needle bar 110 . The sewing needle 101 may be attached to and removed from the attachment portion 111 .
As shown in FIG. 3 , a compression coil spring 155 is mounted around the outer periphery of the trunk portion 126 . The rear end of the compression coil spring 155 is in contact with a stepped portion between the trunk portion 126 and the base end portion 125 . The support shaft 124 is inserted through the through hole 131 of the needle bar base 130 and the groove 139 . In this manner, the needle bar base 130 is supported by the support shaft 124 in a state in which the needle bar base 130 can be rotated around the support shaft 124 . The leading end of the compression coil spring 155 is in contact with the pressing portion 132 of the needle bar base 130 .
A disc-shaped adjustment dial 140 is attached to the leading end portion 127 of the support shaft 124 . Although not shown in detail in the drawings, a hole is provided in the center of the adjustment dial 140 . The trunk portion 126 of the support shaft 124 may be inserted through the hole in the adjustment dial 140 . A nut fixing portion (not shown in the drawings) is formed to the front of the adjustment dial 140 . The nut fixing portion is a recessed portion that is formed in a position such that the center of the nut fixing portion is concentric with the center of the hole in the adjustment dial 140 . A nut 141 is fitted into and fixed to the nut fixing portion. A hemispheric contact portion is formed around the periphery of the hole in the adjustment dial 140 . A straight knurl is formed on an outer peripheral surface of the adjustment dial 140 .
As shown in FIGS. 3 and 4 , the support shaft 124 is inserted through the through hole 131 of the needle bar base 130 . The leading end portion 127 of the support shaft 124 is inserted through the hole in the adjustment dial 140 . The male screw 128 formed on the leading end portion 127 is screwed into a female screw of the nut 141 . The contact portion of the adjustment dial 140 is in contact with the tapered surface of the through hole 131 of the needle bar base 130 . At this time, the compression coil spring 155 is pressed in the rearward direction by the pressing portion 132 of the needle bar base 130 , and is compressed in the axial direction of the support shaft 124 . The compression coil spring 155 presses the pressing portion 132 of the needle bar base 130 toward the side of the leading end portion 127 , from the side of the base end portion 125 of the support shaft 124 . In other words, between the base holder 120 and the adjustment dial 140 , the needle bar base 130 is maintained in a state of being biased toward the adjustment dial 140 , due to the biasing force of the compression coil spring 155 . As described above, the male screw 128 is a right-hand thread screw. Thus, when the adjustment dial 140 is rotated in the clockwise direction, the adjustment dial 140 and the needle bar base 130 are moved toward the rear. In contrast, when the adjustment dial 140 is rotated in the anti-clockwise direction, the adjustment dial 140 and the needle bar base 130 are moved toward the front. In this manner, by rotating the adjustment dial 140 , the adjustment dial 140 may be moved in the axial direction of the support shaft 124 . In accordance with the movement of the adjustment dial 140 , the needle bar base 130 may be moved in the axial direction of the support shaft 124 .
As shown in FIG. 3 , the rectangular plate spring 150 is provided on the attachment portion 119 of the base holder 120 . The rear end (the base end) of the plate spring 150 is fixed to the attachment portion 119 by a screw. A leading end portion 152 of the plate spring 150 is in contact with the outer peripheral surface (the straight knurl) of the adjustment dial 140 , and biases the adjustment dial 140 in the rightward direction (in the radial direction). Specifically, the plate spring 150 regulates the rotation of the adjustment dial 140 .
As shown in FIG. 4 , the guide member 190 is provided on the lower surface of the support portion 122 of the base holder 120 . The guide member 190 is formed of a synthetic resin material. As shown in FIGS. 7 and 8 , the guide member 190 includes a flat plate portion 196 , which is generally L-shaped in a plan view, and a long groove portion 192 . A generally elliptical engaging hole 194 is formed in the flat plate portion 196 . A fixing screw 199 (refer to FIG. 4 ) is inserted through the engaging hole 194 . The fixing screw 199 is screwed into a screw hole 129 of the support portion 122 . By fastening the fixing screw 199 in the screw hole 129 , the guide member 190 is fixed to the base holder 120 .
The guide member 190 includes a protruding portion 195 . The protruding portion 195 is a portion of the flat plate portion 196 that protrudes toward the left. A user may grasp the protruding portion 195 with the user's fingers.
The long groove portion 192 of the guide member 190 protrudes downward from the flat plate portion 196 . The long groove 191 is formed in the center of the long groove portion 192 . The long groove 191 penetrates the long groove portion 192 in the up-down direction (the thickness direction). The long groove 191 has an arc shape that extends in the left-right direction. As will be explained in more detail below, a pin 135 is inserted into and engages with the long groove 191 . The pin 135 (refer to FIG. 4 ) is provided in the support portion 133 of the needle bar base 130 . The (inner side) dimension of the front-rear direction of the long groove 191 (the direction orthogonal to the extending direction of the long groove 191 ) is generally the same as the outer diameter of the pin 135 . A central line, in the front-rear direction, of the long groove 191 intersects with a central line R of a receiving hole 193 , which will be described below.
The receiving hole 193 is formed in the guide member 190 . The receiving hole 193 is positioned, in the upper surface of the guide member 190 , in the vicinity of the left end portion of the long groove 191 . The receiving hole 193 is formed in a circular shape. The central line of the receiving hole 193 is denoted by R. The inner diameter of the receiving hole 193 is generally the same as the outer diameter of the boss portion 123 provided on the support portion 122 of the base holder 120 . The depth (length) of the receiving hole 193 is slightly larger than the height of the boss portion 123 .
As shown in FIG. 4 , when the guide member 190 is fixed to the base holder 120 , the receiving hole 193 fits with the boss portion 123 . At that time, the central line R (refer to FIG. 7 ) of the receiving hole 193 is aligned with the central line Q (refer to FIG. 5 ) of the boss portion 123 .
When the fixing screw 199 is slightly loosened, the fitted state between the receiving hole 193 and the boss portion 123 may be maintained. There may be a slight gap (allowance) between the fixing screw 199 and the engaging hole 194 . Thus, the guide member 190 may be moved by an amount of the gap. Specifically, in a state in which the fixing screw 199 is slightly loosened, the guide member 190 may be rotated (pivoted) relative to the base holder 120 with the central lines R and Q as the center of rotation. The protruding portion 195 of the guide member 190 may protrude (refer to FIG. 3 ) further to the lateral side (to the left side) than the support portion 122 of the base holder 120 . When adjusting the needle gap, which is the clearance between the sewing needle 101 and the hook point 9 of the horizontal shuttle 8 (refer to FIGS. 9 and 10 ), the user may slightly loosen the fixing screw 199 . Then, by grasping and operating the protruding portion 195 with the user's fingers, the user can easily rotate the guide member 190 .
The pin 135 , which is provided on the support portion 133 of the needle bar base 130 , engages with the long groove 191 of the guide member 190 that is fixed to the base holder 120 . The pin 135 may be moved in the left-right direction along the long groove 191 while the pin 135 may not be moved in the front-rear direction. Thus, the needle bar base 130 may be guided in a direction in which the needle bar base 130 may be swung along the long groove 191 with which the pin 135 engages. Further, a range over which the needle bar base 130 may be swung is regulated by the long groove 191 . A needle bar swinging mechanism is a known mechanism and is therefore not illustrated in the drawings and a detailed explanation is omitted here. As shown in FIG. 2 , a connecting rod 53 , which extends in the left-right direction, is coupled to the front surface of the needle bar base 130 . The needle bar swinging mechanism is provided inside the pillar 3 . The needle bar swinging mechanism may move the connecting rod 53 in the left-right direction, so that the needle bar base 130 may be swung in the left-right direction.
As shown in FIG. 3 , a needle bar holder 163 of the needle bar drive mechanism 16 is provided on a middle portion of the needle bar 110 , in a position between the support portion 133 and the bent portion 136 . The needle bar holder 163 holds the needle bar 110 . The needle bar holder 163 is coupled to the leading end of a crank rod 161 . The crank rod 161 is connected to a needle bar crank 160 . The needle bar crank 160 is coupled, via a connecting pin 162 , to the thread take-up crank 52 (refer to FIG. 2 ). When the drive shaft 51 (refer to FIG. 2 ) is rotated, the thread take-up crank 52 is rotated. The needle bar crank 160 may be rotated in accordance with the rotation of the thread take-up crank 52 , and thus the crank rod 161 may be driven. The needle bar crank 160 , the crank rod 161 , and the needle bar holder 163 may work in cooperation with each other, and may convert the rotational movement of the drive shaft 51 into a reciprocating motion in the up-down direction. The needle bar 110 may be moved up and down in this manner.
In the sewing machine 1 of the present embodiment, a stitch may be formed on the work cloth by the needle bar 110 and the horizontal shuttle 8 working in cooperation with each other. At that time, the sewing needle 101 is attached to the needle bar 110 . An upper thread loop that is formed in the eye of the sewing needle 101 must be reliably picked up by the hook point 9 of the horizontal shuttle 8 . In a case where the upper thread loop cannot be picked up by the hook point 9 , a skipped stitch may occur in which the stitch is not formed. In this case, the sewing quality may deteriorate. In order to eliminate the skipped stitch, it is necessary to properly adjust the needle gap, which is the clearance between the sewing needle 101 and the hook point 9 . In the sewing machine 1 of the present embodiment, the user may adjust the needle gap by adjusting (rotating) the adjustment dial 140 . The needle bar 110 may be swung in the left-right direction. Thus, it is necessary to adjust the needle gap both when the sewing needle 101 is in the left needle drop position (the left reference line position) and when the sewing needle 101 is in the right needle drop position (the right reference line position).
In the present embodiment, it is assumed that the right needle gap is adjusted in the right reference line position after adjusting the left needle gap in the left reference line position. Hereinafter, an operation when adjusting a left needle gap X and a right needle gap Y will be explained with reference to FIGS. 9 and 10 . FIG. 9 and FIG. 10 are diagrams schematically showing relationships between a position of the guide member 190 , a position of the sewing needle 101 (the needle bar 110 ), and a position of the hook point 9 of the horizontal shuttle 8 , when seen from above the sewing machine 1 . In FIGS. 9 and 10 , a position of the guide member 190 is shown by dotted lines when the guide member 190 is rotated within a rotatable range. The guide member 190 may be rotated within the range of the allowance between the fixing screw 199 and the engaging hole 194 .
As shown in FIG. 9 , the needle bar base 130 may be swung such that a central axial line position of the sewing needle 101 (the needle bar 110 ) may be positioned on a left reference line position A. At that time, the pin 135 is positioned close to the left end of the long groove 191 of the guide member 190 . The central line P of the pin 135 may be aligned with the central line Q of the boss portion 123 and with the central line R of the receiving hole 193 that engages with the boss portion 123 . The guide member 190 may be rotated in relation to the base holder 120 with the central lines R and Q as the center of rotation. Thus, even when the guide member 190 is rotated within the rotatable range, the position of the central line P of the pin 135 does not change. Thus, the position of the needle bar base 130 that is provided with the pin 135 and the position of the sewing needle 101 that is attached to the needle bar 110 do not change, irrespective of the rotation of the guide member 190 . Specifically, in the left reference line position A, even if the guide member 190 is rotated, the position of the sewing needle 101 does not change. As a result, the left needle gap X does not change.
The adjustment of the left needle gap X may be performed by rotating the adjustment dial 140 provided on the needle bar support mechanism 100 . When the adjustment dial 140 is rotated, the needle bar base 130 is moved in the front-rear direction. As described above, the pin 135 of the needle bar base 130 is engaged with the long groove 191 of the guide member 190 such that the pin 135 may be moved in the left-right direction while the pin 135 may not be moved in the front-rear direction. In this way, even when the needle bar base 130 is moved in the front-rear direction, the position of the pin 135 in the front-rear direction does not change. As a result, the inclination of the needle bar base 130 may change slightly, generally centering on the position at which the pin 135 and the long groove 191 are engaged with each other. More specifically, the adjustment dial 140 may be moved to the front, in a side view of the needle bar support mechanism 100 . In this case, the upper portion of the needle bar base 130 may incline slightly to the front, generally centering on the position at which the pin 135 and the long groove 191 are engaged with each other. In contrast, the adjustment dial 140 may be moved to the rear. In this case, the upper portion of the needle bar base 130 may incline slightly to the rear, generally centering on the position at which the pin 135 and the long groove 191 are engaged with each other. By changing the inclination of the needle bar base 130 in this manner, the sewing needle 101 attached to the lower end portion of the needle bar 110 (which is supported by the needle bar base 130 ) may be moved. When the adjustment dial 140 is moved toward the front, the sewing needle 101 attached to the needle bar 110 is moved in a direction (to the rear) in which the sewing needle 101 comes closer to the hook point 9 . In contrast, when the adjustment dial 140 is moved toward the rear, the sewing needle 101 is moved in a direction (to the front) in which the sewing needle 101 is separated from the hook point 9 .
In actuality, the user may perform the adjustment in a state in which the needle plate 11 is removed. The user may look at the horizontal shuttle 8 from the side of the sewing machine 1 , and thus visually checks the clearance between the sewing needle 101 and the hook point 9 in the left reference line position A. The user may grasp the adjustment dial 140 with the user's fingers and may rotate the adjustment dial 140 . The adjustment dial 140 can easily be operated from the front face of the sewing machine 1 . As described above, when the adjustment dial 140 is rotated in the clockwise direction, the adjustment dial 140 and the needle bar base 130 are moved to the rear. Thus, the sewing needle 101 may be moved to the front and may separate from the hook point 9 . When the adjustment dial 140 is rotated in the anti-clockwise direction, the adjustment dial 140 and the needle bar base 130 are moved to the front. Thus, the sewing needle 101 may be moved to the rear and may approach the hook point 9 . The left needle gap X between the sewing needle 101 and the hook point 9 may be adjusted by the user rotating the adjustment dial 140 with the user's fingers in this manner.
When the adjustment of the left needle gap X is finished, next, the right needle gap Y may be adjusted. As shown in FIG. 10 , the needle bar base 130 may be swung such that the central axial line position of the sewing needle 101 (the needle bar 110 ) is positioned on the right reference line position B. At this time, the pin 135 may be positioned close to the right end of the long groove 191 of the guide member 190 . The central line P of the pin 135 may be displaced from the central line Q of the boss portion 123 and the central line R of the receiving hole 193 .
The user may slightly loosen the fixing screw 199 and may grasp the protruding portion 195 of the guide member 190 with the user's fingers to rotate (swing) the guide member 190 . The guide member 190 may be rotated with the central lines Q and R as the center of rotation. By rotating the guide member 190 , the position of the long groove 191 may be changed. The position of the pin 135 may change generally in the front-rear direction in accordance with the change in the position of the long groove 191 . The lower end of the needle bar base 130 may be moved to the front and the rear in accordance with the change in the position of the pin 135 . By the lower end of the needle bar base 130 moving to the front and the rear, the sewing needle 101 attached to the needle bar 110 may approach or separate from the hook point 9 . The user may look at the horizontal shuttle 8 from the side of the sewing machine 1 . While visually checking the clearance between the sewing needle 101 and the hook point 9 in the right reference line position B, the user may rotate the guide member 190 and may adjust the right needle gap Y.
By rotating the guide member 190 in this manner, it is possible to perform the adjustment of the right needle gap Y. As described above, even though the guide member 190 is rotated, the left needle gap X does not change. Thus, even while adjusting the right needle gap Y, it is possible to maintain the clearance for the left needle gap X. Then, when the adjustment of the right needle gap Y is finished, the user may tighten the fixing screw 199 and may fix the guide member 190 to the base holder 120 . In this manner, the adjustment of the left needle gap X and the right needle gap Y may be completed.
As explained above, in the sewing machine 1 of the present embodiment, the pin 135 of the needle bar base 130 and the long groove 191 of the guide member 190 engage with each other. The guide member 190 may be rotated with respect to the base holder 120 with the central lines Q and R of the boss portion 123 and the receiving hole 193 as the center of rotation. When the needle bar 110 is positioned in the left reference line position A, the central line P of the pin 135 , the central line Q of the boss portion 123 and the central line R of the receiving hole 193 are aligned and are on the same straight line. Thus, even when the guide member 190 is rotated, the position of the central line P does not change. In other words, even when the guide member 190 is rotated, the left needle gap X does not change. On the other hand, in a case where the needle bar 110 is positioned in the right reference line position B, when the guide member 190 is rotated, the central line P of the pin 135 is moved to the front and to the rear. In other words, when the guide member 190 is rotated, the right needle gap Y changes. Thus, after the left needle gap X has been adjusted in the left reference line position A, even when the right needle gap Y is adjusted in the right reference line position B, the left needle gap X does not change. As a result, it is possible to easily perform the adjustment of the left and the right needle gaps.
Due to the simple configuration in which the pin 135 of the needle bar base 130 is inserted into the long groove 191 of the guide member 190 , the guide member 190 and the needle bar base 130 engage with each other. Thus, it is possible to lower the cost of the sewing machine 1 .
Due to the simple configuration in which the receiving hole 193 of the guide member 190 is fitted with the boss portion 123 of the base holder 120 , the base holder 120 and the guide member 190 engage with each other. Thus, it is possible to lower costs.
The protruding portion 195 protrudes from the base holder 120 . The user may therefore grasp the protruding portion 195 with the user's fingers and may easily rotate the guide member 190 . Thus, it is possible to easily adjust the position of the needle bar 110 .
The present disclosure is not limited to the above-described embodiment and various modifications may be made. The guide member 190 is formed of the synthetic resin material. However, the guide member 190 may be formed of a metal material. The long groove 191 penetrates in the thickness direction of the guide member 190 . However, as far as the length of the long groove 191 is sufficient to engage the pin 135 , the long groove 191 need not necessarily penetrate the guide member 190 .
In the present embodiment, after the left needle gap X has been adjusted in the left reference line position A, the right needle gap Y may be adjusted in the right reference line position B. However, the sewing machine may be configured such that the left needle gap X can be adjusted in the left reference line position A after the right needle gap Y has been adjusted in the right reference line position B. In this case also, it is possible to easily perform the adjustment of the left and the right needle gaps.
The apparatus and methods described above with reference to the various embodiments are merely examples. It goes without saying that they are not confined to the depicted embodiments. While various features have been described in conjunction with the examples outlined above, various alternatives, modifications, variations, and/or improvements of those features and/or examples may be possible. Accordingly, the examples, as set forth above, are intended to be illustrative. Various changes may be made without departing from the broad spirit and scope of the underlying principles.
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A sewing machine includes a needle bar, a needle bar base, a base frame, a guide member, and a fixing member. A sewing needle is attachable to a lower end portion of the needle bar. The needle bar base is configured to support the needle bar to allow the needle bar to be moved in an up-down direction. A first engagement portion is provided to a lower end portion of the needle bar base. The base frame is configured to swingably support an upper end portion of the needle bar base. A second engagement portion is provided to a lower end portion the base frame. A guide member includes a third engagement portion configured to engage with the first engagement portion and guide movement of the first engagement portion in a predetermined direction and a fourth engagement portion configured to engage with the second engagement portion.
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FIELD OF THE INVENTION
The invention relates to an electrical contact, in particular according to the precharacterising clause of claim 1.
BACKGROUND OF THE INVENTION
European patent EP 0 762 551 describes a pin contact with a connecting part, a connector tongue, and a locking part. The locking part has a separate locking spring which may be inserted perpendicularly to the pin contact into the locking part. The connector tongue and the locking part are plugged into a mating counterpart and fixed in position therein by the locking spring.
Such pin contacts are conventionally stamped and formed from sheet metal blanks which provides good bending characteristics for cable clamping and which exhibits good electrical conductivity. Such metal is as a rule less usable as a spring material due to a lack of resilience and strength. A compromise material is not capable of fulfilling either requirement optimally.
In EP 0 762 551, a locking spring made from a different suitable material from the pin contact is used. The locking spring is connected with the pin contact using a two part format. Such two-part pin contacts are more expensive to produce than one-part pin contacts. This is because it is necessary to stamp and form two separate components from different materials and to assemble and clamp them together. Assembly and clamping is particularly costly. Moreover, clamping requires more complicated tools, which are not only expensive but also unreliable.
Mounting the locking spring in the direction perpendicular to the connector tongue, as in the European specification recited above, constitutes a considerable simplification relative to the method of sliding one of the two components axially into the other and clamping them together. However, even with the solution proposed in EP 0 762 551, it is still necessary to clamp the two components together to fix the locking spring in the locking part, which is correspondingly costly and time-consuming.
SUMMARY OF THE INVENTION
An object of the invention is to provide a pin contact made stamped and formed from a steel sheet with a separately produced locking spring which is economic to produce and mount.
This object is achieved by the features of claim 1. Because the locking spring has latching means, which fix the locking spring in position through insertion thereof into the locking part, the locking spring may be mounted merely by plugging it into the locking part. Clamping of the components is unnecessary, whereby complicated, time-consuming operations may be eliminated. Because the locking part has openings adapted for insertion and latching of the locking spring, the locking spring mounting process is simplified.
The locking spring may have guide surfaces which contribute to the simplification of locking spring mounting. Latching of the locking spring at its ends makes its connection with the locking part strong.
In order to facilitate mounting a first guide surface, preferably folded at right angles, may be arranged in the area of the rear end of the locking spring on each side thereof. In this way, the locking spring is guided at one end over the entire mounting path.
Handling of the locking spring is also improved. A latching means is provided at least on one of the two first guide surfaces. The latching means cooperate with the openings in the top of the locking part to limit rebound of the locking spring or prevents buckling thereof. The force required to tear the contact out of the chamber is thereby increased.
In various embodiments the latching means may take the form of a channel on the lower edge of a first guide surface or of a hook on a rear edge of a different first guide surface or of a perforation pocket or perforation tongue, which is arranged on the outside of a further first guide surface. The solution using the hook at the lateral edge of the different first guide surface is particularly favourable from a manufacturing perspective.
It is advantageous for the locking spring to have an obtuse-angled first folded portion and an obtuse-angled second folded portion in the area of its front end and for there to be arranged on each side of the obtuse-angled first folded portion a second guide surface folded inwards at right angles. The second guide surface has upper corners bent slightly outwards, which upper corners lie against an inner surface of the top or against an upper side of a side opening in the locking part after latching of the locking spring. The second guide surfaces simplify mounting of the locking spring at the other end thereof. The upper corners effect secure latching thereof in the locking part, wherein latching is reinforced by tensile loading of the locking spring.
An advantageous construction of the invention has an alternate locking spring which has a different obtuse-angled first folded portion, a right-angled second folded portion and an obtuse-angled third folded portion in the area of its different front end. A perforation tongue which is directed towards the connecting part is provided in the obtuse-angled third folded portion. The perforation tongue lies against the different inner surface of a different top of a different locking part after latching of the different locking spring. In this embodiment, the different end of the different locking spring may be produced in a particularly simple manner merely by three folded portions, since the outer edges thereof serve as guide surfaces. In this embodiment, tensile loading of the different locking spring reinforces latching.
In another embodiment, a further locking spring comprises a further obtuse-angled first folded portion, a further right-angled second folded portion and a further obtuse-angled third folded portion in the area of its further front end and in that a further second guide surface folded at right angles is arranged on each side of the further obtuse-angled first folded portion. A free end of the further obtuse-angled third folded portion lies against the further inner surface of a further top of a further locking part after latching-in of the further locking spring. The further second guide surfaces folded at right angles serve simultaneously to fix the locking spring in position in the longitudinal and transverse directions of the pin contact.
It may also be advantageous for the connector tongue to have two halves of arched cross section each with a tip, wherein the two halves adjoin at their edges and are at least pressed and/or welded together at their tips. In this way, the bending strength of the connector tongue is increased and the thickness thereof necessary for good electrical contact is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a pin contact having a connecting part, a locking part and a connector tongue, a locking spring is exploded from the locking part.
FIG. 2 is a perspective representation obliquely from the rear of the pin contact of FIG. 1, the locking spring is exploded from the locking part.
FIG. 3 is a perspective representation obliquely from the rear and above of the pin contact of FIG. 1, with the locking spring mounted in the locking part.
FIG. 4 is a longitudinal section through the locking part of the pin contact of FIG. 1, with the locking spring mounted thereon.
FIG. 5 shows a cross section of the locking part taken along line D-D of FIG. 4 .
FIG. 6 shows a cross section of the locking part taken along line E-E of FIG. 4 .
FIG. 7 is a bottom view of the pin contact of FIG. 1 .
FIG. 8 is a side view of the pin contact of FIG. 1, with the locking spring mounted thereon.
FIG. 9 is a top view of the pin contact of FIG. 1, with the locking spring mounted thereon.
FIG. 10 is a view of two stamped blanks for the pin contact of FIG. 1 .
FIG. 11 is a perspective view of a second embodiment of a pin contact having the connecting part, a second locking part and the connector tongue, a second locking spring is exploded from the second locking part.
FIG. 12 is a perspective representation obliquely from the rear of the second pin contact of FIG. 11, the second locking spring is exploded from the second locking part.
FIG. 13 is a perspective representation obliquely from the rear and above of the second pin contact of FIG. 11, with the second locking spring mounted in the second locking part.
FIG. 14 is a longitudinal section through the second locking part of the second pin contact of FIG. 11, with the second locking spring mounted thereon.
FIG. 15 shows a cross of the second locking part taken along line D-D of FIG. 14 .
FIG. 16 shows a cross section of the second locking part taken along line E-E of FIG. 14 .
FIG. 17 is a bottom view of the second pin contact of FIG. 11 .
FIG. 18 is a side view of the second pin contact of FIG. 11, with the second locking spring mounted thereon.
FIG. 19 is a top view of the second pin contact of FIG. 11, with the second locking spring mounted thereon.
FIG. 20 is a view of two stamped blanks for the second pin contact of FIG. 11 .
FIG. 21 is a perspective view of a third embodiment of a pin contact having the connecting part, a third locking part and the connector tongue, third locking spring is exploded from the third locking part.
FIG. 22 is a perspective representation obliquely from the rear of the third pin contact of FIG. 21, the third locking spring is exploded from the third locking part.
FIG. 23 is a perspective representation obliquely from the rear and above of the third pin contact of FIG. 21, with the third locking spring mounted in the second locking part.
FIG. 24 is a longitudinal section through the third locking part of the third pin contact of FIG. 21, with the third locking spring mounted thereon.
FIG. 25 shows a cross section of the third locking part taken along line D-D of FIG. 24 .
FIG. 26 shows a cross of the third locking part, taken along line E-E of FIG. 24 .
FIG. 27 is a bottom view of the third pin contact of FIG. 21 .
FIG. 28 is a side view of the third pin contact of FIG. 21, with the third locking spring mounted thereon.
FIG. 29 is a top view of the third pin contact of FIG. 21, with the third locking spring mounted thereon.
FIG. 30 is a view of two stamped blanks for the third pin contact of FIG. 21 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 are perspective views of a pin contact 1 . The pin contact 1 serves to connect electrical conductors, not shown. As best shown in FIGS. 1 and 2, pin contact 1 has a connecting part 2 , a locking part 3 and a contact part constructed as a connector tongue 4 . The connector tongue 4 and the locking part 3 are plugged into a mating counterpart (not shown), in order to produce the desired electrical connection.
A stripped electrical conductor (not shown) is attached in the area of the connecting part 2 . In the present example, crimping claws 5 are used for this purpose. However, a soldered connection or a plug part or the like may be used instead.
While the connecting part 2 is open at the top prior to closure of the crimping claws 5 , the adjacent locking part 3 exhibits a closed, rectangular box section. A first side wall 7 and a second side wall 8 are folded upwards at right angles from a base 6 . A top 9 is folded horizontally from the first side wall 7 and is butt-welded to the second side wall 8 . The base 6 , the side walls 7 and 8 and the top 9 together form the locking part 3 .
One half 10 , 11 of the connector tongue 4 is connected with each of the base 6 and the top 9 . The halves 10 , 11 exhibit arched cross sections, which form a lenticular cavity when the halves 10 , 11 are put together. The increased thickness of the connector tongue 4 promotes the rigidity thereof. The tips 12 , 12 ′ of the halves 10 , 11 are latched and/or welded together by a tongue and groove arrangement.
Above the locking part 3 of FIGS. 1 and 2 there is illustrated a locking spring 14 . The locking spring 14 is shown above the locking part 3 for ease of explanation. The locking spring 14 is oriented as if it were mounted in the locking part 3 .
A rectangular first opening 15 is provided in the top 9 of locking part 3 , through which the locking spring 14 is perpendicularly inserted. In the second side wall 8 there is provided a rectangular side opening 16 with an upper side 30 , which serves to latch in the locking spring 14 (see also FIGS. 6 and 8 ). An extension 28 of the second side wall 8 projecting above the top 9 serves in angular orientation of the pin contact 1 in a counterpart and in protecting the locking spring 14 . In the base 6 there is arranged a perforation pocket 17 (FIGS. 4, 5 , 6 , 7 ), which is used to fix the locking spring 14 in the longitudinal direction of the locking part 3 .
In the area of a rear end 18 of the locking spring 14 there is arranged, on each side thereof, a first guide surface 19 , 19 ′ folded at right angles. At the lower edge of the first guide surface 19 there is provided a channel 20 , which, when the locking spring 14 is in the installed position, extends parallel to the top 9 and lies against the inner surface 21 thereof. The rear end 18 of the locking spring 14 is thus latched in the locking part 3 . The front edges 22 , 22 ′ of the first guide surfaces 19 , 19 ′ extend perpendicularly to the top 9 , whereby the length of the first opening 15 is kept as small as possible.
In the area of the front end 23 of the locking spring 14 , an obtuse-angled first folded portion 24 and an obtuse-angled second folded portion 25 are provided. On each side of the obtuse-angled first folded portion 24 there is located a second guide surface 26 , 26 ′ folded inwards at right angles and having upper corners 27 , 27 ′ bent outwards slightly. These engage in the locking part 3 after mounting of the locking spring 14 and come to lie against the inner surface 21 of the top 9 or against the upper side 30 of the side opening 16 in the second side wall 8 . In this way, the front end 23 of the locking spring 14 is also latched in the locking part 3 . When the locking spring 14 is subject to tensile load, the latching connection is reinforced by spreading of the bent upper corners 27 , 27 ′.
FIG. 3 shows a perspective representation, obliquely from the rear and above, of the pin contact 1 with an open connecting part 2 and the locking spring 14 mounted in the locking part 3 . The protective function of the extension 28 in relation to the locking spring 14 is clear to see. The same applies to the second pin contact 32 in FIG. 13 and the third pin contact 56 in FIG. 23 .
FIG. 4 shows a cross section through the locking part 3 with the locking spring 14 latched or mounted therein. It reveals the top 9 with the first opening 15 for insertion of the locking spring 14 and the base 6 with the perforation pocket 17 as axial limit stop therefor in the direction of the connecting part 2 . In the opposite direction, the locking spring 14 rests with its obtuse-angled first folded portion 24 against the narrow side 29 of the first opening 15 .
In addition, FIG. 4 also reveals the channel 20 of the first guide surface 19 , which lies against the inside 21 of the top 9 , and the second guide surface 26 , which rests against the upper side 30 of the side opening 16 .
FIG. 5 shows the first side wall 7 , the second side wall 8 with the extension 28 , the base 6 and the top 9 . Furthermore, the first guide surface 19 is shown, with the channel 20 , which, like the upper corner 27 , lies against the inner surface 21 of the top 9 . The perforation pocket 17 in the base 6 is also visible.
Referring to FIG. 6, upper corner 27 ′ is positioned in the side window 16 of side wall 8 . As shown, the upper corner 27 ′ engages the upper surface 30 of the side window 16 . Here too, the perforation pocket 17 may be seen. Also visible is the point where the upper corner 27 lies against the inner surface 21 of the top 9 . It is also plain that the corners 27 , 27 ′ are spread further when the locking spring 14 is subjected to tensile loading and thereby reinforce the latching connection. Similarly, the protective action of the extension 28 relative to the rear end 18 of the locking spring 14 is visible.
FIG. 7 is a bottom view of the pin contact 1 showing the base 6 of the locking part 3 having the perforation pocket 17 arranged thereon. As previously described, the pocket 17 cooperates with the locking spring 14 to limit the axial movement of the locking spring 14 .
Referring to FIG. 8, the second side wall 8 of the locking part 3 is provided with the side opening 16 , the upper side 30 of which engages the upper corner 27 ′. The end 18 of the locking spring 14 projects only slightly beyond the extension, so that the locking spring 14 is protected, as previously described.
As illustrated in FIG. 9, the first opening 15 of the top 9 of the locking part 3 is confirmed to have the locking spring 14 installed therein. The locking spring 14 engages the narrow side 29 of the first opening 15 thereby allowing the locking spring to pivot or swivel as necessary.
Two stamped or punched blanks for the pin contact 1 are shown in FIG. 10 . The blanks are connected by a conveying strip 31 and constitute part of a reelable strip of blanks. The part of the blank strip from which the locking part 3 is formed displays the first opening 15 , the side opening 16 and the perforation pocket 17 .
The connecting part 2 and the halves 10 , 11 of the connector tongue 4 are integrally attached to the locking part 3 . At the tip 12 of the upper half 10 of the connector tongue 4 there may be seen a groove 13 and at the tip 12 ′ of the lower half 11 a mating tongue 13 ′, which may be clamped together during assembly of the pin contact 1 and optionally secured by welding. The conveying strip 31 is removed when the connecting part 2 is fitted with a cable.
FIGS. 11 and 12 are perspective views of a second embodiment of the pin contact 32 . The locking part 33 and locking spring 34 of the pin contact 32 differ from the locking part 3 and locking spring 14 of the pin contact 1 of FIGS. 1 and 2. Like the locking part 3 , the second locking part 33 has a rectangular cross section, with a top 35 , a base 36 , a first side wall 37 and a second side wall 38 .
A first top opening 39 , a second top opening 40 and a third top opening 41 are provided in the top 35 , the openings are dimensioned to receive the locking spring 34 therein. An extension 42 , here of divided construction, is used for angular orientation of the pin contact 32 and for protection of the locking spring 34 .
In the area of a rear end 43 of the locking spring 34 , there is arranged on each side thereof a first guide surface 44 , 44 ′ folded at right angles. At the rear edge of the first guide surface 44 ′ there is provided a hook 45 , which, when the locking spring 34 is in the installed position, extends parallel to the top 35 and lies against the inner surface 46 thereof (see also FIG. 14 ). In this way, the rear end 43 of the locking spring 34 is latched in the locking part 33 .
In the area of the front end 47 of the locking spring 34 , an obtuse-angled first folded portion 48 , a right-angled second folded portion 49 and an obtuse-angled third folded portion 50 are provided. The transition between the first, second and third folded portions is preferably radial. The second folded portion 49 is preferably U-shaped, wherein the U shape exhibits a fixed radius of curvature. In the obtuse-angled third folded portion 50 there is arranged a first perforation tongue 51 directed towards the connecting part 2 . The tongue 51 lies against the inner surface 46 of the top 35 of the locking part 33 after the locking spring 34 is latched in position. In this way, the front end 47 of the locking spring 34 is also latched in the locking part 33 and the locking spring 34 is thus secured against unwanted removal. The latching connection is reinforced by spreading of the perforation tongue 51 upon tensile loading of the locking spring 34 .
As shown in FIG. 14, second and third perforation tongues 52 , 53 are offset laterally in the base 36 and are each bent up and inward by 90 20 lengthwise but in opposite directions. The tongues fix the locking spring 34 in the longitudinal direction. The obtuse-angled first and third folded portions 48 , 50 are clamped in:between the second and third perforation tongues 52 , 53 . A web 54 in the base 36 (see FIG. 17) between the second and third perforation tongues 52 , 53 serves to provide perpendicular support of the locking spring 34 . The right-angled second folded portion 49 of the locking spring 34 has an opening 55 (see also FIGS. 11 and 12) which mates with the web 54 .
FIG. 15 shows the second side wall 38 with the extension 42 , the first side wall 37 , the top 35 with the inner surface 46 and the base 36 with the second perforation tongue 52 . The components of the locking spring 34 which are visible are the first guide surfaces 44 , 44 ′ and the obtuse-angled third folded portion 50 with the first perforation tongue 51 . The latter lies against the inner surface 46 of the top 35 when the locking spring 34 is in the mounted state.
FIG. 16 shows the third obtuse-angled folded portion 50 with the first perforation tongue 51 and the base 36 with the web 54 .
FIG. 18 shows a side view of the different locking part 33 with the second side wall 38 and the extension 42 thereof, which serve in orienting the pin contact 32 and in protecting the locking spring 33 . The first guide surface 44 ′ thereof is likewise illustrated.
FIG. 19 shows a top view of the pin contact 32 , with the locking spring 34 , which engages in the first, second and third top openings 39 , 40 , 41 of the top 35 of the different locking part 33 .
Two stamped or punched blanks for the pin contact 32 are shown in FIG. 20 . The figure shows the second and third perforation tongues 52 , 53 and the first, second and third top openings 39 , 40 , 41 .
FIGS. 21 and 22 show a third pin contact 56 , again in perspective positions. It differs from the pin contact 1 and the second pin contact 32 by a modified third locking part 57 and a modified third locking spring 58 .
The locking part 57 again exhibits a rectangular cross section, with a top 59 , a base 60 , a first side wall 61 and a second side wall 62 with an extension 78 .
A first top opening 63 and a second top opening 64 are provided in the top 59 , which openings are dimensioned to receive the locking spring 58 .
In the area of a rear end 65 of the locking spring 58 , there is provided on each side thereof a first guide surface 66 , 66 ′ folded at right angles. At the rear surface of the first guide surface 66 there is arranged a perforation pocket 67 , the edge 68 of which lies against an inner surface 69 of the top 59 after mounting of the locking spring 58 (see also FIG. 24 ). In this way, the rear end 65 of the locking spring 58 is latched in the locking part 57 .
In the area of a front end 70 of the locking spring 58 , an obtuse-angled first folded portion 71 , a further right-angled second folded portion 72 (see FIG. 24) and a further obtuse-angled third folded portion 73 are provided.
Two guide surfaces 74 , 74 ′ are folded back on both sides of the obtuse-angled first folded portion 71 , these being inwardly directed, parallel and rectangular. They project downwards beyond the right-angled, second folded portion 72 and engage, when the locking spring 58 is in the mounted state, in first and second base openings 75 , 76 in the base 60 (see FIG. 27) as well as in the first top opening 63 and serve to fix the locking spring 58 in the longitudinal direction.
FIG. 24 illustrates that, after mounting of the locking spring 58 , the free end 77 of the obtuse-angled third folded portion 73 latches in beneath the top 59 and lies against the inner surface 69 thereof, while the right-angled second folded portion 72 lies against the base 60 . In this way, vertical fixing of the locking spring 58 is ensured and unwanted removal is prevented.
As is shown in FIG. 25 and FIG. 26, the edge 68 of the perforation pocket 67 of the first guide surface 66 and the free end 77 of the obtuse-angled third folded portion 73 lie against the inner surface 69 of the top 59 when the locking spring 58 is in the mounted state and thereby effect latching thereof in the locking part 57 .
FIG. 26 also shows the second guide surfaces 74 , 74 ′, which engage in the first and second base openings 75 , 76 of the base 60 and in the first top opening 63 of the top 59 .
The bottom view of FIG. 27 shows the first and second base openings 75 , 76 in the base 60 of the locking part 57 .
The side view of FIG. 28 shows the second side wall 62 with the extension 78 and the second base opening 76 in the locking part 57 together with the locking spring 58 , which is extensively hidden by the protective extension 78 .
The plan view of FIG. 29 shows the locking part 57 with the locking spring 58 and the indicated obtuse-angled first folded portion 71 thereof together with the first guide surfaces 66 , 66 ′.
The punched blanks for the pin contact 56 illustrated in FIG. 30 show the locking part 57 with the first and second base openings 75 , 76 and with the first and second top openings 63 , 64 prior to forming.
In conclusion it may be stated that the pin contacts 1 , 32 , 56 are functionally reliable and simple to manufacture and assemble.
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The invention relates to an electrical pin contact, ( 1, 32, 56 ), having a connecting part ( 2 ) and a connector tongue ( 4 ) together with a locking part ( 3, 33, 57 ). A separate locking spring ( 14, 34, 58 ), is provided which is inserted into the locking part ( 3, 33, 57 ) perpendicularly to the longitudinal axis of the contact ( 1, 32, 56 ). Particularly simple mounting of the locking spring ( 14, 34, 48 ) is achieved in that the latter has latching means, which fix the locking spring ( 14, 34, 58 ) in position in the locking part ( 3, 33, 57 ) through insertion of the locking spring into the locking part ( 3, 33, 57 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Division of Ser. No. 08/632,191, filed Apr. 15, 1996, now U.S. Pat. No. 5,728,265, which is a continuation-in-part of application Ser. No. 08/574,053, filed on Dec. 18, 1995, now abandoned, the entire contents of which are incorporated herein by reference, which application claims the benefit of earlier filed and copending provisional application serial No. 60/000,143, filed on Jun. 12,1995.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved pulping process which utilizes nonionic and anionic surfactants as solubilizing agents to enhance white liquor penetration into wood chips and the like during chemical pulping.
2. Description of the Related Art
Chemical pulping is a process whereby wood chips, wood shavings, and/or sawdust are heated at elevated temperatures in an aqueous acid or alkaline solution, also known as white liquor or cooking liquor, in order to remove enough lignin so that the cellulose fibers can be readily separated from one another. Typically, the process is carried out by heating a mixture of wood chips and cooking liquor in a large pressure vessel called a digester. The cooking temperature is usually in the 170-175° C. range with a corresponding cooking time of 90 minutes. The cooked chips are discharged or blown from the digester under pressure, the mechanical force of which breaks up the wood chips into individual fibers, producing the pulp. The pulp from the digester contains fiber and exhausted liquor which is black in color. The black liquor is washed from the pulp which is then screened to remove uncooked chips and other large fragments and sent on for further processing.
The efficiency of the pulping process is reflected in the degree of delignification which depends upon the extent of the penetration of the cooking liquor and the uniformity of the distribution of the liquor within the chips. Inadequate impregnation usually results in a high level of screen rejects and low pulp yield. The current trends in research and development of the pulping industry are leading towards the use of digester aids. Digester aids are materials that are added to the white liquor to increase the yield and rate. To be most efficient, these digester aids must be soluble and stable under the pulping conditions.
Anthraquinone is an example of a compound that is widely employed as a digester aid because of its relatively low cost and lack of interference with downstream paper making operations.
Unfortunately, the known digester aids are not completely satisfactory, for example, for environmental considerations in certain cases or for lack of adequate penetration and extraction of undesirable organic components in other cases. Despite numerous prior attempts, there exists no known system which enhances the efficiency of the pulp digestion to desired levels while meeting other important criteria. It is therefore a principal object of the present invention to substantially enhance the rate of digestion of wood chips and thereby reduce the pulping cycle times in the production of pulp for the paper making process.
SUMMARY OF THE INVENTION
The present invention is an improvement in the conventional chemical pulping processes by improving the efficiency by which pulp cooking liquor components penetrate the wood and enable lignin and resins to be removed from the cellulosic materials. The surprising discovery has been made that the addition of certain surfactants or combinations of certain surfactants to the white liquor in a conventional pulping process improves both the rate of penetration of white liquor into cellulose pulp and reduces the pulping cycle times. The process according to the invention comprises contacting wood chips and the like with a digester aid which is a liquid mixture comprised of white liquor containing at least one surfactant as disclosed herein below. The surfactant concentration in the liquid mixture and the contact time with the pulp chips are each adjusted so that resinous components are extracted from the pulp without substantial degradation of cellulose. After contacting at least a portion of the resulting liquid mixture-pulp combination is heated to a digestion temperature typically above about 150° C. The heating is also referred to as cooking.
The process according to the invention results in (1) acceleration of the cooking liquor penetration by reducing its surface tension, (2) the dissolution and emulsification of the resinous components that inhibit liquor penetration and diffusion, thereby significantly enhancing the penetration of the liquor into the wood chips, and (3) enhanced delignification. When the pulping solution is alkaline, the affected alkali uptake by the chips increases by several percentage points compared to the uptake obtained in the absence of a surfactants employed in the process according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Other than in the claims and in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients or reaction conditions used herein are to be understood as modified in all instances by the term "about".
As employed herein, the term "white liquor" means an aqueous mixture of alkali metal hydroxide and a sulfide with or without further additives and in concentrations well known in the art. The Kappa number, which is directly proportional to the amount of lignin remaining in the pulp, is the volume (in millimeters) of 0.1N potassium permanganate solution consumed by one gram of moisture-free pulp under the conditions specified in TAPPI method T 236 cm-85, the method used to determine the Kappa number.
The term pulping cycle time as used herein refers to the time required to cook a sample of wood chips and the like to a given residual effective alkali.
In the process according to the invention, wood chips, wood shavings, sawdust and the like are contacted with a liquid mixture comprised of white liquor and one or more surfactants which are soluble in white liquor and which are selected from the group consisting of polymethylalkylsiloxanes of the formula II; alkoxylated silicones; co- or terpolymers of silicones and alkoxylated polyhydric alcohols, alkoxylated aryl phosphates; alkoxylated branched alkyl phosphates; alkoxylated branched alcohols; alkyl polyglycosides and alkoxylated alkyl polyglycosides; alkali metal salts of alkyl aromatic sulfates, sulfosuccinates and a silicone; and mixtures thereof.
Nonionic surfactants which are useful in the practice of this invention are those having an HLB value of from 9 to 16 and are selected from the group consisting of polymethylalkylsiloxanes alkoxylated silicones, co- or terpolymers of alkoxylated silicones; alkoxylated aryl phosphates; alkoxylated branched alkyl phosphates; alkoxylated branched and unbranched aliphatic alcohols; and alkyl polyglycosides. Anionic surfactants which are useful in the practice of this invention are those selected from the group consisting of a mixture of alkali metal salts of alkyl aromatic sulfates, sulfosuccinates and a silicone; and mixtures thereof.
Polymethylalkylsiloxanes are compounds of the formula II ##STR1## wherein A=(CH 2 ) x --O--(C 2 H 4 O) y --(C 3 H 6 O) z --R; R is an organic moiety having from 1 to 8 carbon atoms such as an alkyl and/or alkenyl group, a substituted alkyl and/or alkenyl group, an acyloxy group; m is a number from 1 to 100, n is a number from 0 to 100, x is an integer from 1 to 3, y is a number from 1 to 100 and, z is a number from 0 to 100. Preferred polymethylalkylsiloxanes are those wherein n=0, m=1, x=3, y=8, z=0 and, R is methyl; n=35, m=11, x=3, y=18,z=0 and, R is methyl; n=0, m=1, x=3, y=8, z=0 and, R is acetoxy.
In the case of silicones and copolymers of silicones and ethoxylated polyhydric alcohols, relatively high degrees of ethoxylation, e.g., about 12 to 44, preferably about 22 to 44, have been found to be preferable for the purposes of this invention. These findings are applicable to a wide range of branched alkyl and aryl phosphates, branched alcohols, alkyl polyglycosides, and like compositions and mixtures.
Alkoxylated silicones, co- and terpolymers of alkoxylated silicones are described in WO 92105854, the entire contents of which are incorporated herein by reference.
An alkoxylated polyol is any compound having at least 2 alcohol groups wherein all or substantially all of the alcohol functionalities are etherified with a polyoxyalkylene having a degree of polymerization of at least 2 examples of which include but are not limited to ethoxylated polyols, propoxylated polyols, butoxylated polyols, and random and block ethoxylated-propoxylated polyols. Preferably, the alkoxylated polyols are ethoxylated polyols.
An ethoxylated polyol is any compound having at least 2 alcohol groups wherein all or substantially all of the alcohol functionalities are etherified with polyoxyethylene having a degree of polymerization of at least 2. Such ethoxylated polyols include, but are not limited to, ethoxylated diols such as ethylene glycol, 1,2-propylene glycol, diethylene glycol, triethylene glycol, and polyethylene glycols of various degrees of polymerization; triols such as glycerine, trimethylolethane [2-methyl-2-(hydroxymethyl)-1,3-propanediol], trimethylolpropane [2-ethyl-2-(hydroxymethyl)-1,3-propanediol]. Polyols also include pentaerythritol (2,2-dimethylol-1,3-propanediol), diglycerol (glycerol dimer), dipentaerythritol, triglycerine, and the like.
Alkoxylated aryl phosphates are phosphate esters which are a mixture of mono-, di-, and tri-esters of phosphoric acid esterified with alkoxylated phenols or alkyl-substituted phenols. Alkoxylated branched alkyl phosphates are phosphate esters which are a mixture of mono-, di-, and triesters of phosphoric acid esterified with alkoxylated branched aliphatic alcohols. Preferably, the alkoxylated aryl phosphates are ethoxylated aryl phosphates. Preferably, the alkoxylated alkyl phosphates are ethoxylated alkyl phosphates.
The alkyl polyglycosides which can be used in the invention have the formula I
R.sub.1 O(R.sub.2 O).sub.b (Z).sub.a I
wherein R 1 is a monovalent organic radical having from about 6 to about 30 carbon atoms; R 2 is divalent alkylene radical having from 2 to 4 carbon atoms; Z is a saccharide residue having 5 or 6 carbon atoms; b is a number having a value from 0 to about 12; a is a number having a value from 1 to about 6. Preferred alkyl polyglycosides which can be used in the compositions according to the invention have the formula I wherein Z is a glucose residue and b is zero. Such alkyl polyglycosides are commercially available, for example, as APG®, GLUCOPON®, or PLANTAREN® surfactants from Henkel Corporation, Ambler, Pa., 19002. Examples of such surfactants include but are not limited to:
1. APG® 225 Surfactant--an alkyl polyglycoside in which the alkyl group contains 8 to 10 carbon atoms and having an average degree of polymerization of 1.7.
2. APG® 425 Surfactant--an alkyl polyglycoside in which the alkyl group contains 8 to 16 carbon atoms and having an average degree of polymerization of 1.6.
3. APG® 625 Surfactant--an alkyl polyglycoside in which the alkyl groups contains 12 to 16 carbon atoms and having an average degree of polymerization of 1.6.
4. APG® 325 Surfactant--an alkyl polyglycoside in which the alkyl groups contains 9 to 11 carbon atoms and having an average degree of polymerization of 1.6.
5. GLUCOPON® 600 Surfactant--an alkyl polyglycoside in which the alkyl groups contains 12 to 16 carbon atoms and having an average degree of polymerization of 1.4.
6. PLANTAREN® 2000 Surfactant--a C 8-16 alkyl polyglycoside in which the alkyl group contains 8 to 16 carbon atoms and having an average degree of polymerization of 1.4.
7. PLANTAREN® 1300 Surfactant--a C 12-16 alkyl polyglycoside in which the alkyl groups contains 12 to 16 carbon atoms and having an average degree of polymerization of 1.6.
8. GLUCOPON® 220 Surfactant an alkyl polyglycoside in which the alkyl group contains 8 to 10 carbon atoms and having an average degree of polymerization of 1.5.
Other examples include alkyl polyglycoside surfactant compositions which are comprised of mixtures of compounds of formula I wherein Z represents a moiety derived from a reducing saccharide containing 5 or 6 carbon atoms; a is a number having a value from 1 to about 6; b is zero; and R 1 is an alkyl radical having from 8 to 20 carbon atoms. The compositions are characterized in that they have increased surfactant properties and an HLB in the range of about 10 to about 16 and a non-Flory distribution of glycosides, which is comprised of a mixture of an alkyl monoglycoside and a mixture of alkyl polyglycosides having varying degrees of polymerization of 2 and higher in progressively decreasing amounts, in which the amount by weight of polyglycoside having a degree of polymerization of 2, or mixtures thereof with the polyglycoside having a degree of polymerization of 3, predominate in relation to the amount of monoglycoside, said composition having an average degree of polymerization of about 1.8 to about 3. Such compositions, also known as peaked alkyl polyglycosides, can be prepared by separation of the monoglycoside from the original reaction mixture of alkyl monoglycoside and alkyl polyglycosides after removal of the alcohol. This separation may be carried out by molecular distillation and normally results in the removal of about 70-95% by weight of the alkyl monoglycosides. After removal of the alkyl monoglycosides, the relative distribution of the various components, mono- and poly-glycosides, in the resulting product changes and the concentration in the product of the polyglycosides relative to the monoglycoside increases as well as the concentration of individual polyglycosides to the total, i.e. DP2 and DP3 fractions in relation to the sum of all DP fractions. Such compositions are disclosed in U.S. Pat. No. 5,266,690, the entire contents of which are incorporated herein by reference.
Other alkyl polyglycosides which can be used in the compositions according to the invention are those in which the alkyl moiety contains from 6 to 18 carbon atoms in which and the average carbon chain length of the composition is from about 9 to about 14 comprising a mixture of two or more of at least binary components of alkyl polyglycosides, wherein each binary component is present in the mixture in relation to its average carbon chain length in an amount effective to provide the surfactant composition with the average carbon chain length of about 9 to about 14 and wherein at least one, or both binary components, comprise a Flory distribution of polyglycosides derived from an acid-catalyzed reaction of an alcohol containing 6-20 carbon atoms and a suitable saccharide from which excess alcohol has been separated.
The alkoxylated branched and unbranched aliphatic alcohols which can be used in the process according to the invention are those branched and unbranched alcohols having from 3 to 22 carbon atoms, preferably 8 to 18 carbon atoms. Preferred compounds are ethoxylated branched and unbranched aliphatic alcohols having from 8 to 18 carbon atoms such as ethoxylated tridecyl alcohol. Preferred surfactants include anionic and nonionic surfactants selected from the group consisting of the following: (1) a polymethylalkylsiloxane of the formula II wherein n=0, m=1, x=3, y=8, z=0 and, R is acetoxy; (2) a polymethylalkylsiloxane of the formula 11 wherein n=35, m=11, x=3, y=18, z=0 and, R is methyl; (3) a polymethylalkylsiloxane of the formula 11 wherein n=0, m=1, x=3, y=8, z=0 and, R is methyl; (4) a phosphated aryl ethoxylate which is commercially available as AQUAQUEST® 601P and TRYFAC® from Henkel Corporation; (5) an ethoxylated tridecyl alcohol which is commercially available as TRYCOL® 5941 from Henkel Corporation; (6) a blend of sodium alkyl aromatic sulfonate, sodium sulfosuccinate and silicone which is commercially available as STANTEX® 40 DF from Henkel Corporation.
Under certain conditions, aqueous solutions of non-ionic surfactants such as silicones or ethoxylated surfactants exhibit limited solubility as the temperatures rise. Furthermore, under caustic conditions, these surfactants may phase separate and degrade into a dark gel phase. This lessens their desirability for specific applications as digester additives, despite their very good wetting ability under normal pH and temperatures. Alkyl polyglycosides have been found to enhance the solubility of non-ionic and anionic surfactants in alkaline media. The blends exhibit good thermal stability and remain stable over a wide range of temperatures. Alkyl polyglycosides have been found to enhance the solubility of ethoxylated surfactants. The performance of selected non-ionic and anionic surfactants as wetting agents, penetrants and deresinators improves significantly when used with alkyl polyglycosides. The alkyl polyglycosides which may be used in combination with the surfactants of this invention have the formula I and are set forth above. Combinations of alkyl polyglycosides of the formula I and polymethylalkylsiloxane of the formula 11 are preferred. Mixture containing from about 90/10 to about 10/90 (wt/wt) and preferably from about 75/25 to about 10/75 of a polymethylalkylsiloxane of the formula 11 wherein n=0, m=1, x=3, y=8, z=0 and, R is methyl and an alkyl polyglycoside of the formula I wherein R 1 is an alkyl group having from 8 to 10 carbon atoms b is zero and a is 1.5 are preferred. The most preferred surfactant system is a 10/75 (wt:wt) mixture of a polymethylalkylsiloxane of the formula II wherein n=0, m=1, x=3, y=8, z=0 and, R is methyl and an alkyl polyglycoside of the formula I wherein R, is an alkyl group having from 8 to 10 carbon atoms b is zero and a is 1.5.
The contacting or residence time may vary with the type of pulp and will be easily determinable by those skilled in the art. The residence time for contacting is preferably between about 45 minutes and about 180 minutes. The contacting temperature may vary with the type of pulp and will be easily determinable by those skilled in the art. The contacting temperature is preferably maintained at or below about 80° C. The digestion temperature can vary but will typically be above about 150° C. and is preferably between 160-175° C.
The concentration of surfactant in the white liquor which together form the liquid mixture for contacting the pulp can be any amount that is effective to extract the resinous components from the pulp without substantially degrading the cellulose. Typically, the amount of surfactant will range from 0.05% (w/w) to 1.0% and preferably between about 0.05% (w/w) and about 0.5% (w/w) and most preferably from 0.125% to 0.25% based on the weight of oven dry wood. Typically, the specific components extracted from the wood chips include resins, fatty acids, and lignins.
The liquid mixture which contains one or more surfactants according to the invention and the white liquor is prepared by mixing the surfactants and the white liquor using standard mixing equipment. The amount of liquid mixture that can be used to treat the pulp can vary from 70% to 85% and preferably from 75% to 80% based on the weight of oven dry wood.
The present invention is applicable to any chemical pulping process including the pulping of wood chips from oak, gum, birch, poplar and maple trees. The pulping process may be the well-known Kraft process in which wood chips are cooked in an aqueous solution containing NaOH and Na 2 S, or an acid sulfite system.
The invention is further illustrated by the following examples.
EXAMPLE 1
Liquor Penetration Determination Procedure
The extent of liquor penetration into hardwood or soft wood chips is determined by means of a gravimetric test. The cooking liquor comprises 0.25% of a surfactant in white liquor on a weight basis. The liquor may be sodium hydroxide for soda pulping, or a mixture comprising sodium hydroxide and sodium sulfide for Kraft pulping. The liquor is pre-heated at 70° C. The chips are immersed in the liquor (Kraft or soda) for a period of 30 minutes. The temperature is maintained constant over the impregnation time. The chips are then filtered from the liquor and weighed. The liquor uptake is calculated as a ratio of the weight of penetrated chips over the weight of the initial chips. The black liquors generated are submitted to tests described below. The composition of a typical cooking liquor is as follows:
NaOH Concentration: 25.6 g/l as Na 2 O
Na 2 S Concentration: 9.75g/l as Na 2 O
Sulfidity: 27.6%
Liquor/Wood Ratio: 4/1
EXAMPLE 2
Analysis of Black Liquor
The residual alkali and the amount of organic material extracted from the wood chips are determined according to standard methods. Active alkali, total alkali and effective alkali (EA) are defined in TAPPI Standard T1203 os-61 and are determined using TAPPI methods T624 cm-85 and T625 cm-85. The effective alkali of black liquors is defined as the residual effective alkali. The alkali content is determined by means of a standard titration method as set forth in the TAPPI method. Effective alkali uptake (EAU) is calculated and used as a measure of the hydroxyl uptake at the initial phase of delignification. Effective Alkali Uptake (EAU) is given by the following equation:
EAU=(EA.sub.white liquor -Residual EA.sub.black liquor)/EA.sub.white liquor)×100
The residual sodium sulfide and percent sulfidity are also determined.
EXAMPLE 3
Standard Kraft Pulping Procedure
A 4-liter pressure reactor is charged with white liquor and heated to 80° C. The digester aid, one or more of the surfactants disclosed herein, is added slowly. Wood chips are then added so that the liquor to wood ratio is from 4:1 to 3:1 based on weight of oven dry wood. The reactor is purged with nitrogen and then sealed. The temperature is increased at such a rate that it reaches a maximum of 170° C. in one hour. The temperature is recorded every 10 minutes and used to calculate the total H-factor for a particular pulping study. For example, a pulping reaction is studied so that an H-factor is identified for a given temperature reading at a given time. The H-factors are found in table 13 on page 50 of Pulp and Paper Manufacture, Volume 5, third edition, 1989, the entire contents of which are incorporated herein by reference, which lists the H-factors for temperatures from 100° C. to 199° C. (see also Pulp Paper Mag. Can., Volume 58, pages 228-231 (1957)). The H-factor for each temperature up to 170° C. is recorded and added together. The sum of the H-factors will lie in the range of 800-1150. Pulping runs are cooked to the same H-factors and the data for the same H-factor runs are compared. The shorter the time period required to arrive at a given H-factor the more efficient the pulping reaction and the shorter the cycle time. Black liquor samples are taken from the reactor at the same time intervals that the temperatures are recorded. Lignin and total organic content of black liquors is determined by means of ultraviolet spectroscopy as set forth in Example 6. The Kappa number for each run is determined according to TAPPI method T 236 cm-85. Since the Kappa number measures the amount of lignin remaining in the pulp, the lower the Kappa number for a given cook, the more efficient the lignin removal.
EXAMPLE 4
Solubility and Cloud Point Measurements
Solubility and stability of the surfactants which were used to make up the digester aids according to the invention were assessed through determination of cloud point and phase separation. Solutions comprising a surfactant or a mixed surfactant system were heated up to 100° C., or to the point where the solutions turned turbid or phase separated. The temperature at which turbidity or phase separation is observed is the cloud point of the solution, which is the lowest temperature at which a stable and homogeneous solution can be found, at this concentration.
EXAMPLE 5
Wetting Ability of the Digester Aids
The change in enthalpy per surface area is related to the surface free energy associated with the wetting of wood chips. An exothermic heat is observed when wetting takes place. The magnitude of the change in enthalpy is an indication of the wettability of the chips, and the ability of the digester aids to enhance wetting. Surface tension measurement and critical micelle concentration for specific surfactants provide critical information on wetting and solubilizing ability of the digester aids.
EXAMPLE 6
Lignin and Total Organic Analysis
Black or white liquor is filtered using a 0.2 μm pore size filter. About 20 ml of the filtrate is diluted with distilled water to a volume of 10 ml. UV absorption spectrum is taken with respect to the initial white liquor in the region of 190 nm to 450 nm, using a Perkin-Elmer UV/visible spectrophotometer and 1-cm quartz cuvette. For quantitative determination, the areas under the peaks are integrated using a FTIR-UV software. The UV spectrum shows three specific maxima between 250 nm and 360 nm, at 268, 290, 360 respectively. A standard is made by dissolving alkali lignin in white liquor in a wide range of concentrations. Absorption of the lignin samples is measured as described above. Two maxima are observed in the region between 250 nm-300 nm. Consequently, for the black liquors, the peaks in the 250-300 nm regions are considered specifically caused by lignin structural groups. The total organic extraction is calculated from the maxima obtained in the entire 250-450 region.
Tables 1-5 illustrate the efficacy of the digester aids according to the invention. Table 1 illustrates the effect of surfactant composition on the ability of a digester aid to remove lignin from pulp. The combination of TEGOPREN® 5878 and GLUCOPON® 220 (1:7.2) is most efficient in removing lignin. TEGOPREN® 5878 is a polymethylalkylsiloxane. The amounts of the various extracts is proportional to the absorbency at the indicated wavelengths. Table 2 shows the effect of the preferred digester aid, TEGOPREN® 5878-GLUCOPON® 220 (75:25) as a digester aid in various pulping runs using Scandinavian softwood at a dosage of digester aid equal to 0.125% based on dry wood weight and 28.5% sulfidity. All runs in Table 2 were cooked to an H-factor of 1150. Table 3 shows the Kappa number for various digester aids at two different additive dose rates. Table 4 shows the Kappa number and number of rejects for various digester aids at different active alkali amounts as percentages of dry wood weight. The following surfactant compositions pertain to each of the tables below where indicated. The control is white liquor having no digester additives. Additive A is TRYCOL® 5941--GLUCOPON® 220 (1:1). Additive B is DC® 25212, trademark product of Dow Chemical. Additive C is S911, a trademark product of Wacker Silicones. Additive D is AQUAQUEST® 610-GLUCOPON® 220 (1:1), both trademark products of Henkel Corporation. Additive E is STANTEX® 40DF a trademark product of Henkel Corporation. Additive F is TEGOPREN® 5878-GLUCOPON® 225 (75:25). TEGOPREN® 5878 is a trademark product of Goldschmidt Chemical. Table 5 shows the efficiency of the TEGOPREN® 5878-GLUCOPON® 220 combination at various blend ratios. The data in Tables 1,2 and 5 was obtained using Scandinavian softwood while the data in Tables 3 and 4 was obtained using Scandanavian hardwood.
TABLE 1______________________________________Pulping of Scandinavian SoftwoodLignin Removal EfficiencySurfactant 268 nm.sup.1 290 nm.sup.2 336 nm.sup.3______________________________________Control 0.872 0.795 0.398A 1.036 0.916 0.512B 1.055 0.929 0.552C 0.994 0.934 0.521D 0.990 0.885 0.495E 0.985 0.887 0.484F 1.134 0.986 0.556______________________________________ .sup.1 absorption at 268 nm .sup.2 absorption at 290 nm .sup.3 absorption at 336 nm
TABLE 2______________________________________Efficiency of TEGOPREN ® 5878-GLUCOPON ® 225 (75:25) Kappa Number Number of RejectsActive Alkali Additive Control Additive Control______________________________________18 27 30 0.7 2.820 25.8 25.6 0.7 0.5322 -- 22.27 -- 0.53______________________________________
TABLE 3______________________________________Kappa Number for Various Digester Aidsat Two Different Additive Dose RatesSurfactant.sup.1 At 0.125% At 0.25%______________________________________A 17.9 17.2B 17.4 18.6C 18.1 17D 17.7 17.8E 17.8 17.2F 17.2 16.9______________________________________
TABLE 4__________________________________________________________________________Kappa Number and Rejects for Various Digester Aidsat Different Active AlkaliKappa Number Number of RejectsSurfactant15.5% 16.5% 17.5% 18.5% 15.5% 16.5% 17.5% 18.5%__________________________________________________________________________Control20.1 19.2 17.8 16 2.43 2 1.9 1.7E 19 17.5 17.9 16.7 3 1.8 0.9 1.8F 18.5 17.6 17.2 15.8 1.4 2.6 0.8 1.3__________________________________________________________________________
TABLE 5______________________________________Efficiency of TEGOPREN ® 5878-GLUCOPON ® 220at Various Blend Ratios Pulping of Scandinavian Softwood Sur- factant Re- Blend Additive Active jects Screen Weight Dose* Alkali Kappa Level YieldSurfactant Ratio (w/w %) % Number (%) (%)______________________________________Control 0 0 18 30 2.8 43.1TEGOPREN/ 75:25 0.125 18 27 0.7 45.8GLUCOPON220TEGOPREN/ 1:7.5 0.063 18 28.2 0.8 45.3GLUCOPON220TEGOPREN/ 1:7.2 0.063 18 25.75 0.85 46.1GLUCOPON220______________________________________ *% based on the weight of dry wood
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The efficiency by which pulp cooking liquor components penetrate the wood and enable lignin and resins to be removed from the cellulosic materials is increased by contacting wood chips and the like with a liquid mixture comprised of white liquor containing at least one surfactant selected from the group consisting of a polymethylalkylsiloxane; a co- and terpolymer of silicone and a polyhydric alcohol; an alkoxylated aryl phosphate; an alkoxylated branched alkyl phosphate; an alkoxylated branched alcohol; an alkyl polyglycoside, an alkoxylated alkyl polyglycoside; a mixture of alkali metal salts of alkyl aromatic sulfate, a sulfosuccinate and a silicone; and combinations thereof; for a residence time effective to extract resinous components without substantial degradation of cellulose and thereafter heating at least a portion of the resulting mixture and wood chips.
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FIELD OF THE INVENTION
The present invention pertains to the field of aviation aircrafts and particularly relates to an electrical driven flying saucer based on magnetic suspension.
BACKGROUND OF THE INVENTION
The lift and thrust of a rotary-wing aircraft are formed by a rotary wing rotating at a high speed. The power for the rotation of the rotary wing comes from an engine. The current rotary-wing aircrafts include all kinds of rotary-wing helicopters. The rotary wing and engine are two separate and independent systems and connected with a transmission mechanism.
Compared with ordinary rotary-wing aircrafts, the particularity of a rotary-wing flying saucer is that the rotary-wing system and its power system need to be installed inside a saucer shell. The internal space of the saucer shell is limited and restricts the structure and layout of the rotary-wing system and its power system. Therefore, the paramount task for the design of a rotary-wing flying saucer is how to make full use of the limited internal space of the saucer shell and design a rotary-wing system and its power system with a compact structure, reasonable layout, small weight, high motive power conversion efficiency and easy manipulation and control.
When the rotary wing rotates at a high speed in the saucer shell, due to pneumatic vortex, flexibility of the rotary wing, maneuver of the saucer and other factors, the rotary wing and the saucer shell might collide with each other, resulting in failure and even a serious accident. For more information, please refer to Patent CN 1120008A. There exists the foregoing defect.
Therefore, one of the important tasks for the design of a rotary-wing flying saucer is how to avoid the contact and friction between the high-speed rotary wing and the interior of the saucer shell, reduce the noise of the rotary wing during high-speed rotation as well as the vibration of the saucer shell and the saucer cabin, raise motive power conversion efficiency, reduce energy consumption and guarantee the operational safety of the rotary wing and the flying saucer.
Similar to ordinary rotary-wing aircrafts, reactive torque will be generated when the rotary wing of a flying saucer rotates. For more information, please refer to Patent CN 1114279A. There is the problem that the body of the flying saucer suffers uncontrollable reactive torque. Therefore, how to overcome the reactive torque of the rotary-wing flying saucer is also another important task for the design of a rotary-wing flying saucer.
SUMMARY OF THE INVENTION
The object of the present invention is to make full use of the limited internal space of the saucer shell and design and construct a rotary-wing flying saucer which has a compact structure, reasonable layout, small weight, high motive power conversion efficiency and owns an easily manipulated and controlled rotary-wing system and its power system.
The electrical driven flying saucer based on magnetic suspension provided in the present invention comprises a saucer shell, a saucer cabin, a rotary-wing system and a control system, wherein the rotary-wing system is a magnetic suspension electromotive rotary-wing system and comprises magnetic suspension rotary-wing wheels, an electromotive ring, a magnetic suspension shaft and a magnetic suspension guide rail. The electromotive ring, the magnetic suspension shaft and the magnetic suspension guide rail are fixed to the saucer shell. The magnetic suspension rotary-wing wheels are suspended in the space restricted by the electromotive ring, the magnetic suspension shaft and the magnetic suspension guide rail and go around the magnetic suspension shaft under an electromagnetic thrust.
The magnetic suspension rotary-wing wheels comprise blades, a magnetic suspension inner ring and a magnetic suspension outer ring. The blades are connected between the magnetic suspension inner ring and the magnetic suspension outer ring along the radial direction (X-X) to form an impeller. The magnetic suspension guide rail includes a magnetic suspension inner ring guide rail and a magnetic suspension outer ring guide rail. The magnetic suspension inner ring guide rail comprises an inner ring upper guideway and an inner ring lower guideway. The magnetic suspension outer ring guide rail comprises an outer ring upper guideway and an outer ring lower guideway. The magnetic suspension inner ring of the magnetic suspension rotary-wing wheels surrounds the magnetic suspension shaft in the radial direction (X-X) and is disposed between the inner ring upper guideway and the inner ring lower guideway in the axial direction (Y-Y). The magnetic suspension outer ring of the magnetic suspension rotary-wing wheels is embedded in the electromotive ring in the radial direction (X-X) and disposed between the outer ring upper guideway and the outer ring lower guideway in the axial direction (Y-Y).
The magnetic suspension inner ring of the magnetic suspension rotary-wing wheels and the magnetic suspension shaft form a repulsive or attractive magnetic suspension radial bearing in the radial direction (X-X) based on the principle that like magnetic poles repel, but opposite magnetic poles attract, and relying on permanent magnets, electromagnets or superconducting magnets, and make the magnetic suspension rotary-wing wheels suspended on the magnetic suspension shaft in the radial direction (X-X). The magnetic suspension inner ring of the magnetic suspension rotary-wing wheels and the magnetic suspension inner ring guide rail form a repulsive or attractive magnetic suspension axial bearing in the axial direction (Y-Y) based on the principle that like magnetic poles repel, but opposite magnetic poles attract, and relying on permanent magnets, electromagnets or superconducting magnets, and make the magnetic suspension inner ring suspended between the inner ring upper guideway and the inner ring lower guideway. The magnetic suspension outer ring of the magnetic suspension rotary-wing wheels and the magnetic suspension outer ring guide rail form a repulsive or attractive magnetic suspension axial bearing in the axial direction (Y-Y) based on the principle that like magnetic poles repel, but opposite magnetic poles attract, and relying on permanent magnets, electromagnets or superconducting magnets, and make the magnetic suspension outer ring suspended between the outer ring upper guideway and the outer ring lower guideway.
The magnetic suspension rotary-wing wheels of the rotary-wing system, the electromotive ring and the magnetic suspension shaft constitute a magnetic suspension electric engine. The electromotive ring is a stator, the magnetic suspension rotary-wing wheels constitute a rotor, the magnetic suspension shaft is a spindle, the electromotive ring controls the changes of the current flowing in the electromotive ring according to electromagnetic conversion principle and generates a rotating magnetic field along the ring, and this rotating magnetic field generates a magnetic force upon the magnetic field in the magnetic suspension outer ring of the magnetic suspension rotary-wing wheels and pushes the rotation of the magnetic suspension rotary-wing wheels.
As an improvement of the present invention, two sets of independent magnetic suspension electromotive rotary-wing systems are superposed and mounted coaxially inside the saucer shell in the axial direction (Y-Y), i.e. the upper rotary-wing system and the lower rotary-wing system. Coaxial axial dual magnetic suspension electromotive rotary wings are formed, wherein the upper rotary-wing system and the lower rotary-wing system rotate in reverse directions, adopt reverse inclination directions of blades, can guarantee the coaxial thrusts in the same direction will overcome or offset the reactive torque generated during rotation of the rotary wings and may realize automatic control for self-rotating angles and self-rotating angular velocity of the flying saucer through controlling the velocities and velocity difference of the upper rotary-wing system and the lower rotary-wing system.
As an alternative improvement of the present invention, two sets of independent magnetic suspension electromotive rotary-wing systems are superposed and mounted coaxially inside the saucer shell in a radial direction (X-X), i.e. the inner rotary-wing system and the outer rotary-wing system. Coaxial radial dual magnetic suspension electromotive rotary wings are formed, wherein the inner rotary-wing system and the outer rotary-wing system rotate in reverse directions, adopt reverse inclination directions of blades, can guarantee the coaxial thrusts in the same direction will overcome or offset the reactive torque generated during rotation of the rotary wings and may realize automatic control for self-rotating angles and self-rotating angular velocity of the flying saucer through controlling the velocities and velocity difference of the inner rotary-wing system and outer rotary-wing system.
The magnetic suspension electromotive flying saucer designed in the present invention makes full use of the limited internal space of the saucer shell and has a compact design structure, reasonable layout, small weight and high motive power conversion efficiency. Further, its rotary-wing system and power system can be easily manipulated and controlled. The design of the rotary-wing suspension structure avoids the contact and friction between the high-speed rotary-wing and the interior of the saucer shell, reduce the noise of the rotary wing during high-speed rotation as well as the vibration of the saucer shell and the saucer cabin, raise motive power conversion efficiency, lower energy consumption and guarantee the operational safety of the rotary wing and the flying saucer. The two improvement solutions mentioned in the present invention overcome the problem of reactive torque of the rotary wing under the precondition of meeting the foregoing requirements, and can realize stable and easy power control of the rotary wing.
The present invention is described below in details in connection with the accompanying drawings and embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : A side-view sectional schematic of an electrical driven flying saucer based on magnetic suspension;
FIG. 2 : A top-view schematic of an electrical driven flying saucer based on magnetic suspension;
FIG. 3 : A side-view sectional schematic of coaxial axial dual electrical driven flying saucer based on magnetic suspensions;
FIG. 4 : A side-view sectional schematic of coaxial radial dual electrical driven flying saucer based on magnetic suspensions;
FIG. 5 : A schematic of the radial magnetic suspension structure of a rotary-wing wheel;
FIG. 6 : A schematic of the axial magnetic suspension structure of a rotary-wing wheel;
FIG. 7 : A schematic of an embodiment of an electric engine.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Embodiment 1
Single-Rotary-Wing Electrical Driven Flying Saucer Based on Magnetic Suspension
In reference to FIG. 1 and FIG. 2 , the single-rotary-wing electrical driven flying saucer based on magnetic suspension comprises: a saucer shell 1 , a saucer cabin 2 , a rotary-wing system 3 and a control system 4 , wherein the rotary-wing system 3 is a magnetic suspension electromotive rotary-wing system and comprises magnetic suspension rotary-wing wheels 5 , an electromotive ring 6 , a magnetic suspension shaft 7 and a magnetic suspension guide rail 8 ; the electromotive ring 6 , the magnetic suspension shaft 7 and the magnetic suspension guide rail 8 are fixed to the saucer shell 1 ; the magnetic suspension rotary-wing wheels 5 comprise blades 9 , an magnetic suspension inner ring 10 and a magnetic suspension outer ring 11 , the blades 9 are connected to the magnetic suspension inner ring 10 and the magnetic suspension outer ring 11 along the radial direction (X-X) and form an impeller; the magnetic suspension guide rail 8 includes a magnetic suspension inner ring guide rail 12 and a magnetic suspension outer ring guide rail 13 , the magnetic suspension inner ring guide rail 12 comprises an inner ring upper guideway 14 and an inner ring lower guideway 15 , and the magnetic suspension outer ring guide rail 13 comprises an outer ring upper guideway 16 and an outer ring lower guideway 17 ; the magnetic suspension inner ring 10 of the magnetic suspension rotary-wing wheels 5 goes around the magnetic suspension shaft 7 in the radial direction (X-X) and is disposed between the inner ring upper guideway 14 and the inner ring lower guideway 15 in the axial direction (Y-Y); the magnetic suspension outer ring 11 of the magnetic suspension rotary-wing wheels 5 is embedded in the electromotive ring 6 in the radial direction (X-X) and disposed between the outer ring upper guideway 16 and the outer ring lower guideway 17 in the axial direction (Y-Y).
The magnetic suspension rotary-wing wheels 5 of the electrical driven flying saucer based on magnetic suspension are suspended on the magnetic suspension shaft 7 in the radial direction (X-X) by relying on the magnetic suspension radial bearing formed by the magnetic suspension inner ring 10 and the magnetic suspension shaft 7 ; the magnetic suspension inner ring 10 of the magnetic suspension rotary-wing wheels 5 is suspended between the inner ring upper guideway 14 and the inner ring lower guideway 15 in the axial direction (Y-Y) by relying on the magnetic suspension axial bearing comprising the magnetic suspension inner ring 10 and the magnetic suspension inner ring guide rail 12 ; the magnetic suspension outer ring 11 of the magnetic suspension rotary-wing wheels 5 is suspended between the outer ring upper guideway 16 and the outer ring lower guideway 17 in the axial direction (Y-Y) by relying on the magnetic suspension axial bearing comprising the magnetic suspension outer ring 11 and the magnetic suspension outer ring guide rail 13 .
The magnetic suspension rotary-wing wheels 5 of the electrical driven flying saucer based on magnetic suspension, the electromotive ring 6 and the magnetic suspension shaft 7 constitute a magnetic suspension electric engine. The electric engine of the electrical driven flying saucer based on magnetic suspension may be designed according to general motor theories, the electromotive ring 6 is a stator, the magnetic suspension rotary-wing wheels 5 constitute a rotor, the magnetic suspension shaft 7 is a spindle, and the structure of an ordinary motor is formed. The electric engine of the electrical driven flying saucer based on magnetic suspension adopts a permanent magnet synchronous engine. Its structure is shown in FIG. 7 .
The permanent magnet synchronous motor is characterized by a simple and compact structure, low loss, high efficiency and easy manipulation and control. The rotor of a permanent magnet synchronous motor has different structure. For easy description of the principle, this embodiment adopts a simple plug-in structure and pairs of permanent magnets 23 are embedded in the magnetic suspension outer ring 11 to form an exciter field; as a stator, the electromotive ring 6 has a stator core 24 , stator grooves 25 are evenly distributed on the inner circle of the stator core 24 , and 3-phase symmetric stator windings 26 are distributed inside the stator grooves 25 according to a specific rule to form a rotating magnetic field and push the magnetic suspension rotary-wing wheels 5 as a rotor to rotate.
Embodiment 2
Radial Magnetic Suspension Structure of Rotary-Wing Wheels
An electrical driven flying saucer based on magnetic suspension is provided. Its magnetic suspension rotary-wing wheels 5 are suspended on the magnetic suspension shaft 7 in the radial direction (X-X) according to the magnetic suspension principle.
As shown in FIG. 5 , a radial magnetic suspension structure of the magnetic suspension rotary-wing wheels 5 is designed, pairs of magnets 22 are placed on the outer edges of the magnetic suspension inner ring 10 and the magnetic suspension shaft 7 of the magnetic suspension rotary-wing wheels 5 , the N poles of the magnets of the magnetic suspension inner ring 10 face the inside and the S poles face the outside; the S poles of the magnets of the magnetic suspension shaft 7 face the inside and the N poles face the outside. According to the principle that like poles of magnets expel, the N pole of the outer edge of the magnetic suspension inner ring 10 and the N pole of the outer edge of the magnetic suspension shaft 7 form a repulsive force. Therefore, the radial magnetic suspension structure of the magnetic suspension rotary-wing wheels 5 as shown in FIG. 5 may realize the suspension of the magnetic suspension rotary-wing wheels 5 in the radial direction (X-X) of the flying saucer.
Magnets 22 may be made from a homogeneous and evenly distributed permanent magnet material. Ideally, the outer edge of the magnetic suspension inner ring 10 and the outer edge of the magnetic suspension shaft 7 are in an equal-distance state. When the magnetic suspension rotary-wing wheels 5 are disturbed, the outer edge of the magnetic suspension inner ring 10 and the outer edge of the magnetic suspension shaft 7 may deviate from the equal-distance position. Nevertheless, as magnetic field intensity decreases with the increase of the distance and increases with the decrease of the distance, the magnetic suspension inner ring 10 and the magnetic suspension shaft 7 will automatically return to the equal-distance position. Obviously, the radial magnetic suspension structure of the permanent magnet rotary-wing wheel is a natural stable structure.
Alternatively, the magnets 22 may also be made from an electromagnet material. The radial (X-X) suspension structure of the magnetic suspension rotary-wing wheels 5 designed by using electromagnets may realize good controllability, easy implementation of various advanced control strategies and optimal axial (X-X) magnetic suspension effect of the magnetic suspension rotary-wing wheels 5 .
The magnets of the magnetic suspension inner ring 10 in FIG. 5 may be changed into a superconducting material. When it is in a superconducting state, according to the Meissner effect, the magnetic suspension inner ring 10 will form a repulsive force with the magnetic suspension shaft 7 , thereby realizing superconducting magnetic suspension. By then, if the magnets on the magnetic suspension shaft 7 are permanent magnets, the superconducting magnetic suspension can also obtain a natural stable structure; if the magnets on the magnetic suspension shaft 7 are electromagnets, the superconducting magnetic suspension can also obtain good controllability and may implement various advanced control strategies based on automation theories.
Embodiment 3
Axial Magnetic Suspension Structure of Rotary-Wing Wheels
An electrical driven flying saucer based on magnetic suspension is provided. Its magnetic suspension rotary-wing wheels 5 are suspended on the magnetic suspension guide rail 8 in the axial direction (Y-Y) according to the magnetic suspension principle, i.e.: the magnetic suspension inner ring 10 is suspended between the inner ring upper guideway 14 and the inner ring lower guideway 15 , and the magnetic suspension outer ring 11 is suspended between the outer ring upper guideway 16 and the outer ring lower guideway 17 .
As shown in FIG. 6 , an axial magnetic suspension structure of the magnetic suspension rotary-wing wheels 5 is designed to make the N poles of the magnets of the magnetic suspension inner ring 10 and the magnetic suspension outer ring 11 face upward and the S poles face downward; the S poles of the magnets of the inner ring upper guideway 14 and the outer ring upper guideway 16 face upward and the N poles face downward; the S poles of the magnets of the inner ring lower guideway 15 and the outer ring lower guideway 17 face upward and the N poles face downward. According to the principle that like poles of magnets repel, the N pole at the top of the magnetic suspension inner ring 10 and the N pole at the bottom of the inner ring upper guideway 14 form a repulsive force, and the S pole at the bottom of the magnetic suspension inner ring 10 and the S pole at the top of the inner ring lower guideway 15 form a repulsive force; the N pole at the top of the magnetic suspension outer ring 11 and the N pole at the bottom of the outer ring upper guideway 16 form a repulsive force, and the S pole at the bottom of the magnetic suspension outer ring 11 and the S pole at the top of the outer ring lower guideway 17 form a repulsive force. Therefore, the radial magnetic suspension structure of the magnetic suspension rotary-wing wheels 5 as shown in FIG. 6 may realize the suspension of the magnetic suspension rotary-wing wheels 5 in the axial direction (Y-Y) of the flying saucer. In the radial magnetic suspension structure of the magnetic suspension rotary-wing wheels 5 as shown in FIG. 6 , the magnets may adopt a homogenous and evenly distributed permanent magnet material. Considering weight and other factors, the upper and lower guideways of the magnetic suspension guide rail 8 are designed and different magnetic field intensity is selected to make the magnetic suspension ring located in an approximately equal-distance position of the upper guideway and the lower guideway. When the magnetic suspension rotary-wing wheels 5 vibrate up and down under the influence of air current, the magnetic suspension inner ring 10 and the magnetic suspension outer ring 11 may deviate from the equal-distance position. However, as magnetic field intensity decreases with the increase of distance and increases with the decrease of distance, the magnetic suspension inner ring 10 and the magnetic suspension outer ring 11 will automatically return to the equal-distance position. Thus it may be seen, the axial magnetic suspension structure of the permanent magnet rotary-wing wheels is a natural stable structure. In the radial magnetic suspension structure of the magnetic suspension rotary-wing wheels 5 as shown in FIG. 6 , the magnets may also adopt an electromagnet material. The axial (Y-Y) suspension structure of the magnetic suspension rotary-wing wheels 5 designed with electromagnets may obtain good controllability, easily implement various advanced control strategies and obtain optimal axial (Y-Y) magnetic suspension effect of the magnetic suspension rotary-wing wheels 5 .
The magnets of the magnetic suspension inner ring 10 and the magnetic suspension outer ring 11 of the magnetic suspension rotary-wing wheels 5 in FIG. 6 may be changed into a superconducting material. When they are in a superconducting state, according to the Meissner effect, the magnetic suspension ring of the magnetic suspension rotary-wing wheels 5 will form a repulsive force with the upper guideway and the lower guideway, thereby realizing magnetic suspension. In this case, if the magnets on the inner magnetic suspension guide rail 12 and the outer magnetic suspension guide rail 13 are permanent magnets, the superconducting magnetic suspension can also obtain a natural stable structure; if the magnets on the inner magnetic suspension guide rail 12 and the outer magnetic suspension guide rail 13 are electromagnets, the superconducting magnetic suspension can also obtain good controllability and various advanced control strategies may be implemented according to the automation theory.
Embodiment 4
Electric Engine
An electrical driven flying saucer based on magnetic suspension is provided. The magnetic suspension rotary-wing wheel 5 of its rotary-wing system 3 , the electromotive ring 6 and the magnetic suspension shaft 7 constitute a magnetic suspension electric engine. The electric engine of the electrical driven flying saucer based on magnetic suspension may be designed according to the general motor principle, the electromotive ring 6 is a stator, the magnetic suspension rotary-wing wheels 5 constitute a rotor, the magnetic suspension shaft 7 is a spindle and an ordinary motor structure is formed.
The structure and principle of the electric engine of the electrical driven flying saucer based on magnetic suspension may be same as those of a synchronous motor, an asynchronous motor or a DC motor.
A typical embodiment of the electric engine of the electrical driven flying saucer based on magnetic suspension is a permanent magnet synchronous engine. Its schematic structure is as shown in FIG. 7 .
The permanent magnet synchronous motor is characterized by a simple and compact structure, low loss, high efficiency and easy manipulation and control. The rotor of the permanent magnet synchronous motor may have a different structure. For easy description of the principle, this embodiment adopts a simple plug-in structure and pairs of permanent magnets 23 are embedded in the magnetic suspension outer ring 11 to form an exciter field; the electromotive ring 6 as a stator has a stator core 24 , stator grooves 25 are evenly distributed on the inner circle of the stator core 24 , and the 3-phase symmetric stator windings 26 are distributed inside the stator grooves 25 according to a specific rule to form a rotating magnetic field and push the magnetic suspension rotary-wing wheels 5 as a rotor to rotate.
Embodiment 5
Coaxial Axial Dual Magnetic Suspension Electromotive Rotary Wings
An electrical driven flying saucer based on magnetic suspension adopts coaxial axial dual magnetic suspension electromotive rotary-wing systems when it improves its rotary-wing system to overcome the reactive torque of the rotary wings. The coaxial axial dual magnetic suspension electromotive rotary-wing systems include an upper rotary-wing system 18 and a lower rotary-wing system 19 . The upper and lower rotary-wing systems adopt a same structure and both comprise magnetic suspension rotary-wing wheels 5 , electromotive rings 6 , magnetic suspension shafts 7 and magnetic suspension guide rails 8 .
During work, the respective electromotive rings of the upper and lower rotary-wing systems generate rotating magnetic fields in reverse directions, which drive respective magnetic suspension rotary-wing wheels to rotate in reverse directions. The upper and lower magnetic suspension rotary-wing wheels maintain a same absolute rotation speed and may offset respective reactive torques and maintain stability of the saucer shell; the upper and lower rotary-wing systems provide lift or forward thrust in the same time and greatly enhance the power performance of the flying saucer.
Embodiment 6
Coaxial Radial Dual Magnetic Suspension Electromotive Rotary Wings
An electrical driven flying saucer based on magnetic suspension adopts coaxial radial dual magnetic suspension electromotive rotary-wing systems when it improves its rotary-wing system to overcome the reactive torque of the rotary wings. The coaxial radial dual magnetic suspension electromotive rotary-wing systems include an inner rotary-wing system 20 and an outer rotary-wing system 21 . The upper and lower rotary-wing systems adopt a same structure and both comprise magnetic suspension rotary-wing wheels 5 , electromotive rings 6 , magnetic suspension shafts 7 and magnetic suspension guide rails 8 .
During work, the respective electromotive rings of the inner and outer rotary-wing systems generate rotating magnetic fields in reverse directions, which drive respective magnetic suspension rotary-wing wheels to rotate in reverse directions. The inner and outer magnetic suspension rotary-wing wheels maintain a rated absolute speed difference and may offset respective reactive torques and maintain stability of the saucer shell; the inner and outer rotary-wing systems provide lift or forward thrust in the same time and enhance the power performance of the flying saucer.
The coaxial radial dual magnetic suspension electromotive rotary-wing systems adopt dual rotary-wing systems placed on a same plane, so the air current disturbance between the two magnetic suspension rotary-wing wheels is reduced significantly and the controllability and stability of the rotary-wing systems are significantly improved.
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A magnetic suspension electric rotor flying saucer comprises: a saucer shell ( 1 ), a saucer cabin ( 2 ), a rotor system ( 3 ), and a control system ( 4 ). The rotor wing system is a magnetic suspension electric rotor wing system ( 3 ) composed of a magnetic suspension rotor wing wheel ( 5 ), an electrodynamic ring ( 6 ), a magnetic suspension shaft ( 7 ) and magnetic suspension lead rails ( 8 ). The electrodynamic ring ( 6 ), the magnetic suspension shaft ( 7 ) and the magnetic suspension lead rails ( 8 ) are fixed on the saucer shell ( 1 ). The magnetic suspension rotor wing wheel ( 5 ) is suspended in space limited by the electrodynamic ring ( 6 ), the magnetic suspension shaft ( 7 ) and the magnetic suspension lead rails ( 8 ) and rotates around the magnetic suspension shaft ( 7 ) by the electromagnetic thrust.
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This is a continuation-in-part of U.S. patent application Ser. No. 09/138,049, filed Aug. 21, 1998 now abandoned and which claims benefit of 60/088,555, filed Jun. 9, 1998, and bearing the title “Manufacturing Process For Noncontinuous Galvanization With Zinc-aluminum Alloys Over Metallic Manufactured Products.” Said application, hereinafter referred to as the “'049 application,” is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention refers to an improvement in the production of a zinc-aluminum alloy coating by immersion into molten metal baths and, more precisely, it refers to an improved process to discontinuously coat metallic bodies with zinc-aluminum alloys, by immersion in molten baths of said alloy.
BACKGROUND OF INVENTION
State of the Art
The discontinuous coating of metal bodies with a zinc-aluminum alloy is disclosed in the '049 application. Also as disclosed therein, drawbacks were encountered whereby uneven coatings or bare spots were obtained. Prior to the method disclosed therein, acceptable coatings were obtainable only with difficulty and by complicated, time consuming procedures.
The '049 application discloses a very good solution to such drawbacks, essentially comprising a method whereby the metal bodies to be discontinuously coated are preferably electrolessly pre-coated with a metallic pre-coating, before the immersion in the zinc-aluminum molten bath. The pre-coating is preferably a metal chosen from the group consisting of copper and nickel. Cobalt could be used, but is not preferred for a number of reasons, including cost and toxicity. The pre-coating forms a very thin coating, permitting a good adhesion of the zinc-aluminum alloy.
However, even if a pre-coating is used, the final layer of zinc-aluminum alloy may present a number of adhesion, compactness and appearance defects, attributed to the formation of metal oxides during air drying after the pre-coating and prior to the immersion of the pre-coated metal body in the Zn—Al bath. Such oxides prevent a proper formation of the final coating. This outer oxidation layer, particularly for baths containing 0.1-25% wt. % Al, is a physical barrier against the inter-action or reaction of the pre-coating metal and the Al in the bath.
Attempts were made to eliminate such superficial oxidation through mechanical polishing with emery papers aided by a final treatment with alumina impregnated cloths. Another treatment utilized was a surface activation by pickling in diluted hydrochloric acid, followed by water rinsing and drying. Neither of these approaches yielded consistently satisfactory results.
It is an object of the present invention to avoid those drawbacks, through a surface conversion treatment resulting in a compact, continuous and glossy coating.
DESCRIPTION OF THE INVENTION
According to present invention, after metal bodies are pre-coated with a thin protective metallic layer, but before they are immersed in a zinc-aluminum alloy molten bath, they undergo a surface activation treatment by immersion in a diluted solution containing hydrochloric acid. The objective of the activation treatment is to form a salt layer on the pre-coated surface which protects the surface from further oxidation prior to immersion in the Zn—Al bath. By immersing the pre-coated metal object in hydrochloric acid, a reaction between the pre-coating metal and the hydrochloric acid occurs, thereby forming a chloride salt. When the object is then removed from the hydrochloride acid solution, the acid solvent is allowed to evaporate leaving a dry protective salt layer on the surface. When treatment of the pre-coated surface with hydrochloric acid is followed by water washing, poor results can occur due to the washing away of the salt solution on the object surface. When the surface is then dried, oxides can form on the surface, which oxides interfere with the subsequent galvanizing step in the Zn—Al alloy bath.
Moreover, and as is disclosed in the '049 application, the metallic pre-coating either substantially completely reacts with the Al in the Zn—Al bath (such as is the case with a Ni pre-coating to form an interface Ni—Al compound) or dissolves in the bath (such as is the case with a Cu pre-coating), thereby exposing the surface of the metal object to the Zn—Al alloy. It is therefore necessary that the chloride salt layer created by the activation step have a melting point below the temperature of Zn—Al bath, such that the chloride salt melts in a relatively short time upon immersion of the object in the Zn—Al bath. When Cu is used as the pre-coating metal, the preferred chloride salt that is formed is CuCl. As noted in the Handbook of Chemistry and Physics (CRC Press, 77 th Edition, 1996-1997, pp. 4-54 and 4-55), the melting point of CuCl is 430° C., which is sufficiently low to cause melting when the salt surface is immersed in a Zn—Al bath at a temperature above 430° C., e.g. 450° to 600° C. The melting point of CuCl 2 , on the other hand, is 630° C., too high for consistently good results. In both instances, the chloride reacts with the Cu pre-coating. It is therefore preferred that the reaction between Cu and Cl be controlled so that excess Cl does not cause the CuCl reaction product to further react and form substantial amounts of CuCl 2 . This is accomplished by controlling the Cl concentration in the hydrochloric acid bath, and/or by limiting the reaction time, for example by limiting the immersion time in the hydrochloric acid to a few seconds.
In general, the chloride salt or mixture of chloride salts should melt between about 300 and 600° C., depending upon the Zn—Al composition.
The activation bath may also contain an acid ionic or non-ionic surfactant, as well as one or more added chlorides of elements of groups IA, IIA, IB and IIB. The diluent for the hydrochloric acid is water or an alcohol chosen between methanol, ethanol, propanol, and the like, preferably ethanol and glycerol.
The formation of the thin pre-coating onto the metal body to be coated is obtained through electrolytic or electroless deposition or cementation. Cementation is preferred since it results in a very thin, monoatomic coating.
The concentration of the hydrochloric acid in the treatment solution preferably is between 5 and 20% vol., preferably between 10 and 15, while the added chlorides concentration preferably is between 10 and 100, preferably between 10 and 24, g/l.
Due to the complete evaporation of the solvent, the salts contained in said solution precipitate onto the pre-coated surfaces. In the case of pre-coating with copper, a mixture of cuprous chloride with the above salts is obtained, thus protecting from oxidation the copper surface and acting as fluxant, as they melt during immersion into the zinc-aluminum alloy bath, at a temperature between 430 and 600° C., depending upon the amount of aluminum in the alloy. This ensures a clear surface to be coated and thus a high quality coating.
The following Examples will show some preferred embodiments of present invention, without in any way limiting scope and objects of the invention.
EXAMPLE 1
Copper was coated on steel samples by cementation with ferrous ion, immersing said bodies for 20 s in an aqueous solution at room temperature, containing 10 g/l of CuSO 4 and of 98% H 2 SO 4 .
To improve the homogeneity of the copper coating, the superficial roughness of the steel samples was reduced and the surface oxides removed by polishing said surface with emery paper and with a final treatment with alumina impregnated cloths. After degreasing, the samples were copper coated by cementation, water rinsed, air dried and then immersed for 30, 60, 120, 240, 480, 960 s in a molten bath of zinc alloy containing 5% by weight of aluminum (Zn—Al 5%) at 450° C.
No immersion time gave good coatings. Though a very quick dissolution of the copper layer was expected, due to its very high solubility in molten zinc, copper was still present on the samples surface, even after long immersion times. As above discussed, this is attributed to surface oxidation of copper to CuO 2 before the immersion into the molten bath, or during the immersion, at the interface air/bath.
EXAMPLE 2
Steel samples were degreased, washed, pickled, rinsed and electrolitically copper coated (to a thickness of about 1 μm) in a solution at 40° C. containing 402 g/l of copper pyrophosphate, 98 g/l of potassium pyrophosphate, with addition of phosphoric acid to bring the pH to 8.5. A copper anode was utilized, with a current density of between 3 and 8 A/dm 2 . The copper-coated samples were again rinsed and then air dried. Said samples underwent a surface activation treatment in 10% by weight hydrochloric acid, at room temperature for a few seconds, followed by water rinsing and air drying. They were then immersed in a Zn—Al5% molten bath at 450° C. for 4 minutes. Results were not reproducible, in that they are strongly dependant on the time between drying and immersion into the molten bath.
EXAMPLE 3
Copper was electrolitically coated onto steel samples, utilizing the same solution of Example 2.
The samples were degreased, washed, pickled, rinsed, copper coated, again rinsed and air dried. Then, they underwent a surface activation treatment in a 10% by weight HCl solution, at room temperature for a few seconds, followed by air drying at 50° C.
As solvents for HCl were separately utilized, water, methanol, ethanol, propanol, and glycerol. Mixtures of these solvents may also be used.
The samples were then immersed in a Zn—Al 5% molten bath at 450° C. for 4 minutes, and then extracted at a speed of about 15 mm/s.
All the samples, for any solvent utilized for the surface activation, were fully coated, with smooth, bright surfaces.
A SEM analysis, at a magnification of 1000×, of metallographic sections of the samples did not reveal any formation of fragile phases at the interface, with a coating total thickness of about 30 μm.
Adhesion of the coating was tested by 90° bending. The coating proved perfectly adherent and crack-free both in the compression and the elongation zones.
EXAMPLE 4
Since very good results were obtained with electrolitically coated samples, other experiments were carried out utilizing cemented samples. A copper coating was produced utilizing the solution of Example 1.
Samples were degreased, washed, pickled, rinsed, copper coated, again rinsed and then air dried. A surface activation treatment was then carried out, consisting in immersing for a few seconds the samples in a 10% b/w solution of HCl in glycerol, and then air drying them at 50° C.
The samples were then immersed for 4 minutes in a molten bath of Zn—Al 5% alloy at 440° C., and subsequently extracted at a rate of around 15 mm/s. The bath temperature can also be lowered, since with electroless coating a lower amount of copper to be dissolved into the bath is present on sample surfaces.
The coated sample surfaces had a very good appearance, without any fragile phases growth at the interface, with a coating thickness of about 30 μm.
EXAMPLE 5
The following Example also employed cementation as a copper coating technique.
The surface conversion treatment tested is reliable and yields coatings that are of good quality.
Samples are prepared by degreasing in a solution of 80 g/l solution of alkaline soap at 50-60° C. for 10 minutes, washing in demineralized water at room temperature, pickling in HCl 1:1 at room temperature for 3 minutes, and washing in demineralized water at room temperature. The cementation coating with copper follows, in a 10 g/l solution of copper sulfate and 10 g/l of 98% sulfuric acid, at room temperature for about 20 s. The samples are then rinsed, at room temperature, in demineralized water and then dried in air at 50-60° C. The surface conversion treatment is then carried out by immersion in a 1:10 solution of HCl in methyl alcohol at room temperature for a few seconds and subsequent drying in air blown at 50-60° C. The sample is then immersed in a molten Zn—Al 5% alloy bath at 440° C. for 3 to 4 minutes. Samples are then extracted from the bath at a rate of between 10 and 15 mm/s, and cooled in still air. Consistently good coatings are obtained.
EXAMPLE 6
Various Zn—Al baths were tested, with varying concentrations of Al. Al ranges below 0.0005% also were tested, although these concentrations are so low as not to yield the corrosion-resistant properties of Zn—Al coatings having higher Al concentrations (e.g. >0.1%, preferably about 5%, and up to 25% or even higher). Also, the problems heretofore encountered with higher Al-content Zn—Al coatings are not encountered with very low Al concentrations (i.e., conventional Zn coatings result). In the following tests, an electroless Cu flash to a thickness of 0.3 μm was followed by hot-dip into Zn—Al at 450° C., 6 min. immersion time.
wt. %
Activation
No activation
Zn 99.999
X
Good coating quality
completely covering
workpiece
Zn + 0.0005 Al
X
Good coating quality
completely covering
workpiece
Zn + 0.005 Al
X
Workpiece not
completely coated
Zn + 0.005 Al
X
Good coating quality
completely covering
workpiece
Zn + 0.1 Al
X
10% uncoated area
Zn + 0.1 Al
X
Good coating quality
completely covering
workpiece
Zn + 0.5 Al
X
50% uncoated area
Zn + 0.5 Al
X
Good coating quality
completely covering
workpiece
Zn + 5 Al
X
80% uncoated area
Zn + 5 Al
X
Good coating quality
completely covering
workpiece
Though the invention was described with reference to a treatment in a molten Zn—Al 5% b/w bath, the aluminum content can be varied in a vast composition field, generically comprised between 1 and 60% b/w, without substantial modifications to the process.
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A process for non-continuous galvanization of a metal object with a Zn—Al alloy including the steps of pre-coating the object with a metallic layer of sufficient thickness to protect the object from oxidation and yet sufficiently thin to permit the pre-coating to substantially completely react with or dissolve in the molten Zn—Al bath, subjecting the precoated object to a surface activation treatment by immersing it in hydrochloric acid and thereafter allowing the surface to dry with a protective coating of a chloride salt, and thereafter immersing the object in the Zn—Al bath.
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BACKGROUND
The invention relates to an endoscope having two lenses formed at a distal end, said lenses being arranged offset with respect to one another for recording a stereoscopic image, and having an image recording chip, which is configured for electronically recording images captured by the lenses, wherein a mirror, movable between a first position and a second position, is provided in the distal end region, wherein, in the first position, an image captured by a first lens of the two lenses can be conducted onto the image recording chip and, in the second position, an image captured by a second lens of the two lenses can be conducted onto the image recording chip.
The invention furthermore relates to a method for recording at least one stereoscopic image by means of an endoscope.
In order to evaluate the images captured by the two lenses, previous proposals suggested guiding the optical beam paths through the endoscope tube and evaluating them separately at the proximal end.
Alternative proposals suggested using one image recording chip for both lenses, wherein different recording regions of the image recording chip are employed for respectively one lens. Here, each lens respectively only uses half of the recording surface of the image recording chip, which is disadvantageous in terms of the achievable image resolution.
There has also been a proposal to develop a prism which unifies the beam paths downstream of the lenses and which, by means of polarizable attachments—so-called optical or electronic shutters—is configured in such a way that the various beam paths can be switched off separately from one another. However, it was found that the use of such shutters leads to an undesirable reduction in the conducted luminous energy.
SUMMARY
The invention is based on the object of improving arrangements of stereoscopic lenses in endoscopes.
In order to achieve this object, provision is, according to the invention, made in an endoscope of the type mentioned at the outset for respectively one deflection prism to be arranged behind each lens in the beam direction, by means of which deflection prism the image captured by the respective lens can be deflected onto the mirror, and for the deflection prisms to be formed on an integral prism body. Arranging the image recording chip in the distal end region provides the advantage that the beam paths required for image capture can be formed to be as short as possible. Hence, a desired flexibility of the endoscope can be achieved in the remaining sections in a simple fashion. The use of an adjustable mirror on the one hand offers the advantage of being able to employ the recording surface of the image recording chip in an optimum fashion for both images of the stereoscopic image and on the other hand offers the advantage of the luminous energy passing along the beam path being attenuated as little as possible. It is therefore possible to provide an endoscope which can provide high resolution and high quality images while having small dimensions.
An advantage arising when using deflection prisms is that it is possible to obtain a comparatively short length dimension.
A particularly compact design is achievable as a result of the fact that the deflection prisms are formed on an integral prism body. Moreover, the assembly of the endoscope is simplified since fewer components have to be assembled individually.
A simple mechanical arrangement arises if the mirror is suspended in a pivotable fashion. As a result, the mirror can be moved between the positions by pivoting.
In one embodiment of the invention, provision can be made for an actuation apparatus, by means of which the mirror can be adjusted electrically. Here, it is advantageous that the mirror can be adjusted in a very compact space. It is furthermore advantageous that the current position of the mirror can easily be synchronized with a downstream image processing unit, for example in order to enable the assignment of the right-hand and left-hand images of the stereoscopic image in a simple fashion.
By way of example, the mirror can be embodied as a DLP-mirror. DLP-mirrors (microsystems also known as DMD-mirrors [digital micro-mirror device mirrors]) are known per se, for example for use in beamers, and are distinguished by small spatial requirements and by reliable mechanical functional properties.
In one embodiment of the invention, provision can be made for the mirror to be suspended in a holding frame. Hence, the pivoting movement of the mirror can be guided in a simple fashion.
In one embodiment of the invention, provision can be made for the mirror and the holding frame to be integrally connected. It is furthermore advantageous that a mechanically robust suspension of the mirror can be provided.
In one embodiment of the invention, provision can be made for the mirror and the holding frame to be cut to size from a flat material. The production can thus be simplified. It is furthermore advantageous in this case that the spatial requirements can be minimized.
In one embodiment of the invention, provision can be made for the holding frame of the mirror to be attached to the prism body. It is advantageous in this case that the mirror can be inserted into the endoscope together with the prism body in a common production step. It is furthermore advantageous that the mirror, in the assembled position thereof, can be automatically aligned or alignable in relation to the deflection mirrors.
It is particularly expedient if the mirror can be pivoted in the case of an elastic deformation of a connecting web between the mirror and the holding frame or a holding frame. In this case, it is advantageous that a mechanically robust suspension is created. By way of example, provision can be made for the pivoting of the mirror to be able to be brought about by means of switchable electrostatic fields. To this end, corresponding field generators of the actuation apparatus or an actuation apparatus of the mirror can be formed, which exert an electrostatic or electromagnetic force onto the mirror and thus pivot the latter between the aforementioned two positions.
In one embodiment of the invention, provision can be made for the prism body to have a passage opening, through which beam paths are deflected from the lenses onto the image recording chip. The result of this is particularly compact beam guidance and the prism body can be supported by a sleeve or a wall of the endoscope.
A particularly stable embodiment can provide for the prism body to have an annular design and form a passage opening or the passage opening. In a further embodiment, the prism body can have an open or interrupted design on a circumferential section of the annular shape.
In one embodiment of the invention, provision can be made for the prism body to be a single crystal. It is advantageous in this case that the deflection prisms can be formed in a simple fashion. By way of example, the prism body can be made from a wafer with a corresponding thickness.
For manufacturing which can be reproduced particularly well, provision can be made for the prism body to be produced from a single crystal block by an etching process. It is advantageous in this case that the external geometry of the prism body can be defined and manufactured in a simple fashion.
It is particularly expedient if the deflection prisms respectively have a preferably planar reflection surface. In this case, provision can be made for the reflection surfaces respectively to lie in a crystal plane of the prism body. It is advantageous here that the angle at which the beam path from the respective lens is incident on the deflection prism and the reflection surface can easily be prescribed by the crystal geometry. What can, in a simple and reproducible fashion, be achieved by this is that the reflection surface has defined angles in relation to the external geometry of the prism body. Moreover, the reflection surfaces can easily be formed in the prism body by etching. Compared to convex or concave reflection surfaces, for example compared to hollow mirrors, flat reflection surfaces offer the advantage of aberrations being largely avoidable.
By way of example, it is possible to obtain a length dimension that is as short as possible by virtue of the fact that the reflecting surface of the mirror is formed on the side of the mirror facing away from the lenses. In this case, the deflection prisms can be configured in such a way that the light rays respectively incident from the lenses are cast back at the deflection prisms. This can result in a Z-shaped beam path.
For the purposes of a further space-saving embodiment, provision can be made for the mirror to be suspended from the prism body.
In order to be able to employ the image recording chip in an optimum fashion for each image, provision can be made for the mirror to illuminate, i.e. completely or at least substantially completely fill, the recording region of the image recording chip in each of the two positions.
In one embodiment of the invention, provision can be made for at least one lens element to be arranged in the beam path between the mirror and the image recording chip. By using a lens element, the beam path can easily be widened or focused in such a way that the recording region of the image recording chip is illuminated. This can be used for reducing the required installation length. It is particularly expedient for the lens element to be embodied as magnification lens element. Hence the recording region of the image recording chip can easily be illuminated with an otherwise tightly guided beam path.
In order to be able to penetrate very small openings without detriment to the image quality of image resolution, provision can be made for the distal end region to have a cross section which is determined by the dimensions of the image recording chip. The cross section is preferably dimension in such a way that the image recording chip just fits into the cross section.
Simple optical geometries emerge if the image recording chip is arranged with its recording region looking in the longitudinal direction of the endoscope. Hence the sensor surface is aligned perpendicular to the longitudinal direction.
In order to achieve the object, the invention provides, in the method mentioned at the outset, for a mirror, arranged in an end region of the endoscope, to be mechanically adjusted between a first position and a second position, wherein, in the first position, an image captured by a first lens and reflected by a first reflection surface of a prism body is deflected onto an image recording chip arranged in a distal end of the endoscope and, in the second position, an image captured by a second lens and reflected by a second reflection surface of the prism body is deflected onto the image recording chip, and for the image recording chip to record images when the mirror is positioned in the first position and in the second position and provide said images for stereoscopic viewing. The mirror is preferably adjusted alternately between the two positions. The invention therefore provides a simple manageable method, by means of which images for stereoscopic view can be obtained with the highest possible image resolution and image quality in the smallest possible space. An optical throughput of the captured images from the distal end to the proximal end can be dispensed with. The images can be transmitted electronically, which can be achieved in a space-saving fashion.
In one embodiment of the invention, provision can be made for the mirror to be held integrally connected to a holding frame, wherein the change between the first position and the second position of the mirror is brought about under elastic deformation of a connecting element between the mirror and the holding frame.
A device according to the invention is preferably used in the method according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in more detail on the basis of exemplary embodiments; however, it is not restricted to these exemplary embodiments. Further exemplary embodiments emerge from combining individual features or a number of features of the patent claims amongst themselves and/or with individual features or a number of features from the exemplary embodiments.
In detail:
FIG. 1 shows an endoscope according to the invention in a three-dimensional perspective view,
FIG. 2 shows a schematic diagram of the endoscope in accordance with FIG. 1 , with the mirror in a first position,
FIG. 3 shows the arrangement in accordance with FIG. 2 , with the mirror in a second position, and
FIG. 4 shows a further endoscope according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The endoscope, which is shown in a schematic diagram in FIG. 1 and denoted in its entirety by 1 , has a first lens 3 and a second lens 4 at its distal, i.e. facing away from the user, end 2 . The lenses 3 , 4 are arranged offset to one another and next to one another in a manner known per se for recording a stereoscopic image and capture a right-hand and a left-hand image.
The captured images are recorded electronically by an image recording chip 5 . In order to be able to supply the right-hand and left-hand images to the image recording chip 5 in an alternating fashion, provision is made for a mirror 7 in the distal end region 6 , which accommodates the lenses 3 , 4 and the image recording chip 5 .
FIG. 2 and FIG. 3 show, in a plan view, the components of the endoscope 1 according to the invention, which components are required to explain the functional principle and arranged in the distal end region 6 . The remaining components, required in an endoscope 1 , and the prism body 20 , described below, have been omitted in order to simplify the illustration.
The mirror 7 is arranged such that it can be adjusted between a first position 8 , which is shown in FIG. 2 , and a second position 9 in accordance with FIG. 3 .
In the exemplary embodiment, the mirror 7 is embodied as DLP-mirror and embodied in an electronically pivotable fashion. The details in this respect are known per se and have not been imaged here in order to simplify the illustration.
In the first position 8 in accordance with FIG. 2 , the mirror 7 with its reflecting surface 10 forms a first beam path 11 , by means of which an image captured by the first lens 3 can be conducted and is conducted onto the image recording chip 5 through the passage opening 21 of the prism body 20 .
Hence, in the first position 8 of the mirror 7 , the image recording chip 5 records a right-hand image via the first lens 3 .
In the second position 9 of the mirror 7 , cf. FIG. 3 , the reflecting surface 10 defines a second beam path 12 , via which the image captured by the second lens 4 can be conducted and is conducted onto the image recording chip 5 through the passage opening 21 of the prism body 20 .
In the second position 9 of the mirror 7 , the image recording chip 5 therefore receives a left-hand image via the second lens 4 .
FIG. 1 shows the mirror in a central position, in which the surface normal 13 of the reflecting or mirrored surface 10 is aligned along the direction of extent of the distal end region 6 and faces away from the lenses 3 , 4 . In this position, no image is conducted onto the image recording chip 5 from the lenses 3 , 4 .
In order to obtain the Z-shaped course of the beam paths 11 , 12 , visible in FIG. 2 and FIG. 3 , provision is made for deflection prisms 14 , 15 , which cast the respective rays arriving at the lenses 3 , 4 back onto the mirror 7 .
The deflection prisms 14 , 15 are formed on a common prism body 20 and hence integrally connected.
The prism body 20 is pressed or cast as a glass body. It can also be polished or etched from a single crystal.
The deflection prisms 14 , 15 respectively have one reflection surface 22 , 23 , at which the beam paths 11 , 12 are reflected. The first beam path 11 of the image captured by the first lens 3 is therefore reflected at the first reflection surface 22 of the prism body 20 , while the second beam path 12 of the image captured by the second lens 4 is reflected at the second reflection surface 23 of the prism body 20 .
The prism body 20 surrounds a central passage opening in an annular fashion, through which passage opening the beam paths 3 , 4 are guided onto the recording region 17 of the image recording chip 15 .
The prism body 20 is formed with an external contour which fills the cross section 18 of the endoscope 1 . Hence the prism body 20 is held directly by the sleeve 19 .
A lens element 16 —a positive lens element—is arranged between the mirror 7 and the image recording chip 5 , which lens element widens or focuses the beam paths 11 , 12 in such a way that the sensitive recording region 17 of the image recording chip 5 is illuminated.
In order to enable the largest possible recording region 17 in the case of the smallest possible dimensions of the endoscope 1 in the distal end region 6 , the dimensions of the image recording chip 5 are fitted into the cross section 18 of the distal end section 6 .
With its recording region 17 , the image recording chip 5 looks at the lenses 3 , 4 in the longitudinal direction of the distal end region 6 .
A protective sleeve 19 or a protective tube surrounds the distal end region 6 or the whole endoscope 1 . The external contour of the prism body 20 is matched to the cross section 18 of the endoscope in such a way that the rounded-off corners 28 , 29 , 30 , 31 of the prism body 20 , otherwise having a rectangular or square cross section transversely to the longitudinal axis of the endoscope 1 , are fitted into the sleeve 19 or the tube.
In the exemplary embodiment shown in FIGS. 1 to 3 , the lenses 3 , 4 are formed separately from one another. In further exemplary embodiments, the lenses 3 , 4 can also be formed on a common optical element. In this case, the lenses 3 , 4 can consist of a common lens element.
In the exemplary embodiment in accordance with FIGS. 1 to 3 , the deflection prisms 14 and 15 are be formed integrally on a common optical element—the prism body 20 .
A further exemplary embodiment is shown in FIG. 4 , in which components with the same function are denoted by the same reference sign as in FIGS. 1 to 3 . The functional description provided there therefore also applies to this exemplary embodiment.
In the exemplary embodiment in accordance with FIG. 4 , provision is likewise made for an integral prism body 20 , on which the deflection prisms 14 , 15 are formed.
The annular shape of the prism body 20 , by means of which the passage opening 21 is surrounded, renders it possible to suspend the mirror 7 on the prism body 20 in such a way that the mirror 7 guides the beam paths 11 , 12 onto the recording region 17 through the passage opening 21 .
On two sides, the mirror 7 is integrally connected to a rectangular holding frame 25 , which is merely indicated and not visible in any more detail, via connecting webs 24 . The holding frame 25 extends around the passage opening 21 at the edge of the latter and is attached to the prism body 20 over a large surface. The mirror 7 , the connecting webs 24 and the holding frame 25 are cut out of flat material.
The prism body 20 is etched out of a single crystal.
Here, the reflection surfaces 22 , 23 are embodied in such a way that they respectively describe one crystal plane of the prism body 20 .
Hence the reflection surfaces 22 , 23 keep a defined angle in relation to the side surfaces 26 , 27 and the remaining side surfaces of the prism body 20 if the side surfaces 26 , 27 and the remaining side surfaces likewise describe crystal planes of the prism body 20 . These angles are fixedly prescribed by the crystal structure of the single crystal and set during the etching process.
During operation of the endoscope 1 , the mirror 7 is alternately pivoted between the positions 8 , 9 . In the process, the connecting webs 24 are deformed elastically. These connecting webs 24 therefore bring about a restoring force for the mirror 7 to return to the rest position as per FIG. 4 . The image recording chip 5 is read-out synchronously thereto, and so left-hand and right-hand images are captured separately. These images are provided for stereoscopic viewing.
The deflection of the mirror 7 is brought about by electrostatic or electromagnetic fields, which are exerted onto the mirror of via an appropriate field generator (not illustrated in any more detail). Such switchable field generators for generating electrostatic or electromagnetic fields are known per se.
A proposal for the endoscope 1 provides that the mirror 7 , which can be moved by mechanical or electrical means, is arranged between two lenses 3 , 4 which are configured for stereoscopic image recording and an image recording chip 5 , by means of which the light captured by the lenses 3 , 4 can alternately be guided onto the image recording chip 5 .
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An endoscope ( 1 ) is provided in which a mechanically or electrically adjustable mirror ( 7 ) is interposed between two lenses ( 3, 4 ) adapted for stereoscopic image recording and an image recording chip ( 5 ), the mirror allows light captured by the lenses ( 3, 4 ) to be alternately guided onto the image recording chip ( 5 ).
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FIELD OF DISCLOSURE
[0001] The present invention relates to a washer, and more particularly, to a washer having a heating element retainer.
BACKGROUND
[0002] FIG. 1 illustrates a conventional washer 2 having a tub 6 and a rotatable drum 4 in the tub 6 . FIG. 2 illustrates a side view of an assembly of the tub 6 and drum 4 .
[0003] The tub 6 may have an opening that permits a heating element (not shown) to penetrate a wall of the tub 6 of the washer 2 . A base of the heating element typically may be hermetically sealed in the cavity, which is formed in the tub 6 of the washer 2 . A heating element retainer (not shown) typically is provided to secure the heating element in the cavity of the tub 6 .
SUMMARY
[0004] In the assembly of a conventional washer, a heating element retainer generally may be inserted into an opening formed in the tub of the washer. The heating element retainer typically may be configured to retain the heating element in a secure manner in the cavity.
[0005] FIGS. 3A to 3E show an exemplary assembly process of a conventional heating element retainer and heating element. In order to secure the heating element 26 , some conventional heating element retainers 36 may have a plate 38 that is perpendicular to the longitudinal extent of the heating element 26 . In some conventional retainers 36 , the plate 38 may have a complex design of a hole 42 , which may be, for example, a notch, slot, groove, etc., that receives the heating element 26 as the heating element 26 is inserted in a direction parallel to the longitudinal extent of the heating element 26 . In some conventional retainers 36 , the plate 38 may be retained in the hole 42 by frictional forces between the surfaces of the hole 42 in the plate 38 and surfaces of the heating element 26 . In some other conventional retainers 36 , the plate 38 may have a complex design of tabs or spring pieces formed in the hole 42 to press against the heating element 26 .
[0006] In the conventional heating element retainer 36 , the plate 38 typically may be located near the middle of the retainer 36 along a longitudinal extent of the retainer 36 . Accordingly, when the heating element 26 is completely assembled in the retainer 36 , the plate 38 typically may retain the heating element 26 near a middle portion of the heating element 26 with respect to a longitudinal extent of the heating element 26 , as shown in FIG. 3E .
[0007] An exemplary assembly process of the conventional heating element retainer 36 and heating element 26 will now be described with reference to FIGS. 3A to 3E .
[0008] As shown in FIGS. 3A and 3B , when the heating element 26 is inserted into the cavity 40 of the tub 6 , a first end of the heating element 26 typically may reach the plate 38 of the retainer 36 before the base 24 of the heating element 26 can be aligned in the cavity 40 . Therefore, the heating element 26 may need to be aligned with the hole 42 by the installer before the base 24 of the heating element 26 can be aligned in the cavity 40 . As shown in FIGS. 3A and 3B , the installer may have limited or no visibility with respect to the location of the hole 42 in the plate 38 , which is inside the cavity 40 of the tub 6 . Hence, the first end of the heating element 26 typically may contact the surface of the plate 38 of the retainer 36 , as shown in FIGS. 3A and 3B , instead of passing through the hole 42 . In this case, the installer may need to make several attempts to align the heating element 26 with the hole 42 in the plate 38 until the heating element 26 is successfully installed in the hole 42 , which may increase the time and effort to install the heating element 26 .
[0009] Next, as shown in FIG. 3C , when the heating element 26 is inserted into the hole 42 in the plate 38 , a force F 0 may be applied to the heating element 26 by the plate 38 , which may cause the heating element 26 to be tilted or rotated in a plane that it not perpendicular to the plate 38 . Accordingly, the heating element 26 may be misaligned during insertion into the cavity 40 of the tub 6 , which may cause the base 24 of the heating element 26 to catch on or be interfered with by a top of the cavity 40 on the tub 6 , as shown in FIG. 3C . Therefore, in the conventional systems, the base 24 of the heating element 26 may need to be manually aligned with the cavity 40 using an installation tool 50 , as shown in FIGS. 3C and 3D . The installer may then need to apply a force F 1 to the tool 50 to push the base 24 of the heating element 26 into the cavity 40 , as shown in FIGS. 3C to 3E .
[0010] Moreover, as shown in FIGS. 3C to 3E , in most conventional systems, a large portion of the heating element 26 may need to be pushed through the hole 42 in the plate 38 of the retainer 36 , since the plate 38 may be in the middle of the retainer 36 with respect to the longitudinal extent of the retainer 36 . Thus, the installer may need to apply a large amount of force F 1 to the tool 50 to push the heating element 26 through the hole 42 until the heating element 26 is completely assembled in the retainer 36 , as shown in FIG. 3E .
[0011] Furthermore, in conventional washers, a different heating element retainer typically may need to be used for European design washers and U.S. design washers.
[0012] In comparison to the conventional retainers, the exemplary aspects of the invention may retain the heating element near a first end of the heating element, thereby reducing or preventing misalignment during the assembly of the heating element into the cavity of the tub. Thus, the heating element retainer according to the invention may be more easily installed as compared to the conventional retainers. The heating element retainer according to the invention also may minimize or reduce the time and effort to install the heating element in the heating element retainer.
[0013] Moreover, the exemplary aspects of the invention may reduce an amount of linear translation of the heating element into the engaging portion of the heating element retainer. Further, the exemplary aspects of the invention may reduce an amount of force needed to insert or push the heating element into the heating element retainer.
[0014] Additionally, the exemplary aspects of the invention also may provide greater flexibility for accommodate heating elements of different sizes. Thus, the exemplary aspects of the invention also may be universal, for example, to both European designs and U.S. designs.
[0015] The exemplary aspects of the invention also may reduce a complexity of the heating element retainer and reduce an amount of material that may be needed to form the heating element retainer, which may reduce manufacturing costs of the heating element retainer.
[0016] For example, an exemplary embodiment is directed to a washer including a housing, a tub in the housing, a laundry drum rotatably mounted in the tub, a heating element in the tub, and a heating element retainer, on an inner surface of the tub, for retaining the heating element. The heating element retainer includes a first longitudinal end and a second longitudinal end. The heating element further includes an engaging portion that is formed closer to the second longitudinal end than to the first longitudinal end, and that retains a first end of the heating element.
[0017] Another exemplary embodiment is directed to an apparatus including a tub, a heating element in the tub, and a heating element retainer, on an inner surface of the tub, for retaining the heating element. The heating element retainer includes a first longitudinal end and a second longitudinal end, and an engaging portion that is formed closer to the second longitudinal end than to the first longitudinal end, and that retains a first end of the heating element.
[0018] Another exemplary embodiment is directed to a heating element retainer for a washer having a housing, a tub in the housing, a laundry drum rotatably mounted in the tub, and a heating element in the tub. The heating element retainer includes a first longitudinal end and a second longitudinal end, and an engaging portion that is formed closer to the second longitudinal end than to the first longitudinal end, and that retains a first end of the heating element.
[0019] The features of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of exemplary embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The accompanying drawings are presented to aid in the description of embodiments of the invention and are provided solely for illustration of the embodiments and not limitation thereof.
[0021] FIG. 1 is a schematic view of a conventional washer.
[0022] FIG. 2 is a schematic side view of a conventional washer.
[0023] FIGS. 3A to 3E are schematic side views of an assembly process of a conventional heating element retainer and heating element.
[0024] FIG. 4 is a schematic side view of a heating element retainer according to an embodiment of the invention.
[0025] FIG. 5 is a schematic top view of a heating element retainer according to an embodiment of the invention.
[0026] FIG. 6 is a schematic front view of a heating element retainer according to an embodiment of the invention.
[0027] FIG. 7 is a schematic perspective view of a heating element retainer according to an embodiment of the invention.
[0028] FIGS. 8A to 8D are schematic side views of an assembly process of a heating element and heating element retainer according to an embodiment of the invention.
[0029] FIG. 9 is a schematic top view of an assembly of a heating element and heating element retainer according to an embodiment of the invention.
[0030] FIG. 10 is a schematic side view of a heating element retainer according to an embodiment of the invention.
[0031] FIG. 11 is a schematic side view of an assembly of a heating element and heating element retainer according to an embodiment of the invention.
DETAILED DESCRIPTION
[0032] Aspects of the invention are disclosed in the following description and related drawings directed to specific embodiments of the invention. Alternate embodiments may be devised without departing from the scope of the invention. Additionally, well-known elements of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention.
[0033] The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Likewise, the term “embodiments of the invention” does not require that all embodiments of the invention include the discussed feature, advantage or mode of operation.
[0034] With reference to FIGS. 1-11 , exemplary embodiments of the invention will now be described.
[0035] A heating element retainer 10 according to an embodiment of the invention may have a first longitudinal end 14 and a second longitudinal end 34 . The heating element retainer 10 may include an engaging portion, which may be positioned to be closer to the second longitudinal end 34 than to the first longitudinal end 14 , for receiving and securing a first end of the heating element 26 in the cavity 40 of the tub 6 .
[0036] For example, in the embodiment shown in FIGS. 4-7 , the retainer 10 may be formed such that a pressing portion 8 A is opposed to a supporting surface 16 , thereby forming the engaging portion that receives and secures the first end of the heating element 26 . One of ordinary skill in the art will recognize that the engaging portion may be formed by other elements, such as one or more crimping elements, pressing elements, supporting surfaces, etc.
[0037] As shown in FIGS. 4-7 , the longitudinal end 34 may have a closed-end formed by folding the retainer 10 to form the pressing portion 8 A. However, the longitudinal end 34 may be open-ended in other exemplary embodiments.
[0038] In the exemplary embodiment shown in FIGS. 4-7 , the heating element retainer 10 also may have a first guide surface 12 A, a second guide surface 12 B, and a third guide surface 12 C for guiding the heating element 26 into the cavity 40 of the tub 6 and between the opposed pressing portion 8 A and supporting surface 16 . The retainer 10 also may include a fourth guide surface 8 B formed on the pressing portion 8 A for guiding the first end of the heating element 26 between the pressing portion 8 A and the supporting surface 16 .
[0039] As shown in FIG. 4 , the supporting surface 16 of the retainer 10 also may have a guide element, such as a bump or protrusion 18 , which may be used to guide the heating element 26 into the retainer 10 . For example, the protrusion 18 may be configured to fit between parts of the heating element 26 to guide the heating element 26 into the retainer 10 , as described below with respect to FIG. 9 .
[0040] The retainer 10 also may include holes 20 A, 20 B, and 22 for mounting the retainer 10 to the wall 32 of the cavity 40 . The hole 20 A may have a diameter that is larger than a diameter of a fastener, such as a screw 70 , such that the screw 70 may be inserted through the hole 20 A and into the hole 20 B during the assembly process. The holes 20 B and 22 may have diameters that are smaller that the diameter of the screw 70 .
[0041] According to an embodiment of the invention, the heating element retainer 10 may be on (e.g., mounted on) the wall 32 of the cavity 40 of the tub 6 . For example, the first longitudinal end 14 and the second longitudinal end 34 of the retainer 10 may contact the wall 32 of the tub 6 . In the embodiment, the heating element retainer 10 may be fixedly attached to the wall 32 using screws 70 , which extend through holes 20 B and 22 into the wall 32 .
[0042] An exemplary embodiment of an assembly of a heating element 26 and a heating element retainer 10 , will now be described with reference to FIGS. 8A-8D and 9 .
[0043] As shown, for example, in FIGS. 8D and 9 , a heating element 26 may have a base 24 . The base 24 may have a seal, or be received by a seal disposed in the cavity 40 formed in the wall 32 , to hermetically seal the heating element 26 in the cavity 40 of the tub 6 . One of ordinary skill in the art will recognize that other configurations of a heating element 26 may be used within the spirit and scope of the invention.
[0044] In an embodiment of the invention, the pressing portion 8 A and the supporting surface 16 of the second longitudinal end 34 of the retainer 10 may cooperate to receive a first end of the heating element 26 . When the first end of the heating element 26 is inserted between the pressing portion 8 A and the supporting surface 16 , the pressing portion 8 A may apply pressure on the first end of the heating element 26 to secure the heating element 26 in place.
[0045] As shown, for example, in FIGS. 8D and 9 , only the first end of the heating element 26 is inserted between the pressing portion 8 A and the supporting surface 16 of the heating element retainer 10 , according to the embodiment of the invention. Accordingly, the exemplary aspects of the invention may reduce an amount of linear translation of the heating element 26 between the pressing portion 8 A and the supporting surface 16 of the retainer 10 . Further, the exemplary aspects of the invention may reduce an amount of force needed to push the heating element 26 into the heating element retainer 10 . Moreover, the exemplary aspects of the invention also may provide greater flexibility, for example, since the pressing portion 8 A of the retainer 10 may flex to accommodate heating elements 26 of different sizes. Thus, the exemplary aspects of the invention also may be universal to both European designs and U.S. designs.
[0046] An exemplary assembly process of a heating element 26 and a heating element retainer 10 , according to the exemplary embodiments of the invention, will now be described with reference again to FIGS. 8A-8D and 9 .
[0047] As shown in FIG. 8A , the cavity 40 is formed in the wall 32 of the tub 6 . The heating element retainer 10 is mounted within the cavity 40 and on the wall 32 of the tub 6 . When the heating element 26 is inserted into the cavity 40 , the first guide surface 12 A may guide the first end of the heating element 26 onto the second guide surface 12 B.
[0048] As shown in FIG. 8B , the heating element 26 may be pushed further into the cavity 40 along the guide surface 12 B. During the installation, if the first end of the heating element 26 is tilted downward, then the third guide surface 12 C may guide or funnel the first end of the heating element 26 toward the pressing portion 8 A and the supporting surface 16 . On the other hand, if the first end of the heating element 26 is tilted upward, then the fourth guide surface 8 B may guide or funnel the first end of the heating element 26 toward the pressing portion 8 A and the supporting surface 16 .
[0049] As shown in FIGS. 8B and 8C , the third guide surface 12 C and the fourth guide surface 8 B also may help to align the base 24 of the heating element 26 with the cavity 40 . As the heating element 26 is inserted further into the tub 6 , the base 24 is aligned and inserted into the cavity 40 . As shown in FIG. 8C , since only the first end of the heating element 26 may need to be pushed into the retainer 10 , the base 24 of the heating element 26 may be aligned with the cavity 40 before the heating element 26 is received in the engaging portion of the retainer 10 . That is, the heating element 26 may be installed into the cavity 40 of tub 6 up to the base 24 on heating element 26 prior to inserting the first end of the heating element 26 between the pressing portion 8 A and the supporting surface 16 of the retainer 10 . Therefore, in contrast to the conventional retainers, the embodiment may minimize or avoid any misalignment of the heating element 26 due to pressure being applied on the heating element 26 from the retainer 10 . Accordingly, the exemplary aspects of the invention may reduce or prevent misalignment of the heating element 26 in the cavity 40 and simplify the installation process.
[0050] When the base 24 of the heating element 26 is aligned with the top of the cavity 40 in the tub 6 , the heating element 26 may be pushed into the engaging portion of the retainer 10 . For example, as shown in FIG. 8D , the first end of the heating element 26 may be inserted between the pressing portion 8 A and the supporting surface 16 of the retainer. As set forth above, the exemplary aspects of the invention may reduce an amount of linear translation of the heating element 26 between the pressing portion 8 A and the raised supporting surface 16 of the retainer 10 , and also may reduce an amount of force needed to push the heating element 26 into the heating element retainer 10 .
[0051] As shown in FIG. 9 , the raised supporting surface 16 of the retainer 10 also may have a guide element, such as a bump or protrusion 18 , which may further guide the heating element 26 into the retainer 10 . The protrusion 18 may be configured to fit between parts of the heating element 26 to guide the heating element 26 between the pressing portion 8 A and the supporting surface 16 . For example, in the exemplary embodiment shown in FIG. 9 , the heating element 26 may have a plurality of U-shaped parts. In this embodiment, the heating element 26 may be inserted between the pressing portion 8 A and the supporting surface 16 such that the protrusion 18 interposes adjacent U-shaped parts of the heating element 26 , thereby guiding the heating element 26 between the pressing portion 8 A and the supporting surface 16 of the retainer 10 .
[0052] Accordingly, the exemplary aspects of the invention may reduce or prevent misalignment of the heating element 26 in the cavity 40 and simplify the installation process.
[0053] As shown, for example, in FIG. 8D , the second guide surface 12 B of the retainer 10 may be formed such that a first gap 28 is formed between the second guide surface 12 B of the retainer 10 and the wall 32 of the tub 6 of the washer 2 . The second guide surface 12 B of the retainer 10 also may be formed such that a second gap 30 is formed between the second guide surface 12 B and the heating element 26 . In this embodiment, the second guide surface 12 B of the retainer 10 may form, for example, a heat shield that may protect the wall 32 of the tub 6 from excessive heat from the heating element 26 .
[0054] The aspects of the invention are not limited to the exemplary embodiments described above. For example, a heating element retainer 10 according to another embodiment of the invention is illustrated in FIGS. 10 and 11 .
[0055] As shown in FIGS. 10 and 11 , a heating element retainer 10 according to another embodiment of the invention may be formed such that second guide surface 12 B of the retainer 10 abuts directly against the wall 32 of the tub 6 . Accordingly, in this embodiment, there is substantially no gap formed between the retainer 10 and the wall 32 of the tub 6 .
[0056] Referring again to the embodiment of FIGS. 10 and 11 , the second guide surface 12 B may extend from the first longitudinal end 14 to the third guide surface 12 C. Thus, the first end of the heating element 26 may be guided by the second guide surface 12 B to the engaging portion of the retainer 10 .
[0057] Accordingly, the exemplary aspects of the invention may reduce a complexity of the heating element retainer and reduce an amount of material that may be needed to form the heating element retainer. Further, the exemplary aspects may reduce manufacturing costs of the heating element retainer. The exemplary aspects of the invention also may retain the heating element near a first end of the heating element, thereby reducing or preventing misalignment during the assembly of the heating element into the cavity of the tub. Thus, the heating element retainer according to the invention may be more easily installed as compared to the conventional retainers. The exemplary aspects of the invention also may be universal to both European designs and U.S. designs.
[0058] While the foregoing disclosure shows illustrative embodiments of the invention with reference to a washer having a heating element retainer, it is nevertheless not intended to be limited to the details shown. For example, another embodiment of the invention is directed to an apparatus having a heating element retainer.
[0059] It should be noted that various changes and modifications could be made herein without departing from the scope of the invention as defined by the appended claims and a range of equivalents thereof. Furthermore, although elements of the invention may be described or claimed in the singular, the plural is contemplated unless limitation to the singular is explicitly stated.
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A washer is provided. The washer includes a housing, a tub in the housing, a laundry drum rotatably mounted in the tub, a heating element in the tub, and a heating element retainer, on an inner surface of the tub, for retaining the heating element. The heating element retainer includes a first longitudinal end and a second longitudinal end. The heating element further includes an engaging portion that is formed closer to the second longitudinal end than to the first longitudinal end, and that retains a first end of the heating element.
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STATEMENT OF RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to U.S. patent application Ser. No. 10/444,156 filed on May 23, 2003.
COPYRIGHT NOTICE
[0002] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates generally to mechanical gaming systems, and more particularly, to an enhanced reel strip and a method for producing an enhanced reel strip for use in a mechanical gaming system.
[0005] 2. Background of the Invention
[0006] A variety of gaming machines are known in the art. This diversity provides players with many different options for gaming, interactivity and entertainment. In the past, gaming machines were mechanical or electro-mechanical in nature. However, more recently, there has been an emphasis in the gaming industry on computer or video gaming machines. One reason for the popularity of computer or video gaming machines is that each machine may be designed to provide a number of different games or gaming options to players. Additionally, computer or video gaming machines may have enhanced displays, such as sounds, flashing lights, scrolling text, and the like, which entice players to play and add to the overall excitement and entertainment of the games.
[0007] A persistent issue with computer or video gaming machines is that they are typically more complicated than mechanical gaming machines. This complexity requires specialized maintenance and electronics personnel to service the computer and video gaming machines. Moreover, a significant portion of the public has a fear or distrust of computers and computer generated games, such as video gaming machines, and prefer the electro-mechanical or mechanical gaming machines.
[0008] In this regard, much effort has been directed towards making the mechanical or electro-mechanical gaming machines more enticing and exciting to players. Many attempts have been made to increase the excitement and interactivity of mechanical gaming devices by adding secondary game features, such as additional buttons, bells, lights, whistles, top boxes, visual graphics, and the like. However, for some of the most popular mechanical gaming machines, i.e. reel spinners and slot machines, many manufacturers have directed their design efforts to the appearance of the reels themselves. By varying the overall appearance of the reels or the reel strips which are applied to the reels, it is possible to achieve gaming machine reel designs that look more elegant, are more entertaining and which add to the excitement and appeal of the game.
[0009] Those skilled in the art have designed reels capable of displaying multiple symbols or being implemented in different mediums. For instance, the symbols may be screen printed or stamped upon the reels themselves, inherently providing contrast between the symbol and the reel. However, this method limits the symbols on the reels to only one pattern and the reels must be swapped out from the machine to achieve different looks. Alternatively, symbols are screen printed, stamped or otherwise applied to the reel strips and the reel strips are then applied to the reels. In this regard, the reel strips may be swapped out to easily and quickly vary the reel symbols and appearances. Designers have also implemented different mediums for the reels, including fluorescent, prismatic, translucent, and transparent materials. These same materials are also used in the design of the reel strips so as to provide different effects as the reels are spun in the gaming machines.
[0010] Another popular effect is to use lighting to emphasize the reels of the gaming machines. For example, the gaming machine may be designed with front lights that shine on the exterior of the reels to highlight or reflect the reel surfaces. The effects of front lighting are relatively limited and do not provide much latitude for adding excitement in the design. Alternatively, gaming machines may be equipped with back lighting that highlights the underside of the reels and gives the effect that the reels are lit from within. While back lighting is easy to implement, depending on the materials utilized in the reels and the reel symbols, it may not give a dramatic and exciting effect to the reels.
[0011] It is also popular to light the reels themselves with electroluminescent lighting. In this regard, conductive materials are incorporated into the reel or reel strips, and when a voltage is applied across the reels, light elements are illuminated. Although electroluminescent lighting may provide dramatic and exciting enhancement of the reels, there are frequently problems with crimping and failure of the conductive materials in the reels such that the luminescent features are easily lost and costly to repair. Moreover, the difficulty and costs associated with manufacturing electroluminescent reel strips are prohibitive. Finally, for any of the above lighting options for reels or reel strips, if the light source on the gaming machine is malfunctioning, most if not all of the lighting effects are lost.
[0012] One significant problem with enhanced reel strips, in general, is that they are difficult and costly to manufacture. For example, the quality of the images applied on to the reel strips by processes such as screen-printing, digital imaging or photographic imaging may be compromised. Often the images do not have sufficient depth of color or are blurred. Likewise, the images may lack vibrancy and look dull, particularly where harsh lights or backlighting are used. Also, there is concern for the quality of the strip where a designer seeks to add borders, outlines around the images, or an appliqué effect to the strip. Without precise placement of the borders, outlines, or appliqués, the overall quality and appearance of the reel strips is significantly diminished.
[0013] Gaming machine manufacturers are always seeking new ways to increase the attractiveness and excitement of mechanical gaming devices. However, while having a gaming machine that attracts and excites players is important, the simplicity of the operation and maintenance of the machine and the cost effectiveness of enhancements to the gaming machine are also important. Similarly, for reel strips, the difficulty and costs of manufacturing enhanced reel strips are essential considerations. The present invention clearly addresses these needs and other concerns.
SUMMARY OF THE INVENTION
[0014] Briefly, and in general terms, the present invention resolves the above and other problems by providing an enhanced reel strip and method for manufacturing the same, which provides for increased attractiveness and excitement of mechanical gaming machines. More particularly, the present invention discloses enhanced reel strips and a method for producing the enhanced reel strips such that quality and appearance are dramatically improved while a relatively simple manufacturing process maintains cost effectiveness.
[0015] In accordance with the present invention, an enhanced reel strip is comprised of two main components, namely a base strip and an overlay strip. Each of the base strip and the overlay strip are selected and processed so as to achieve a variety of desired effects on the resultant enhanced reel strip. The base material comprising the base strip is typically a flexible, translucent or transparent material upon which symbols are applied. The symbols can be of almost any design and may be applied to the base material by any method that results in suitable color depth, image clarity and fastness. The overlay strip is also typically a flexible material, however because it is intended to be decorative, it is usually colored, patterned or textured. Sections of the overlay strip are removed to form cut-outs. The underside of the overlay strip is adhered to the front side of the base strip in such a manner that the symbols on the base strip are visible through the cut-outs of the overlay strip. In this regard, it is preferred that the cut-outs will be sized slightly larger than the symbols so as to produce an open border area around each symbol.
[0016] The overlay strip may be comprised of a multitude of different materials. By way of example only and not by way of limitation, different overlay materials may include metalized foil, holographic, prismatic, glitter, phosphorescent, fluorescent, mirrored or textured materials. Likewise, it is envisioned that the overlay material may be provided in a variety of colors, be plain, and/or have a pattern. Preferably, the overlay material is visually stimulating. Further, the overlay material preferably corresponds to the machine environment in which it is used, particularly the lighting environment of back light or non-back light applications. Preferably, the overlay material is easily incised and manipulated to facilitate the removal of the cut-outs from the overlay strip. Additionally, the overlay material preferably is sufficiently flexible and capable of attachment to the base reel strip to ensure that the resultant enhanced reel strip may be wrapped and secured about the slot reel.
[0017] In accordance with the present invention, the cut-outs are sized slightly larger than the symbols, which create an open border area around the symbols. Consequently, when the resultant enhanced reel strip is used in a backlight application, the symbols and the open border areas around them are backlit. That is, light passing through the open border areas of the cut-outs appears clear and very bright, while the light passing through the symbols appears colored, thus highlighting the symbols on the reels. Moreover, even if the enhanced reel strips are used in a non-backlight application, such as front lighting or ambient lighting, the difference in the light passing through the open border areas and the light passing through the symbols is still perceptible. Thus, in any foreseeable lighting application, the open border areas and the decorative overlay serve to emphasize the symbols and add to the overall attractiveness of the enhanced reel strip.
[0018] In accordance with one aspect of the present invention, the enhanced reel strips are produced via a series of manufacturing steps. First, a base reel strip is produced by applying symbols to a base material. The base material suitable for production of the base reel strip is preferably a flexible, translucent material that is capable of accepting the applied symbols. By way of example only, and not by way of limitation, suitable base materials are flexible, translucent or substantially transparent materials, such as plastics, mylars, polyesters, or similar composite materials. The application of the symbols to the base reel strip is preferably accomplished by a method, including but not limited to, screen-printing, appliqués, digital imaging or photographic imaging. However, any method of application, which produces a clear and firmly-fixed symbol to the base material, is acceptable.
[0019] Next, an overlay strip for the base reel strip is produced. This overlay strip is decorative and may be produced in a variety of shapes, colors, iridescence, and the like to provide different effects to the reel strip. In areas of the enhanced reel strip that are to be highlighted, the overlay material is removed by cutting the designated portions of the overlay material to produce a desired effect. By way of example only, and not by way of limitation, methods for removing designated portions of the overlay material includes die cutting, pin routing, laser cutting, or other such methods. Preferably, the back surface of the overlay material, which will not be visible when the enhanced reel strip is in use, is treated with a flexible adhesive or other similar fastening substance for affixing the overlay material to the base reel strip.
[0020] Once the overlay strip and base reel strip are prepared, they are joined or affixed together. A preferred method for applying or joining the overlay strip and the base reel strip, and thereby produce the enhanced reel strip, is a registration or pin system. Using the methodology, a base reel strip is placed into a registration system with the symbols of the base reel strip facing outward, i.e. the front surface of the base reel strip, facing outward. Additionally, this method includes preparing the underside adhesive surface of the overlay strip. The overlay strip is then aligned with and placed over the base reel strip in the registration system. Slight pressure methods, such as hand or light mechanical pressure, are used to initially contact the base reel strip and the overlay strip together. Preferably, the two strips are then firmly adhered together using a press or pinch roller system. Similar mechanisms may also be utilized.
[0021] In accordance with another aspect of the present invention, the process for producing enhanced reel strips is preferably also used to produce other portions of the gaming machine to increase visual presentation, design, theme and excitement. For example, the process may be used for manufacturing inserts for top awards, denomination information pertaining to play of the game, associated toppers, door inserts, and the like.
[0022] Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate by way of example only, and not by way of limitation, the features of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a perspective view of a slot reel mechanical gaming device;
[0024] FIG. 2 is a perspective view of a slot reel illustrating a surface upon which a reel strip may be attached;
[0025] FIG. 3 is a perspective view of a slot reel strip having solid and removed or transparent portions;
[0026] FIG. 4 is a perspective view of a slot reel wherein a reel strip is attached to the outside perimeter of the slot reel;
[0027] FIG. 4A is a perspective view of a reel strip illustrating notches and a tongue and groove for attachment of the reel strip about the perimeter of the slot reel;
[0028] FIG. 4B is a schematic of the joining of first and second ends of a reel strip using a tongue and groove for attachment of the reel strip about the perimeter of the slot reel;
[0029] FIG. 5 is a perspective view of a base reel strip having symbols applied thereto and an overlay strip with designated areas of the overlay material having been removed, pursuant to an embodiment of the present invention;
[0030] FIG. 6 is a perspective view of an enhanced reel strip wherein a base reel strip, with applied symbols, and an overlay strip have been joined, pursuant to an embodiment of the invention; and
[0031] FIG. 7 is a flow diagram of a process for manufacturing an enhanced reel strip, pursuant to an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] A preferred embodiment of the present invention is directed to an improved system and method for producing an enhanced reel strip for use in a mechanical slot reel gaming device. The enhanced reel strip and method for producing it provides a visually enticing, attractive and exciting gaming system. The enhanced reel strip production method further provides reel strips of improved quality, while maintaining the cost efficiency of manufacturing the enhanced reel strips. The preferred embodiments of the improved reel strip and method are illustrated and described herein by way of example only, and not by way of limitation.
[0033] Referring now to the drawings FIGS. 1-7 , wherein like reference numerals denote like or corresponding parts throughout the drawing figures, and particularly to FIGS. 5-7 , an enhanced reel strip system and method is provided for use in a mechanical slot reel gaming device 10 . As illustrated in the mechanical slot reel machine embodiment of FIG. 1 , the slot reels 11 , 12 , 13 are visible to a player through the corresponding viewing windows 15 , 16 , 17 . Although FIG. 1 shows a gaming machine having three slot reels 11 , 12 , 13 and three viewing windows 15 , 16 , 17 , it is known that gaming machines may be configured with fewer or more than three reels and/or viewing windows. Moreover, the reels may be placed in other areas of the gaming machine, such as, by way of example and not by way of limitation, a top box, to create additional features or awards for the play of game. A player initiates play of the gaming machine by inserting coins into the coin-in 20 , betting using the “bet” button 22 , and activating the lever 24 or “spin” button 21 to cause the reels 11 , 12 , 13 to spin. If a winning combination is displayed on the reels along the payout line 18 , a payout is dispensed to the player in the tray 25 or through other means.
[0034] As shown in the FIG. 2 , a slot reel 30 is configured with a support structure 31 having a circumferential surface 32 . It is around this circumferential surface 32 that various reel strips may be applied or mounted (see, e.g., FIG. 4 ). FIG. 3 is a reel strip 40 showing a top surface 48 that is displayed to a player of the game as the reels 30 are spun. The top surface 48 of the reel strip 40 includes solid portions 42 and removed or transparent portions 44 . The reel strip 40 may also include a bottom surface 46 that is placed against the circumferential surface 32 of the slot reel 30 . In this regard, the removed or transparent portions 42 and solid portions 44 of the reel strip 40 provide different effects and appearances for the reels.
[0035] As demonstrated in FIG. 4 , a reel strip 40 may be applied or mounted to a slot reel 30 by winding the reel strip around the slot reel and securing the ends of the reel strip. Two screw holes 41 are provided at a first end of the reel strip 40 and two screw slots 43 are provided at a second end of the reel strip. The screw holes 41 correspond to screw holes 47 formed in a reel strip fixing means 45 . The screw holes 41 , screw slots 43 , and screw holes 47 on the reel strip fixing means 45 are fashioned such that they overlap when the reel strip 40 is wound around the circumference of the slot reel 30 , and the reel strip may be secured with screws through the reel strip fixing means 45 . In this manner, the reel strip 40 is secured about the slot reel 30 .
[0036] Alternatively, as shown in FIGS. 4 , 4 A, and 4 B, first and second ends of the reel strip 40 are configured with notches 34 . These notches 34 , correspond to notches 36 on the slot reel 30 and aid to secure the reel strip 40 into position about the slot reel. The first end of the reel strip 40 is further configured with a tongue 37 and the second end of the reel strip is configured with a groove 38 . The tongue 37 and groove 38 are matched such that when the reel strip 40 is placed about the slot reel 30 , the tongue 37 joins with the groove (see FIG. 4B ) to aid in securing the reel strip in place about the slot reel. Preferably, the enhanced reel strip 64 of the present invention is secured about a slot reel 30 , as described above or in a similar manner.
[0037] An embodiment of the present invention is disclosed in FIGS. 5 and 6 . In a preferred embodiment, the enhanced reel strip and production method facilitates a larger diversity of reel appearances through the manufacture and use of enhanced reel strips, which are easily and economically produced. In FIG. 5 , two strips, the base strip 60 and the overlay strip 62 , are shown. As exhibited in FIG. 6 , these two strips comprise the enhanced reel strip 64 .
[0038] The base reel strip 60 comprises a suitable base material 54 and symbols 56 . In a preferred embodiment, the base material 54 is a flexible, translucent material. Additional suitable base materials include, but are not limited to, flexible, translucent or substantially transparent plastics, mylars, polyesters or similar composite materials. As the symbols 56 are applied to the base material 54 to produce the base reel strip 60 , the base material should be capable of accepting the applied symbols 56 and producing clear, firmly-fixed symbols on the base material. In this regard, various methods may be used to apply the symbols 56 to the base material 54 , including by way of example only, and not by way of limitation, screen-printing, appliqués, digital imaging, or photographic imaging. In order to achieve a variety of effects with enhanced reel strips 64 , the overlay strip 62 may be comprised of a multitude of types of materials, each offering a different appearance to the reels. In one embodiment, for example, that the overlay material 50 is selected from metalized foil, holographic, prismatic, glitter, phosphorescent, fluorescent, mirrored, and textured materials. Preferably, the overlay material 50 is provided in a variety of colors and may be plain or have a pattern. The overlay material 50 is selected to be visually stimulating and work well with the machine environment (i.e., lighting) in which it is used. Preferably, the overlay material 50 is easily manipulated to facilitate the removal of cut-outs 52 from the overlay strip 62 , and is sufficiently flexible to facilitate wrapping about the slot reel. Further, the overlay material must also be capable of firm attachment to the base reel strip 60 .
[0039] In a preferred embodiment, the cut-outs 52 are configured to correspond in shape to the symbols 56 , but are slightly larger than the symbols. In this regard, the cut-outs 52 create an open border area 58 around the symbols 56 when the overlay strip 62 is centered over and applied to the base reel strip 60 . By altering the size of the cut-outs 52 relative to the size of the symbols 56 , the effect of the open border areas 58 may be manipulated. In another embodiment, the open border areas 58 are not equally-spaced and/or centered relative to the symbols 56 . Moreover, in still other embodiments, the cut-outs 52 have a shape other than that of the corresponding symbols 56 . That is, shapes such as, by way of example only, and not by way of limitation, squares, circles and triangles might comprise cut-outs 52 corresponding to symbols 56 shaped as, by way of example only, and not by way of limitation, sevens, cherries and bars.
[0040] When the enhanced reel strip 64 is used in conjunction with a backlighting system, the symbols 56 and the open border areas 58 around them are backlit. In this regard, light passing through the open border areas 58 of the cut-outs 52 appears clear, while the light passing through the symbols 56 appears colored. This backlighting produces additional effect and draws a player's attention to the symbols 56 on the reels 30 .
[0041] In a further embodiment where front lighting is used, the light passes through the open border areas 58 , while the light passing through the symbols 56 highlights the colors of the symbols 56 . Additionally, in embodiments where no internal machine lighting is provided, ambient light from the surroundings provides an effect that is similar to, but less intense, than front lighting. In either instance, the open border areas 58 serve to emphasize the symbols 56 on the enhanced reel strip 64 . Contemporaneously, the selection of the overlay material 50 itself also provides emphasis to the symbols 56 and to the enhanced reel strip 64 .
[0042] In accordance with one aspect of the preferred embodiment, the enhanced reel strips 64 are produced in a series of manufacturing steps as illustrated in FIG. 7 . First, a base reel strip 60 is produced 72 by selecting a suitable base material 54 and applying symbols 56 to the base material. In order to be suitable for the production of the enhanced reel strips 64 , the base material 54 of the base reel strip 60 is preferably a flexible, translucent material. By way of example only, and not by way of limitation, suitable base materials are flexible, translucent or substantially transparent materials such as plastics, mylars, polyesters or similar composite materials. Since the symbols 56 are applied to the base material 54 , the base material should be capable of accepting the applied symbols 56 and producing clear, firmly-fixed symbols 56 on the base material. In this regard, the application of the symbols 56 to the base material 54 may be accomplished by any number of methods, including but not limited to, screen-printing, appliqués, digital imaging or photographic imaging. The application of the symbols 56 to the base material 54 creates the base reel strip 60 .
[0043] Once the base reel strip 60 has been created 72, the next step in the process of manufacturing the enhanced reel strip 64 is to select an overlay material 50 that is suitable to create the desired effect on the enhanced reel strip 64 and to facilitate removal of designated portions of the overlay material 50 , thereby forming cut-outs 52 ( 74 ). Preferably, the overlay material 50 is flexible, capable of being affixed to the base reel strip 60 , suitable for easy incision and removal of designated cut-outs 52 , and visibly appealing. The overlay strip 62 is decorative and may be produced in a variety of shapes, colors, iridescence, and the like to provide different desired effects to the enhanced reel strip 64 .
[0044] In order to highlight areas of the enhanced reel strip 64 , certain portions, i.e. the cut-outs 52 , of the overlay material 50 are removed. The removal of the cut-outs 52 of the overlay material 50 creates the overlay strip 62 ( 74 ). When the overlay strip 62 and the base reel strip 60 are aligned 76 and joined, the symbols 56 on the base reel strip 60 are visible through the cut-outs 52 in the overlay material 50 . Although almost any means for removing the cut-outs 52 from the overlay material 50 may be used, preferred methods for removing designated portions of the overlay material 50 include, but are not limited to, die cutting, pin routing, and laser cutting.
[0045] Once the base reel strip 60 and the overlay strip 62 are created, the strips are prepared to be affixed 78 and thereby form the enhanced reel strip 64 . In order to facilitate the application of the overlay strip 62 to the base reel strip 60 , the back surface of the overlay material 50 , which is not be visible when the enhanced reel strip 64 is in use, is treated with a flexible adhesive or other similar fastening substance 78 . Alternatively, an overlay material 50 having a pre-treated back surface is used, wherein the back surface includes a flexible adhesive and a protective backing 78 . In this manner, the protective backing on the overlay material 50 is simply removed to prepare the overlay strip 62 for adherence to the base reel strip 60 ( 78 ). Thus, the adhesive surface of the overlay strip 62 is readied by removing a backing material, wetting to activate the adhesive or otherwise preparing the overlay strip 62 for adherence to the base reel strip 60 . In one embodiment, a flexible adhesive is applied to the top surface of the base reel strip 60 , in addition to, or instead of the back surface of the overlay strip 62 to facilitate adherence of the two strips 78 . In this embodiment, the overlay strip 62 is affixed to the base reel strip 60 to jointly comprise the enhanced reel strip 64 .
[0046] As illustrated in FIG. 7 , the final step 80 of the process for manufacturing an enhanced reel strip is to adhere the overlay strip 62 to the base reel strip 60 . The attachment of the overlay strip 62 and base reel strip 60 may be accomplished by any method that results in proper alignment. However, a preferred method for applying or joining the overlay strip 62 and the base reel strip 60 is a registration or pin system. In this regard, the base reel strip 60 is placed into the registration system with the symbols 56 facing outward. The overlay strip 62 is then aligned with, placed over, and adhered to, the base reel strip 60 . Together, the overlay strip 62 and the base reel strip 60 form the enhanced reel strip 64 .
[0047] The base reel strip 60 and the overlay strip 62 components are initially contacted and pressed together using modest pressure. For example, but not by way of limitation, hand pressure or gentle mechanical pressure methods may be used to adhere the two components. In one preferred embodiment, as shown in FIG. 6 , the base reel strip 60 and the overlay strip 62 are aligned and centered such that an equal amount of open border area 58 is apparent on all sides of the symbols 56 . Alternatively, in an embodiment that utilizes cut-outs 52 of a different shape than the corresponding symbols 56 , the symbols should be centered within the cut-outs. Once proper alignment of the overlay strip 62 and the base reel strip 60 is ensured, the two strips are firmly adhered together using a press, roller system, pinch roller system, or similar mechanism.
[0048] In accordance with another aspect of a preferred embodiment, the process for producing enhanced reel strips is used to produce other portions of the gaming machine, thereby increasing visual presentation, design, theme and excitement. For instance, the process may be used for manufacturing inserts for top awards, denomination information pertaining to play of the game, associated toppers, door inserts, or the like.
[0049] Furthermore, the various embodiments and methodologies described above are provided by way of illustration only, and should not be construed to limit the invention. Those skilled in the art will readily recognize various modifications and changes may be made to the present invention without departing from the true spirit and scope of the present invention. Accordingly, it is not intended that the present invention be limited, except as by the appended claims.
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An enhanced reel strip includes a base reel strip and an overlay strip, wherein the base reel strip has symbols applied thereto and the overlay strip has designated portions thereof removed to create cut-outs. The base reel strip and overlay strip are affixed in such a manner that the symbols of the base reel strip are visible through the cut-outs of the overlay strip. The joined strips produce an enhanced reel strip. Furthermore, these enhanced reel strip production methods dramatically improve the quality and appearance of reel strips while utilizing a relatively simple manufacturing process that maintains cost effectiveness.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to U.S. Pat. application Ser. No. 08/452,020, filed Jun. 12, 1995 entitled "Low Cross Talk and Impedance Controlled Electrical Connector" and to U.S. Pat. application Ser. No. 60/027,611, filed Oct. 10, 1996 entitled "Low Profile Array Connector".
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to electrical connectors and more particularly high I/O density array connectors.
2. Brief Description of Prior Developments
The drive to reduce the size of electronic equipment, particularly personal portable devices, and to add additional functions to such equipment, has resulted in an ongoing drive for miniaturization of all components, especially electrical connectors. Efforts to miniaturize connectors have included reducing the pitch between terminals in single or double row in-line connectors, so that a relatively high number of I/O or other lines can be interconnected by connectors that fit within tightly circumscribed areas on the circuit substrates being electrically connected. The drive for miniaturization has also been accompanied by a shift in preference to surface mount techniques (SMT) for circuit board manufacture. The confluence of the increasing use of SMT and the required fine pitch of in-line connectors has resulted in approaching the limits SMT for high volume, low cost operations. Reducing the pitch of the terminals increases the risk of bridging adjacent solder pad or terminals during reflow of the solder paste. To satisfy the need for increased I/O density, array connectors have been proposed. Such connectors have a two dimensional array of terminals mounted on an insulative substrate and can provide improved density. However, these connectors present certain difficulties with respect to attachment to the circuit substrates by SMT techniques because the surface mount tails and most of the terminals must be beneath the connector body. As a result, the techniques used must be highly reliable because it is not possible to visually inspect the solder connections or repair them if faulty. In the mounting of an integrated circuit (IC) on a plastic or ceramic substrate the use of ball grid array (BGA) and other similar packages has become common. In a BGA package, spherical solder balls are positioned on electrical contact pads of a circuit substrate by means of a paste typically applied with a stencil or supporting device. The unit is then heated. The IC may thereby be connected to the substrate without need of external leads on the IC.
While the use of BGA and similar systems in connecting an IC to a substrate has many advantages, a corresponding means for mounting an electrical connector on a printed wiring board (PWB) or other substrate has yet to be developed. It is, for example, important that the completed solder balls be of a similar size so that in the final application the balls will reflow and solder evenly to a printed circuit board substrate. Any significant differences is solder ball size on a given substrate could cause problems when the final assembly is applied to a printed circuit board. The final size of the ball is dependent on the total volume of solder initially available including the solder paste and the solder balls. In applying balls to a connector contact, this limitation could be a particular problem since variations in the volume of the connector contact adds to the potential variability.
Another problem presented in soldering connectors to a substrate is that connectors often have insulative housings which have relatively complex shapes such as having numerous cavities. Such housings may, therefore, tend to become warped or twisted either initially or after heating to reflow the solder balls. Such warping or twisting of the housing can cause a dimensional mismatch between the final connector assembly and the printed circuit board, resulting in unreliable soldering because the balls are not sufficiently in contact with the solder paste on the PWB prior to soldering.
A need, therefore, exists for a means of using of BGA or a similar package to fix an electrical connector on a substrate.
SUMMARY OF THE INVENTION
The electrical connector of the present invention is one in which one or more contacts are fused to an electrically conductive so as to be electrically connected by means of that material to a substrate. Preferably this electrically conductive material is a solder ball which has been reflowed to provide the primary electrical current path between the connector and a substrate.
The present invention includes a method for placing an exterior conductive contact on an element of an electrical connector. There is at least one recess on the exterior side of the connector elements. A conductive contact extends from adjacent the interior side of the conductor element into the recess on the exterior side of the housing. A conductive element which will ordinarily be a solder ball is positioned in the recess on the exterior side of the housing. The conductive element emplaced in the recess is then heated to a temperature sufficient to soften the conductive element and fuse the conductive element to the contact extending into said recess.
Also encompassed by this invention is a contact for use in an electrical connector which comprises a terminal tab area where said contact is connectable to a solder ball. This terminal tab is plated with a solderable metal. A contact area is positioned in opposed relation to said terminal tab and plated with a precious metal. A medial area is positioned between said terminal tab and said contact area and said medial area is plated with a non-solderable metal. By means of this plating system wicking of the solder from the solder ball beyond the non-solderable metal is avoided.
This invention also includes an element of an electrical connector which has at least one flattened contact having opposed major sides and opposed minor ends. The contact is mounted in a slot in the housing and a generally pyramidal shaped projection extends from said housing into said slot to about one of said major sides of said contact. By means of this arrangement, stress build up is prevented so as to prevent warping and twisting of the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
The method and connector of the present invention is further described with reference to the accompanying drawings in which:
FIG. 1 is a top plan view of a receptacle element of a preferred embodiment of the connector of the present invention;
FIG. 2 is a cut away end view of the receptacle shown in FIG. 1;
FIG. 3 is a top plan view of a plug element of a preferred embodiment of the present invention;
FIG. 4 is a cut away end view of the plug element shown in FIG. 3;
FIG. 5 is a cut away end view of the receptacle and plug shown in FIGS. 1-4 in unmated relation;
FIG. 6 is an end view of the receptacle and plug shown in FIG. 5 in mated relation;
FIGS. 7a, 7b and 7c are cut away end views showing respectively first, second and third sequential stages in the mating of the receptacle end plug shown in FIG. 5;
FIG. 8 is a bottom plan view of the receptacle shown in FIG. 1;
FIG. 9 is a plan view of the PWB pattern which mates with the receptacle shown in FIG. 8;
FIG. 10 is a detailed cut away view of area 10 in FIG. 1;
FIG. 11 is an enlarged view of the cut away area in FIG. 4;
FIG. 12 is an enlarged view of the cut away area in FIG. 10;
FIG. 13 is an enlarged cross sectional view through 13--13 in FIG. 10;
FIG. 14 is a top plan view of a receptacle element of an alternate preferred embodiment of the connector of the present invention;
FIG. 15 is an end view of the receptacle shown in FIG. 14;
FIG. 16 is a top plan view of a plug element of the second preferred embodiment of the receptacle of the present invention;
FIG. 17 is an end view of the plug shown in FIG. 16;
FIG. 18 is an end view of the mated receptacle and plug shown in FIGS. 14-17;
FIG. 19 is a top plan view of a receptacle used in a third preferred embodiment of the connector of the present invention;
FIG. 20 is an end view of the receptacle shown in FIG. 14;
FIG. 21 is a top plan view of the plug element of the third preferred embodiment of the connector of the present invention;
FIG. 22 is an end view of the plug element shown in FIG. 28; and
FIG. 23 is an end view of the mated receptacle and plug shown in FIGS. 19-22;
FIG. 24 is a side cross sectional view in fragment of another preferred embodiment of the connector of another preferred embodiment of the connector to the present invention in which the plug and receptacle are metal;
FIG. 25 is a front cross sectional view in fragment of the connector shown in FIG. 24 in which the plug and receptacle are unmated;
FIGS. 26a and 26b is a graph showing temperature versus time and distance during solder reflow in Examples 1 and 2 of the method of the present invention;
FIGS. 27a-27f are generated profiles of the product of Example 3 of the method of the present invention; and
FIGS. 28a and 28b are x-ray diffraction photographs showing the product of Example 4 of the method of the present invention;
FIGS. 28c and 28d electron microscope photographs showing the product of Example 4 of the method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A design and method of attaching solder balls to connector contacts which will minimize the variability of solder ball sizes will be discussed. This particular design consists of a connector contact with a terminating tab. The contact is inserted into a plastic housing. The contact base is inserted into a rectangular cavity and retained by frictional coupling between a generally pyramidal shaped projection. This projection is designed to hold the contact with sufficient retention, but not to allow stresses to build up in a housing which has many cavities. This is done to prevent warp and twisting of the housing either initially or after heating to reflow the solder balls. The termination tab of the connector contact projects into a square or round cavity in the plastic housing. This cavity is designed to accept solder paste. The solder paste can be applied with a simple squeegee. The solder balls are then applied to the surface of the paste. The final assembly is then reflowed to produce the final product. Variations in ball size can be minimized since the cavity can be precisely defined by the molding process, the variation in solder paste volume can be minimized, as compared to more standard processes such as screening. Furthermore, variations in the termination tab insertion depth or cutoff length are masked since the volume of the cavity is the same whether the termination tab is larger or smaller makes little difference, since the solder paste displaces any differences. This results in solder balls of uniform size and height. This particular design the solder in the cavity locks the contact into place into the connector housing, providing some structural support, so that the contacts cannot be displaced during application and use.
Referring generally to FIGS. 1-2 and 12-13, the connector according to a first embodiment of a high density connector of the present invention includes a receptacle which is shown generally at numeral 10. A base section of the receptacle is shown generally at numeral 12. Referring first to the base section, this element includes a base wall 14 which has an exterior side 16 and an interior side 18. On the exterior side there are outer recesses as, for example, recesses 20, 22, 24, 26 and 28 (FIG. 12). On the interior side there are inner signal contact receiving recesses as, for example, recesses 30, 32, 34, 36 and 38. Connecting these inner and outer recesses are medial slots as, for example, slots 40, 42, 44, 46 and 48. Each of the outer recesses has a base wall and a lateral wall as, for example, base wall 50 and lateral wall 52 (FIG. 12). Each of the inner signal contact receiving recesses has a base wall and intersecting lateral walls as, for example, base wall 54 and lateral walls 56 and 58. Each of the inner ground or power contact receiving recesses also has a base wall and diagonal lateral walls as, for example, base wall 60 and lateral walls 62 and 64. The above described inner and outer recesses and connecting medial slots holds ground or power contacts or signal contacts.
The ground or power contacts are made up of an upper section shown generally at numeral 66 which are made up of two contacting forks as at fork 68 and 70. Each of these forks has a converging section 72, a contact point and an outwardly diverging section 76. The ground or power contacts also include a medial section 78 passing through the lower wall of the receptacle and the lower section 80 where it enters the outer recess where it is fused to a solder ball 82. Such terminal tabs will be plated with a solderable metal such as gold or other precious metal or tin. Above this the contact will preferably be plated with a non-solderable metal such as nickel. Further above in the contact area, there will preferably be gold or other precious metal plating. With this plating system, undue wicking of solder from the recess area up the contact will be avoided. Alternatively, the entire contact may be plated with gold or other precious metal if a suitable florine based anti-wicking coating is used.
Each of the signal contacts (FIGS. 12 and 13) includes an upper section shown generally at numeral 84 having a forward projection 86, a rearward bend 88 and a groove 90. The signal contacts may also include a medial section 92 which passes through the lower wall of the receptacle. A generally pyramidal shaped feature as on the housing such as converging walls 94 and 96 bear against each signal contact to help stabilize the entire connector housing from warping or bending. The signal contacts also include a lower section 98 which enters the outer recess (for example, recess 22 in FIG. 15) and where it is fused to a solder ball 100 as will be explained below.
Referring to particularly to FIGS. 1-2, the base section of the receptacle includes latching structures, for example, as is shown generally at numeral 102. This latching structure includes an upward tab 104 which is superimposed over a vertical groove 106 and which has an outward projection 108. The base section of the receptacle also has other similar latching structures 110, 112 and 114. The receptacle also includes an upper section shown generally at 116 which is superimposed over the base section. This upper section has a top wall 118 and a peripheral side wall 120. This upper section is fixed to the base section by means of latching structures as is, for example, shown generally at numeral 122. Each of these latching structures has a side wall recess 124 and a U-shaped latch 126 which extends downwardly from the top wall and is spaced from the side wall recess. The tab 104 fits between the U-shaped latch 126 and the side wall recess 124 to enable the U-shaped to engage the outward projection 108 on the latching structure 102 of the base section. The upper section includes other similar latching structures 128, 130 and 132 which engage, respectively, latching structures 110, 112 and 114 on the base section. The upper section also has mounting brackets 134 and 136 which have respectively fastener apertures 138 and 140. On the upper wall 118 of the upper section 116 there are also signal contact access apertures as, for example, apertures 142 and 144. It will be observed that these apertures are arranged in a plurality of rows which correspond to rows of signal contacts in the base section. Interposed between these rows of signal contact access apertures are elongated ground or power contact access slots as, for example, slots 146 and 148.
Referring to FIGS. 3-4 and FIG. 11, the plug element of the connector is shown generally at numeral 150. The plug includes a base wall 152 and a peripheral side wall 154. There are opposed gaps 156 and 158 in the side wall and there is an open side 160 in opposed relation to the base wall. Projecting laterally from the plug there are mounting brackets 162 and 164 which have, respectively, fastener receiving apertures 166 and 168 that are alignable with the fastener receiving apertures in the mounting brackets of the receptacle. On the outer side of the base wall there are outer signal contact receiving recesses as at recess 170. Also on the outer side of the base wall are outer power or ground contact receiving recesses as at recess 172. In opposed relation to the outer recesses on the base wall there are inner signal contact receiving recesses as at recess 174 in inner power or ground contact receiving recesses as at recess 176. Connecting the outer and inner signal contact receiving recesses and the outer and inner power or ground contact receiving recesses are, respectively, medial slots 178 and 180. Mounted in the power ground contact receiving recesses and their medial slot is a power or ground contact which is shown generally at numeral 182. This contact has an elongated inner section 184, an elongated medial section 186 which is mounted in a base wall and an outer section 188 which is fused to a solder ball 190. It will be observed that this outer section and the solder ball are partially contained in the outer recess 172. The plug also includes a plurality of signal contacts as is, for example, shown generally at 192. These signal contacts have an inner section 194, a medial section 196 which are mounted in the base wall, and an terminal tab 198 which are fused to a solder ball 200. Again it will be observed that this outer section and the solder ball are partially contained in the outer recess as at 170.
Referring to FIGS. 5-7c, it will be seen that the plug described above is mounted on a PWB 202 and the receptacle is mounted on a PWB 204. The plug and receptacle thereby forms a board to board interconnection, as illustrated in FIG. 6. In addition to the contacts previously noted, the plug has signal contacts such as 206 fused to solder 208 and the ground power contact 210 which is fused to solder ball 212 and ground or power contact 214 which is fused to solder ball 216. It will be seen that the solder balls are also fused to the PWB 202 to fix the entire plug to the PWB and effect electrical contact between the signal and ground or power contacts in the plug and the PWB. It will be appreciated that although not all contacts are illustrated in FIG. 5, all such contacts are connected to solder balls and to the PWB in the same way. Similarly it will be seen that signal contact 218 which is mounted in slot 142 is fused to solder ball 100 and that solder ball is fused to the PWB 204. Similarly signal contact 222 which is mounted in the slot 144 is fused to solder ball 224 which is itself fused to PWB 204. Ground power contact 226 is mounted in slot 148 and is fused to solder ball 228 and that solder ball is itself used to PWB 204. It will also be seen that the plug is aligned with the receptacle so that the peripheral side wall 154 of the plug overlaps the peripheral side wall 120 of the upper section 116 of the receptacle. Referring particularly to FIGS. 7a-7c the engagement of the plug and receptacle is shown in greater detail. In FIG. 7a after initial alignment the signal contacts in the plug initially engage the signal contact receiving slots in the receptacle and the power ground contacts in the plug initially engage corresponding power or ground receiving slots in the receptacle. In FIG. 7b the signal contacts in the plug initially engage the corresponding signal contacts in the receptacle and the power ground contacts in the plug become engaged between the opposed leaves of the power ground contacts in the receptacle. In FIG. 7c it is shown that the signal contacts in the plug become fully engaged with the signal contacts in the receptacle and the power ground contacts in the plug become positioned at the base of the fork of the power ground contacts in the receptacle.
Referring to FIG. 8, the exterior side 16 of the base section 12 of the receptacle is shown prior to the application of the solder balls. At this stage the exterior recesses, for example, outer recesses 20, 22, 24, 26 and 28 are shown. Prior to the application of the solder balls the terminal tabs of the signal contacts, for example, terminal tab 82 and, for example, of the power ground contacts, terminal tab 98 would be disposed within the recess. The solder balls would be applied by positioning a solder ball in each of the exposed recesses as is shown in FIG. 9, where, for example, solder ball 82 is shown in recess 20 and solder 100 is shown in recess 22. Additional solder balls, 230, 232 and 234 are shown, for example, in recesses 24, 26 and 28. It will be understood that the solder ball will be positioned in all of the outer recesses of the receptacle. It will also be understood that the exterior side of plug will be substantially identical to the exterior side of the receptacle before placement of the solder balls as is shown in FIG. 8 and after emplacement of the solder balls as is shown in FIG. 9.
Referring to FIGS. 14-18, a second preferred embodiment of the connector of this invention. Referring particularly to FIGS. 14-15, this connector includes a receptacle shown generally at numeral 236. This receptacle includes an insulative housing shown generally at 238 which has an inner side 240, a lateral side 242 and an exterior side 244. The housing also includes opposed alignment projections 246 and 248. On the inner side of the housing there are contacts 250, 251 and 252 each having sections which bow away from each other and then converge to a contact point from which then again diverge. Contacts 251 are mounted on base 231 in the same manner as the embodiment shown in FIGS. 1-13. Solder ball 254 is mounted to the board side of contacts 251 in the same manner as described above. Referring particularly to FIGS. 16 and 17 the receptacle also includes a plug shown generally at 258 which includes an insulative housing shown generally at 260 having an inner side 262, a peripheral lateral side 264 and an exterior side 266. At one end of the housing there are a pair of vertical end walls 268 and 270 with a medial end recess 272. At the opposed end of the housing there are another pair of end walls 274 and 276 with a medial end recess 278. Extending from the inner side of the housing there are a plurality of contacts as at contact 280 that extend from recesses as at 282. These contacts are each fused to a solder ball 284. It will also be seen that these contacts are positioned in a staggered arrangement. For example, contact 286 is axially offset with contact 280 so as to increase contact density. Referring particularly to FIG. 18, it will be seen that each contact in the plug such as contact 280 is vertically aligned with one of the pairs of converging contacts such as 250 and 252 in the receptacle and is interposed between these converging contacts. It will also be seen that the alignment projections 246 and 248 also engage the end recesses 272 and 278 in the plug. In this embodiment the separate ground/power contacts used in the FIGS. 1-13 embodiment are not present. Such functions can, if designed, be incorporated into the undivided contacts pairs.
Referring to FIGS. 19-23, a third preferred embodiment is shown. This connector includes a plug shown generally at numeral 290. This plug includes a housing generally at 292 which has a base wall 294 and a peripheral lateral wall 296 as well as opposed alignment projections 298 and 300. The base wall of the housing has an inner side 302 and an outer side 304. Signal contacts, such as contact 306 extend from inner side 302. It will be seen that the signal contacts are also staggered such that contacts in alternate rows, such as signal contact 308, are offset from contact 306. The plug also includes ground or power contacts 310, 312, 314 and 316 which are arranged adjacent each of the sides of the plug parallel to one side of the lateral wall. On the exterior side of the base wall there are signal contact solder balls such as solder ball 318 and power ground contact solder balls such as 320 which are fused to their respective contacts in the same way as was described with respect to the first embodiment. This connector also includes receptacle shown generally at numeral 322 which has an insulative housing 324 that includes a base wall 326, a peripheral lateral wall 328 and alignment projection receiving recesses 330 and 332. The base wall also has an exterior side 334 and an inner side 336. Projecting from the inner side there are signal contacts as at contact 338 and contact 340. It will be seen that these contacts in adjacent transverse rows are also axially offset to allow an increase in contact density. Parallel to each side of the peripheral wall there are lateral power or ground contacts 342, 344, 346 and 350. On the exterior side of the base wall there are for each signal pin a solder ball such as solder ball 352 and there are solder balls as at solder ball 354 for attaching each of the power or ground pins. Referring to particularly to FIG. 23, it will be seen that at the plug 290 engages receptacle 322.
Referring to FIGS. 24-25, another embodiment of the invention is shown. The receptacle of this connector is shown generally at numeral 324. This receptacle has a base wall 326 which has an exterior side 328 and an interior side 330. On the exterior side there are recesses as at recess 332, 334, 336, 338, 340, 342 and 344. On the interior side there are recesses as at recess 346, 348, 350, 352, 354, 356 and 358. Each of these recesses has a base wall as at wall 360 and a lateral wall as at wall 362. Between the exterior and interior recesses there are medial slots as at slot 364, 366, 368, 370, 372, 374 and 376. Each of these slot has a wide lower section as at section 378 and a narrower upper section as at section 380. In, for example, slot 364 there is a ground/power contact shown generally at numeral 382. This contact has a lower section 384 from which there is a perpendicular tab 368. This contact also has an upper section shown generally at numeral 388 which is made up of forks 390 and 392. Each of these forks has a converging section and an outwardly diverging section 396. The perpendicular tab 386 is attached to a solder ball 398. Other ground/power contacts as at contacts 400 and 402 are also attached respectively in the same way to solder balls 404 and 406. The receptacle also includes a signal contact shown generally at numeral 408 which has an upper section 410 with a forward projection 412 and rearward bend 414. The signal contact also has a medial section 416 where it engages the insulative housing and a lower perpendicular tab 418 where it engages a solder ball 420. Other signal contacts as at contacts 422 and 424 engage respectively solder balls 426 and 428. The connector also includes a plug shown generally at numeral 430 which includes a base wall 432 having an exterior side 434 and an interior side 436. On the exterior side there are recesses as at recess 438, 440, 442, 444 and 446. Each of these recesses has a base wall as at wall 448 and a lateral wall as at 450. Connecting with each of these recesses is a contact receiving slot as at slot 452, 454, 456, 458 and 460. The plug also has a number of power/ground contacts as, for example, is shown generally at numeral 462. Each of these contacts has a contact section 464 where it engages the forks of the ground/power contact on the receptacle. These contacts also have a medial section 466 where it engages the housing and a perpendicular tab 468 where they engage a solder ball 470. Other ground/power contacts as, for example, 472 engage solder balls as at 474. The plug also includes a number of signal contacts as, for example, is shown generally at numeral 476. Each of these signal contacts includes a contact section 478 which engages the signal contacts in the receptacle, a medial section 480 where it engages the housing and a perpendicular tab 482 which engages a solder ball. Other signal contacts as at 486 and 488 engage respectively other solder balls as at 490 and 492.
In the method of this invention the conductive element will preferably be a solder ball. Those skilled in the art, however, will appreciate that it may be possible to substitute other materials which have a melting temperature less than the melting temperature of the contents and that the conductive element will be heated to a temperature greater than its melting temperature. The solder ball or other conductive element will also preferably have a diameter which is from about 50 percent to 200 per cent of the width of the recess. This diameter will also preferably be related to the depth of the recess and be from 50 percent to 200 per cent of that depth. The volume of the solder ball will preferably be from about 75 percent to about 150 percent of the volume of the recess and, more preferably, will be about the same volume as the recess. The contact tab will extend into the recess by a sufficient amount to present adequate surface area to fuse to the solder ball, and will usually preferably extend into the recess from about 25 percent to 75 percent and more preferably to about 50 percent of the depth of the recess. The recess ordinarily will be circular, square or any other regular polygon in cross section. When a solder ball is used, any conventional tin lead alloy used in soldering compositions would be acceptable, but the use of a eutectic solder is preferred. Before the solder ball or other conductive element is positioned in a recess, that recess would usually be filled with solder flux. Any conventional organic or inorganic solder flux is believed to be suitable for this purpose, but a no clean solder cream or paste is preferred. Heating is preferably conducted in a panel infra red (IR) solder reflow conveyor oven. The solder element would ordinarily be heated to a temperature of from about 185° to 195° C. but, depending on the material of the housing, solders having melting temperatures up to about 800° F. may be used. The conveyor oven would preferably be operated at a rate of speed from about 10 to 14 inches per second and would be moved through a plurality of successive heating phases for a total time of about 5 minutes to about 10 minutes.
The method of the present invention is further described with reference to the following examples.
EXAMPLE 1
An insulative housing for a connector plug and receptacle substantially is described above in connection with FIGS. 1-18 was made. Contacts also substantially in accordance with that description were also positioned in the housing. These contacts were beryllium copper and were plated with gold over their entire surface area to a thickness of 30 microns. The housing material was DUPONT H6130 liquid crystal polymer (LCP). The length and width of the plug were respectively 52.5 inches (including mounting brackets)and 42.36 inches. The recesses on the exterior surfaces of the plug and receptacle housing were cross sectionally square having a side dimension of 0.62 mm and a depth of 0.4 mm. About 2 mm of the contact extended into the recess. Other dimensions were generally in proportion to the above dimensions in accordance with FIGS. 1-18. On the exterior sides of both the plug and receptacle the recesses were filled or substantially filled with CLEANLINE LR 725 no clean solder cream which is commercially available from Alphametals, Inc. of Jersey City, N.J. Both the plug and receptacle were turned over on their exterior sides on a quantity of spherical solder balls so that a solder ball became embedded in each of the recesses. The solder balls used were ALPHAMETAL no flux 63SN/37PB spherical solder balls which had a diameter of 0.030 inch ±0.001 inch and a weight of 0.00195 g. The plug and receptacle were then treated with FLUORAD which reduces wicking and is available from 3M Corporation. After such treatment the plug and receptacle were then placed in a BLUE MAX convection oven and heated at 105° C. for two hours. The plug and receptacle were then positioned on separate boards made up of conventional reinforced epoxy printed circuit board material. These boards have lengths of 6 inches, widths of 1.5 inches and thicknesses of 0.061 inches. Referring to FIG. 8, a thermocouple was placed on the exterior surface of the plug in position T. Another thermocouple was centrally positioned upon the supporting board surface adjacent the plug. Both the plug and the receptacle were then treated in a KIC panel-infrared (IR) conveyer solder reflow oven. As is conventional for this type of oven, the plug and receptacle were moved through six zones in the reflow oven. The conveyor speed was 13 in/min. Heating temperatures in each zone are shown in Table 1. Minimum and maximum temperature for the plug and for the supporting board are shown in Table 2. Temperature by time and distance for the plug is shown in the curve in FIG. 24a wherein the heavy line is temperature at the thermocouple on the supporting board and the light line is temperature at the thermocouple on the plug exterior surface. A visual inspection of the plug and the receptacle after solder reflow was that nearly all the solder balls had fused to the contact leads in their respective cavities. Solder ball height above the exterior surfaces of the plug and the receptacle also appeared to be relatively uniform. There was no noticeable warping or bending of the housing.
TABLE 1______________________________________Temperature (° C.)ZONE #1 #2 #3 #4 #5 #6______________________________________UPPER 350 Unheated 275 230 310 UnheatedLOWER Unheated Unheated 275 230 310 Unheated______________________________________
TABLE 2__________________________________________________________________________Connector BoardExampleMax Temp (° C.) Time (Min. & Sec.) Max Temp (° C.) Time (Min. & Sec.)__________________________________________________________________________1 187 4:09.2 -- --1 -- -- 234 4:33.62 191 4:53.2 -- --2 -- -- 209 5:10.4__________________________________________________________________________
EXAMPLE 2
Another plug and receptacle were prepared in essentially the same way as was described in Example 1 and solder balls were emplaced in the recesses on the exterior sides. Several hours after the treatment in the KIC Panel/IR conveyor solder reflow oven in Example 1 when atmospheric conditions were somewhat different another plug and receptacle essentially similar to the ones used in Example 1 were subjected to similar reflow heating as were used in Example 1. Oven conditions are shown in Table 1. Minimum and maximum temperatures of the plug and the adjacent supporting board are shown in Table 2. Temperature by time and distance is shown in FIG. 26b. It will be seen that the curve shown in FIG. 26b is somewhat different than that shown in FIG. 26a which difference is attributed to different ambient atmospheric conditions. A visual inspection of the resulting connector showed similar results to those achieved in Example 1.
EXAMPLE 3
Another connector was made using essentially the same conditions as were described in Examples 1 and 2 except that the specific curves shown in FIGS. 26a and 26b may have been somewhat different because of atmospheric conditions. After the completion of this connector, the solder balls at six locations on the exterior surface of the plug were examined by Laser Point Range Sensor (PRS) available from Cyber Optics Corporation of Minneapolis, Minn. Referring to FIG. 9, these locations are identified as areas 27a and 27b when the laser was directed from L 1 , as areas 27c and 27d when the laser was directed from L 2 and as areas 27e and 27f when the laser was directed from L 3 . At all these areas a laser profile was taken of the profiles of the five solder balls in each of these areas. Reproductions of these laser profile are shown in FIGS. 27a-27f. The height of each of these solder balls at its highest point above the plane of the exterior side of the plug is shown in Table 3. For each of these groups the solder ball closest to the front of the plug as shown in FIG. 9 was considered the first position in Table 3 and was the solder ball on the left of the graphs in FIGS. 27a-27f. An examination of these results reveals that in each group of five solder balls there was what was considered to be an acceptable degree of uniformity for the height of the solder balls.
TABLE 3______________________________________POSITION HEIGHT (.001 in.)GROUP 1 2 3 4 5______________________________________26a 18.1 18.9 19.5 19.6 19.126b 19.2 18.5 17.6 18.5 18.026c 20.4 21.1 21.6 21.1 21.426d 19.9 20.1 20.1 21.2 20.526e 18.2 18.9 19.3 18.2 18.726f 19.1 18.2 19.0 18.2 18.9______________________________________
EXAMPLE 4
Another connector was made essentially according to the conditions described in Examples 1 and 2 except because of atmospheric conditions the specific curves shown on FIGS. 26a and 26b may have been somewhat different. In almost all cases solder balls were satisfactorily fused to the contact leads and solder balls were of an acceptably uniform height above the plane of the exterior surfaces of the plug and receptacle on visual inspection. A stencil with a pattern matching the solder balls on both the plug and receptacle with conductive solder pads on two different circuit boards each having a length of 41/8 inches, a width of 21/2 inches and a thickness of 0.061 inches. The plug was positioned on one stencil and one piece of circuit board material and the receptacle was positioned on the other stencil and piece of circuit board material. The plug and receptacle were then separately again treated in the KIC Panel/IR conveyor oven under conditions similar to those described in fusing the solder balls to the leads except that conveyor speed was decreased to 11 in/sec. After cooling, the plug and receptacle were found to have been satisfactorily fused to their respective boards. Referring to FIG. 9, the solder balls were examined by x-ray diffraction. A photograph showing these x-rays at these positions are attached respectively at FIGS. 28a and 28b. Cross sectional electron microscope photographs were taken to show the fusing of the solder balls to the signal contact leads and the fusing of the solder balls to the printed circuit board material. These electron microscope photographs are shown respectively at FIGS. 28c and 28d. There was only one short between only adjacent signal contacts and good connections were made between the contacts and the solder balls and between the solder balls and the boards.
It will be appreciated that electrical connector and the method of its manufacture has been described in which the connector has contact leads which, surprisingly and unexpectedly, are able to be fused to solder balls and in which those solder balls in turn may be fused to a PWB.
Surprisingly and unexpectently it was also found that therre was a relatively high degree of uniformity in the profiles of the solder balls and, in particular, in the weights of the solder balls above their substrates.
While the present invention has been described in connection with the preferred embodiments of the various figures, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiment for performing the same function of the present invention without deviating therefrom. Therefore, the present invention should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims.
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Disclosed is an electrical connector in which the contacts are fused to a solder ball conductive material which are reflowed to provide a primary electrical current path between the connection and a substrate. Also disclosed is a method for fusing the conductive element to the contacts of the connector. There is at least one recess on the exterior side of the connector elements. A conductive contact extends from adjacent the interior side of the conductor element into the recess on the exterior side of the housing. A conductive element which will ordinarily be a solder ball is positioned in the recess on the exterior side of the housing. The metallic element emplaced in the recess is then heated to a temperature sufficient to soften the metallic element and fuse the metallic element to the contact extending into said recess.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to weight lifting apparatus and, more particularly, to weight apparatus utilizing weights secured to a bar and a rotatable sleeve secured to the bar.
2. Description of the Prior Art
Generally, the weight lifting apparatus of the prior art utilizing a bar comprises simply a bar to which weights are secured by a pair of collars. The collars are secured on opposite sides of the weights, typically by set screws or the like. The bar is grasped by the user and the bar and weights comprise a single unit in the hands of the users.
On some weight lifting bars, the weights include bearings so that the weights rotate with respect to the bar, but the bar itself is rigid with respect to the user.
U.S. Pat No. 2,470,816 (Harvey) discloses an exercise apparatus in which there are a pair of hand grips, one fixed at one end of a bar, and another hand grip movable relative to the bar.
U.S. Pat. No. 3,756,597 (Monti) discloses exercise apparatus in which a pair of hand grips are secured to a bar adjacent to the ends of the bar, with weights extending in a pendulum fashion downwardly from the ends of the bar. The weights move or pivot relative to the bar on bearing material. U.S. Pat. No. 3,904,198 (Jones) discloses exercise apparatus of a configuration generally similar to that of the '597 ( Monti) patent. The '198 (Jones) patent utilizes a pair of hand grips secured to a bar, and the hand grips are freely rotatable relative to the bar.
U.S. Pat. No. 4,043,553 (Suarez) discloses an exercise apparatus which also utilizes a pair of hand grips that are rotatable or moveable relative to a bar. Again, weights extend downwardly from opposite ends of the bar, similar to the general concept of both the '597 (Monti) patent and the '198 (Jones) patent.
U.S. Pat. No. 4,231,569 (Rae) discloses an exercise frame apparatus that utilizes dumbbells and some type of a bearing system. Details of the bearings are not disclosed.
U.S. Pat. No. 4,361,324 (Baroi) discloses a freely rotating sleeve disposed about a connecting bar in a dumbbell embodiment.
U.S. Pat. No. 4,455,020 (Schnell) discloses the use of low friction bearing sleeves to support weights on a bar. The sleeves allow the weights to rotate relative to the bar.
U.S. Pat. No. 4,775,147 (Bold, Jr.) discloses a wheel rotatable mounted on a sleeve, and the sleeve in turn rotates about a bar. A weight is secured to the wheel.
British patent 151,840 (Pullum) discloses weight lifting apparatus in which there are a plurality of sleeves disposed about a central bar. Included in the various sleeves are hand grips which rotate relative to the bar.
British patent 1,588,973 (Castle) discloses deformable sleeves rotatably mounted on a shaft. The sleeves are radially deformable between their ends to provide frictional resistance to the rotation of the sleeves.
In the above discussed patents, either the weights rotate relative to the bar, or fixed hand grips rotate relative to the bar. In the apparatus of the present invention, a central sleeve rotates relative to a bar, and the weights are fixed to the bar. The utilization of the rotatable sleeve allows the placement of the users hands at any desired location on the sleeve and convenient for a particular user for a particular exercise, and permits a more fluid motion of the user in raising the bar and weights while exercising. A more coordinated movement is possible because the user lifts only weight without any rotary forces of the weights on the bar wording against the user. Moreover, weight lifting exercises may be accomplished without the rasping noise of the weights on the bar in prior art apparatus as the weights move relative to the bar, or as they attempt to move relative to the bar.
SUMMARY OF THE INVENTION
The invention described and claimed herein comprises weight lifting apparatus in which weights are secured to a central bar, and a tubing or sleeve element is secured between a pair of collars which are in turn secured to the bar. The sleeve or tubing element rotates relative to the bar and to the weights.
Among the objects of the present invention are the following:
To provide new and useful weight lifting apparatus;
To provide new and useful weight lifting apparatus in which a sleeve is rotatable relative to a bar;
To provide new and useful apparatus in which a pair of collars is secured to a bar, and sleeve is rotatably secured between the collar; and
To provide new and useful weight lifting apparatus in which weights may be fixedly secured to a bar, and a hand grip is rotatably secured to the bar.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of weight lifting embodying of the present invention.
FIG. 2 is a view in partial section taken generally along line 2--2 of FIG. 1.
FIG. 3 is an exploded perspective view of the weight lifting apparatus including the apparatus of the present invention.
FIG. 4 is an exploded perspective view of the apparatus of the present invention.
FIG. 5 is a view in partial section taken generally along line 5--5 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a perspective view of a portion of weight lifting apparatus 10 which includes a bar 12 to which is secured a collar 20 embodying the present invention. The apparatus includes a bearing assembly 60 secured to the collar 20 and a sleeve 70 secured to the bearing assembly 60 and disposed over the bar 12. That is, the bar 12 extends through the sleeve to and through a pair of collars 20 on opposite ends of the sleeve 70. For convenience, only one end of the bar 12 and the sleeve 70 and the weights associated therewith are shown in the drawing. The weight lifting apparatus is, of course, symmetrical.
A pair of weights 80 and 82 are secured to the bar 12 adjacent to the collar 20. The weights 80 and 82 are held onto the bar 12 by an outer collar 90. The outer 90 is in turn secured to the bar 12 by means of a set screw 92 which extends through the collar 90.
FIG. 2 is a side view in partial section of the weight lifting apparatus 10 of FIG. 1 taken generally along line 2--2 of FIG. 1. FIG. 3 is an exploded perspective view of the weight lifting apparatus 10. with the bar 12, the weights 80 and 82, and the collar 90 and its set screw 92 shown in dotted line. The collar 20 and the sleeve 70 are shown in perspective in their relationship to the bar 12 and to the weight 80 and the collar 90.
FIG. 4 is an exploded perspective view of the collar 20 and the elements associated with the collar 20. FIG. 5 is a view in partial section through the collar 20, taken generally along line 5--5 of FIG. 2.
For the following discussion of the weight lifting apparatus 10, and particularly of the collar 20 and its associated elements, including the sleeve 70, reference will be made to all five of the figures.
The bar 12 is a standard or conventional weight lifting bar to which or on which a plurality of weights may be secured for allowing a user to perform weight lifting exercises. Only one end of the bar is illustrated, for purposes of clarity. It will be understood that a substantially indentical group of elements is also secured to the opposite end of the bar 12. In the alternative, rather than a relatively long bar used for two handed exercising, the weight lifting apparatus 10 may be a relatively short bar or dumbbell to which weights may be secured for one handed exercising. Regardless of whether a dumbbell type short bar is used or a conventional long bar, the elements involved in the apparatus of the present invention are substantially the same.
The collar 20 includes a generally circular disc 22 which includes a relatively flat back or rear side 24 and a relatively flat front side 26. The weight 80 is shown disposed against the back or rear side 24.
The circular disc 22 also includes an outer periphery 28. The outer periphery is, of course, relatively circular. Between the outer periphery 28 and the front side 26 is a chamfered or rounded edge 27.
A bore 30 extends through the disc 22. The bore 30 is appropriately sized to receive the bar 12. The weights 80 and 82, and the over collar 90 are in turn secured to the bar 12 outwardly from the collar 20. As is well known and understood, the weights and over collars include a central bore for receiving a weight lifting bar. The bore 30 accordingly has a slightly larger diameter than that of the bar 12, likewise, the diameters of the weights 80 and 82 and the collar 90 are slightly larger than the diameter of the bar 12.
The collar 20 also includes a centerbore 32 coaxially aligned with the bore 30. The counterbore 32 has a substantially larger diameter than the bore 30. The counterbore 32 receives a bearing assembly 60.
Extending radially through the disc 22, and communicating with the bore 30, are three radial bores, includes a radial bore 34, and radial bore 40, and a radial bore 46. The radial bores 34., 40, and 46 are equally spaced apart, and thus are spaced at about 120 degree intervals.
Extending inwardly from the periphery 28 of the disc 22 at the bores 34, 40, and 46 are three counterbores. The counterbores, are coaxially aligned with their respective bores. The radial bore 34 includes a counterbore 36, the bore 40 includes a counterbore 42, and the bore 46 includes a counterbore 48.
A screw is disposed in each of the three bores, with the head of each screw disposed in the respective counterbores. A screw 38 is disposed in the bore 34, a screw 44 is disposed in the bore 40, and a screw 50 is disposed in the bore 46. The purpose of the screws is to secure the collar 20 to the bar 12. This is best shown in FIG. 5.
The bearing assembly 60 is disposed in the counterbore 32, and thus extends into the disc 22 from the front side 26. The sleeve 70 is press fitted into the bearing 60. The bearing 60 is in turn press fitted into the counterbore 32 of the disc 22.
The inner diameter of the sleeve 70 is slightly greater than the outer diameter of the bar 12. The bearing assembly 60, to which the sleeve 70 is secured, allows the sleeve 70 to rotate independently relative to the bar 12 and to the weights 80 and 82 and the collars 90 and 20, all of which are appropriately secured to the bar 12. Accordingly, a user of the weight lifting apparatus 10 will be able to use the apparatus 10 without the drag of the weights on the sleeve 70, and accordingly without drag from the weights on the users hands.
Drag from the weights normally accompanies the lifting of weights due to the mass of the bar 12 and the weights 80 and 82, for example, as the weight lifting apparatus 10 is raised and lowered through an arcuate path without the sleeve 70 and collar 20. The sleeve 70, secured to the collar 20, and of course to a mirror image collar, weights, etc., at the opposite end of the bar 12 from that illustrated in the drawing, is not hampered by the inertia due to the weights that tends to cause the bar 12 to rotate as the bar and weights are moved arcuately upwardly and downwardly. Thus, a fluid motion by the user of the apparatus 10 is possible as the user raises and lowers the weight lifting apparatus. The bar 12 and the weights 80, 82, and their opposite or corresponding weights (not shown) on the opposite end of the bar 12 (not shown) rotate independently of the sleeve 70.
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Weight lifting apparatus includes a bar to which weights are fixedly secured. The weights are spaced apart from each other and a rotatable sleeve is disposed about the bar between the weights. A pair of collars supports the rotatable sleeve, and the weights are disposed against the collars supporting the sleeve. The collars are secured to the bar.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is related to Japanese applications Nos. 2003-31429 and 2003-335008, filed on Feb. 7, 2003 and Sep. 26, 2003, respectively, whose priorities are claimed under 35 USC § 119, and the disclosures of which are incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an automatic breadmaking apparatus and a method of making bread, particularly to an automatic apparatus and a method for making bread with use of rice flour as a main ingredient.
[0004] 2. Description of the Background Art
[0005] Recently in Japan, with a growing campaign for improving the self-sufficient rate in food and with decreased rice consumption owing to westernized diet and the like, new measures for raising rice consumption have been encouraged. In the circumstances, in order to extend the range of uses of rice flour over existing ones such as rice dumplings, various techniques have been proposed for using rice flour as a wheat flour substitute (see Japanese Examined Patent Publication No. 1995-100002 and Japanese Patent Publication No. 3076552). Bread baked using rice flour produced by the techniques has been expected to grow in popularity among consumers because it has a higher water content and creates the sensation of fullness in a smaller amount than bread baked using wheat flour.
[0006] However, rice flour produced according to the above-mentioned techniques sometimes turns out to be defective when cooked in the same manner as wheat flour is cooked. For example, in cases where the rice flour is used for baking bread in place of wheat flour, gluten does not form well and the bread baked from the rice flour does not rise satisfactorily if the rice flour is cooked as wheat flour is.
SUMMARY OF THE INVENTION
[0007] The present invention has been made in view of this current situation, and an object of the invention is to provide an automatic breadmaking apparatus that enables bread to be adequately baked even using rice flour as the main ingredient.
[0008] In addition, rice flour has a higher moisture content than wheat flour, but, as time passes, the rice flour tends to release moisture that it has absorbed. For this reason, if making bread requires a long time, bread materials are baked in the released moisture. In other words, the bread is baked from the materials in a porridge state. As a result, the baked bread is not tasty. Therefore, another object of the invention is to provide an automatic breadmaking apparatus that enables bread to be made in minimal time.
[0009] In one aspect, the present invention provides an automatic breadmaking apparatus adapted to automatically carry out breadmaking operations from kneading to baking, the automatic breadmaking apparatus comprising a housing, a container receivable in the housing into which breadmaking ingredients are fed, a stirrer for stirring the breadmaking ingredients fed in the container, a stirring control section for controlling an operation of the stirrer, a temperature control section for controlling temperature in the container and a central control section for controlling the stirring control section and the temperature control section in accordance with a breadmaking sequence using rice flour.
[0010] According to this aspect, when the bread making ingredients are fed in the container, the stirring control section and the temperature control section are so controlled that the breadmaking sequence of baking bread from rice flour as a main ingredient is carried out.
[0011] With this constitution, bread can be adequately baked with use of rice flour as the main ingredient.
[0012] In another aspect, the present invention provides an automatic breadmaking apparatus adapted to automatically carry out breadmaking operations from kneading to baking, the automatic breadmaking apparatus comprising a housing, a container receivable in the housing into which the breadmaking ingredients are fed, a stirrer for stirring the breadmaking ingredients fed in the container, a stirring control section for controlling an operation of the stirrer, a temperature control section for controlling temperature in the container and a central control section for controlling the stirring control section and the temperature control section, thereby forming dough by kneading the breadmaking ingredients, fermenting the formed dough and baking the fermented dough, sequentially in the container.
[0013] According to this aspect, the breadmaking ingredients are baked after kneaded into the dough without being subjected to punching or the like which may cause damage to the dough.
[0014] With this constitution, even if the rice flour does not contain gluten, the viscosity of the dough can be prevented from declining owing to damage to the dough and the bread can swell sufficiently during baking. Thus, if the automatic breadmaking apparatus is used for baking bread using rice flour as the main ingredient, the bread can be adequately baked.
[0015] In the automatic breadmaking apparatus of the present invention, the central control section may control the stirring control section and the temperature control section so that a primary rise of the breadmaking ingredients takes place in the container before the dough is formed by kneading.
[0016] With this constitution, even if the bread is made using rice flour, which is less easy to hydrate than wheat flour, the primary rise provides enough time for the rice flour contained in the breadmaking ingredients to hydrate. Thus, if the automatic breadmaking apparatus is used for baking bread using rice flour as the main ingredient, the bread can be adequately baked.
[0017] In the automatic breadmaking apparatus of the present invention, the central control section may control the stirring control section so that the breadmaking ingredients are mixed before the primary rise.
[0018] With this constitution, the hydration of the rice flour during the primary rise can be promoted with more reliability. Also the mixing of the breadmaking ingredients before the primary rise can prevent the breadmaking ingredients from changing into the dough. More particularly, this mixing can prevent the breadmaking ingredients from increasing its viscosity and turning into the dough faster than desired and consequently can avoid the dough having decreased its viscosity when baked.
[0019] In the automatic breadmaking apparatus of the present invention, the stirrer may include a blade mounted on a bottom of the container and a rotating member for rotating the blade, and the central control section may cause the stirring control section to execute such a control that the number of revolutions of the blade per given time is smaller at mixing the breadmaking ingredients than at kneading the breadmaking ingredients.
[0020] With this constitution, it is possible to avoid the flying of powdery components contained in the breadmaking ingredients when mixed, and it is also possible to avoid with higher reliability the breadmaking ingredients raising their viscosity and changing into dough earlier than desired and avoid the dough having decreased its viscosity before baked.
[0021] In another aspect, the present invention provides a method of making bread comprising mixing breadmaking ingredients containing rice flour, subjecting the mixed breadmaking ingredients to a primary rise, kneading the breadmaking ingredients to form dough after the primary rise, fermenting the formed dough and baking the fermented dough.
[0022] With this constitution, the breadmaking ingredients are simply mixed without being kneaded at first so that the breadmaking ingredients do not change into the dough before the primary rise. Thereby it is possible to suppress the increase of the viscosity of the breadmaking ingredients at early stages and thereby prevent the reduction of the viscosity of the dough before baked. Further, in the case where bread is made from rice flour, which is harder to hydrate than wheat flour, the primary rise provides enough time for the rice flour to hydrate and the bread can be adequately baked.
[0023] A time required for mixing the breadmaking ingredients may be set shorter than a time required for kneading the breadmaking ingredients after the primary rise. Thereby the breadmaking ingredients containing the rice flour can maintain fluidity while mixed and change into dough which does not have fluidity while kneaded. Since this setting shortens the time from the change into the dough to the baking of the dough, it is possible to bake the dough before the rice flour in the dough releases moisture. Thus tasty bread can be baked.
[0024] The breadmaking ingredients may not contain wheat flour. Thereby it is possible to make bread that is safe to a person allergic to wheat.
[0025] The breadmaking ingredients may contain sugar, salt, oil, fat, dry yeast and/or skimmed milk powder in addition to the rice flour as the main ingredient. These ingredients help production of various kinds of bread meeting tastes of users.
[0026] The breadmaking ingredients may contain gluten. The gluten contained in the breadmaking ingredients allows production of as softly risen bread as that made from wheat flour.
[0027] The breadmaking ingredients may be free of gluten. According to the breadmaking method of the invention, even if gluten is not contained in the breadmaking ingredients, viscous dough can be obtained. The gluten-free breadmaking ingredients allow production of bread that is safe to a person allergic to wheat.
[0028] To sum up major effects of the invention, which have been mentioned above with regard to each feature of the invention, since the invention can carry out the sequence for baking bread using rice flour as the main ingredient, bread can be adequately baked by the automatic breadmaking apparatus even with use of rice flour as the main ingredient.
[0029] Also, according to the present invention, the breadmaking ingredients are baked after kneaded into dough without punching which might damage the dough. Thus, even with use of breadmaking ingredients containing rice flour but not containing gluten, it is possible to avoid the reduction of the viscosity of the dough due to damage thereto and ensure enough rising of the bread baked. Therefore, the bread can be adequately produced by the automatic breadmaking apparatus even with use of rice flour as the main ingredient.
[0030] Further, according to the present invention, because the breadmaking process as a whole can be simplified by saving a punching step after kneading, it is possible to shorten a required time up to completion of fermentation.
[0031] These and other objects of the present application will become more readily apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] [0032]FIG. 1 is a perspective view of an automatic breadmaking apparatus in accordance with an embodiment of the present invention;
[0033] [0033]FIG. 2 is a vertical sectional view of the automatic breadmaking apparatus of FIG. 1, as seen from the front, with a cooking container for breadmaking placed therein;
[0034] [0034]FIG. 3 is a vertical sectional view of the automatic breadmaking apparatus of FIG. 1, as seen from the front, with a cooking container for making rice cake placed therein;
[0035] [0035]FIG. 4 is a block diagram showing control in the automatic breadmaking apparatus of FIG. 1;
[0036] [0036]FIG. 5 is an enlarged sectional view of the automatic breadmaking apparatus of FIG. 1, showing the vicinity of a control display panel;
[0037] [0037]FIG. 6 is a plan view of the control display panel of the automatic breadmaking apparatus of FIG. 1;
[0038] [0038]FIG. 7 shows a state of the automatic breadmaking apparatus of FIG. 1 before the cooking container is locked to a water vessel of a boiler of the apparatus;
[0039] [0039]FIG. 8 shows a state of the automatic breadmaking apparatus of FIG. 1 after the cooking container is locked to the water vessel of the boiler of the apparatus;
[0040] [0040]FIG. 9 is a vertical sectional view taken along line A-A in FIG. 7;
[0041] [0041]FIG. 10 is a flowchart illustrating an operation of the automatic breadmaking apparatus of FIG. 1; and
[0042] [0042]FIGS. 11A and 11B illustrate each step carried out in automatic breadmaking operations by the automatic breadmaking apparatus of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0043] The present invention is now described in detail by way of example with reference to the attached drawings. FIG. 1 is a perspective view of an automatic breadmaking apparatus 99 as an embodiment of the present invention, showing an outer appearance thereof.
[0044] The automatic breadmaking apparatus 99 includes a housing 1 , an open/close lid 2 , a control display panel 3 , a baking chamber 4 , a baking heater 5 , a boiler 6 as an example of a steam generator, two kinds of cooking containers 7 , 8 called hoppers, a motor 9 , a power transfer unit 10 and a control unit 11 . Both the cooking containers 7 , 8 are removably placed above the boiler 6 in the baking chamber 4 . The cooking container 7 is used for breadmaking, and the cooking container 8 is used for making rice cake and for steam-cooking.
[0045] The automatic breadmaking apparatus 99 is now described in further detail with reference to FIGS. 2 to 8 . FIG. 2 is a vertical sectional view of the automatic breadmaking apparatus 99 , as seen from the front, with the cooking container 7 for breadmaking placed therein. FIG. 3 is a vertical sectional view of the automatic breadmaking apparatus 99 , as seen from the front, with the cooking container 8 for making rice cake placed therein. FIG. 4 is a control block diagram of the automatic breadmaking apparatus 99 . FIG. 5 is an enlarged sectional view of the automatic breadmaking apparatus 99 , showing the vicinity of the control display panel 3 . FIG. 6 is a plan view of the control display panel 3 . FIG. 7 shows a state before the cooking container 7 or 8 is locked to a water vessel of the boiler 6 . FIG. 8 shows a state after the cooking container 7 or 8 is locked to the water vessel of the boiler 6 .
[0046] The housing 1 is formed in an almost rectangular parallelepiped shape. On the top thereof, a top opening is formed in an area about two-thirds as long as the housing 1 in a longitudinal direction. The open/close lid 2 is attached to the top opening so that the open/close lid 2 can be upwardly opened. A lid switch 14 for detecting an opened and a closed state of the open/close lid 2 is mounted on the top opening of the housing 1 . As shown in FIG. 5, the lid switch 14 includes a movable pin 14 A, which is pressed to an ON-state when the open/close lid 2 is closed and is restored to an OFF-state when the open/closed lid 2 is opened.
[0047] The control display panel 3 is provided in the remaining one-third area of the top of the housing 1 and includes various keys and lamps. The keys on the control display panel 3 are, for example, a start key 31 for starting an automatic breadmaking operation, an immersing key 32 for immersing glutinous rice in water, a steaming key 33 for steaming the glutinous rice, a pounding key 34 for pounding the steamed glutinous rice, a cancel key 35 and the like. The lamps on the control display panel 3 are, for example, a breadmaking operation lamp 36 which turns on/off in response to an ON/OFF operation of the start key 31 , an immersing operation lamp 37 which turns on/off in response to an ON/OFF operation of the immersing key 32 , a steaming operation lamp 38 which turns on/off in response to an ON/OFF operation of the steaming key 33 , a pounding operation lamp 39 which turns on/off in response to an ON/OFF operation of the pounding key 34 and the like. The control display panel 3 also includes a menu key 31 A for selecting the kind of bread to be made, a menu display section 31 B indicating the kinds of bread to be selected, a display section 31 C for displaying a menu number selected by the menu key 31 A and a preset time set on a timer, a setting button 31 D for setting the timer for the preset time and the like. The kinds of bread displayed by the menu display section 31 B include “loaf of bread” to be made with use of wheat flour as the main ingredient and “rice bread” to be made with use of rice flour instead of wheat flour as an ingredient.
[0048] The baking chamber 4 forms an atmosphere for baking the dough and is provided in an region within the housing 1 which region corresponds to the top opening. An ambient temperature sensor 15 for detecting the temperature of the atmosphere within the baking chamber 4 is mounted on a peripheral wall of the baking chamber 4 .
[0049] The baking heater 5 regulates the temperature of the atmosphere within the baking chamber 4 and is mounted on an inner peripheral wall of the baking chamber 4 near the bottom thereof.
[0050] The boiler 6 includes a water vessel 61 and a boiler heater 62 . The water vessel 61 is placed at the bottom of the baking chamber 4 , is formed in a substantially elliptic shape as seen in plan view and has an opening on the top. The boiler heater 62 is mounted on an outer periphery at the bottom of the water vessel 61 and evaporates water in the water vessel 61 . A cylindrical wall 63 is provided in a central region of the water vessel 61 . A spindle 12 is rotatably passed in a vertical direction through a horizontal wall provided at a vertically midpoint position of the cylindrical wall 63 . A drive gear 13 is fixed at a projecting upper end of the spindle 12 . A steaming temperature sensor 16 for detecting a steaming temperature is mounted on an outside bottom face of the water vessel 61 of the boiler 6 .
[0051] The motor 9 rotates the spindle 12 mounted to the boiler 6 by the power transfer unit 10 . The motor 9 is provided in a region below the control display panel 3 within the housing 1 .
[0052] The power transfer unit 10 is mounted on an inside bottom of the housing 1 and transfers rotating power of the motor 9 to the spindle 12 . The power transfer unit 10 is composed of a pulley 101 fixed to an output axis of the motor 9 , a pulley 102 attached to a lower end of the spindle 12 and an endless belt 103 looped over the pulleys 101 and 102 .
[0053] The control unit 11 controls breadmaking and rice cake making operations and is provided in a region between the control display panel 3 and the motor 9 within the housing 1 . The control unit 11 includes a microcomputer 111 composed of a CPU (central processing unit), a ROM (read only memory) and a RAM (random access memory), an I/O (input/output) circuit 112 , a motor drive circuit 113 , a heater drive circuit 114 and a boiler drive circuit 115 . The microcomputer 111 corresponds to a central control section.
[0054] The construction of the cooking containers 7 , 8 is now described in detail. The cooking container 8 for making rice cake is provided with a plurality of through-holes 81 for introducing steam at the bottom thereof, while the cooking container 7 for breadmaking is not provided with such through-holes at the bottom thereof. That is a main difference between the cooking containers 7 and 8 . As shown in FIG. 1, the cooking container 8 for making rice cake has a close lid 19 , as an attachment, which can be attached to and detached from a top opening of the cooking container 8 . The close lid 19 is used for steam-cooking.
[0055] The cooking containers 7 and 8 are formed in a shape corresponding to bread of one-and-half loaf size, i.e., in a rectangular parallelepiped shape. The cooking container 8 for making rice cake has outside dimensions a size smaller than inside dimensions of the cooking container 7 for breadmaking. Thus the cooking container 8 can be put in the cooking container 7 in storage.
[0056] Rotation shafts 71 and 82 are provided at the center of the bottom of the cooking containers 7 and 8 . The rotation shafts 71 and 82 pass through the bottom. Stirring blades 17 and 18 for kneading the breadmaking ingredients or rice cake ingredients can be attached to and detached from projecting upper ends of the rotation shafts 71 and 82 , and follower gears 72 and 83 which engage with the drive gear 13 of the spindle 12 are mounted to lower projecting ends of the rotation shafts 71 and 82 .
[0057] Bases 73 and 84 for fixing the cooking containers 7 and 8 to the water vessel 61 of the boiler 6 are mounded on an outside bottom of the cooking containers 7 and 8 . The bases 73 and 84 are formed in such a shape that they cover the water vessel 61 of the boiler 6 and serve as a lid for sealing the water vessel 61 .
[0058] As shown in FIGS. 7 and 8, for immovable fixation of the cooking containers 7 and 8 to the boiler 6 within the baking chamber 4 , engagement pawls 74 and 85 are mounded on outside faces at both longitudinal ends of the bases 73 and 84 of the cooking containers 7 and 8 (two pawls at each end, four in total), and engagement portions 65 which engage with the engagement pawls 74 and 85 are formed at both longitudinal ends on the top face of a base 64 of the water vessel 61 of the boiler 6 . For fixing the cooking container 7 or 8 to the boiler 6 , the base 73 or 84 of the cooking container 7 or 8 is placed over the water vessel 61 of the boiler 6 , and in this state, the engagement pawls 74 or 85 are engaged with the engagement portions 65 . Then the cooking container 7 or 8 is turned in a predetermined direction, for example, clockwise in FIG. 8, so that the engagement pawls 74 or 85 are locked to the engagement portions 65 . In order to allow this locking operation, the outer shape of the bases 73 and 84 is larger than that of the water vessel 61 . In order that the water vessel 61 of the boiler 6 is sealed with the bases 73 and 84 of the cooking containers 7 and 8 , the bottom of peripheral walls of the bases 73 and 84 are contacted by pressing to a packing 20 mounted on the outer periphery of the base 64 of water vessel 61 .
[0059] [0059]FIG. 9 is a vertical sectional view taken along line A-A in FIG. 7. FIG. 9 corresponds to a sectional view of the packing 20 .
[0060] The packing 20 is formed of a soft rubber in a shape of almost reverse U as seen in cross section, and the packing 20 is hollow. The packing 20 is attached to the base 64 with a lower opening 20 A of the packing 20 fitted in a groove 64 A formed in the outer periphery of the base 64 . When the base 73 or 84 is placed over the water vessel 61 , the lower end of the peripheral walls of the base 73 or 84 is contacted by pressing with the top 20 B of the packing 20 . Since the packing 20 is hollow, the packing 20 can readily change its form to fit to the shape of the lower end of the peripheral walls of the base 73 or 84 and consequently a close contact can be obtained. Thus steam can be effectively prevented from leaking out of the water vessel 61 , and steam generated in the water vessel 61 can all be supplied into the cooking container 8 without waste. Therefore, glutinous rice and the like can be effectively steamed.
[0061] As shown in FIG. 2, the cooking container 7 for breadmaking includes a steam bypass hole 75 in the base 73 thereof. Unlike the cooking container 8 for making rice cake, the cooking container 7 does not have the steam introduction holes 81 on the bottom. If the cooking container 7 is mistakenly used for making rice cake, an internal pressure will rise owing to steam generated from the boiler 6 . The steam bypass hole 75 prevents this rise in the internal pressure.
[0062] The cooking container 8 for making rice cake includes an identification member 86 on a peripheral wall of the base 84 thereof as shown in FIG. 3, while the cooking container 7 for breadmaking does not include such an identification member. In this connection, a cooking container identification switch 21 is mounted on the bottom of the baking chamber 4 . The cooking container identification switch 21 is activated by the identification member 86 of the cooking container 8 .
[0063] The stirring blades 17 , 18 are formed in shapes allowing for the kneadability of ingredients. More particularly, the stirring blade 17 is a kneading blade for breadmaking and has a shape suitable for kneading breadmaking ingredients and dough. On the other hand, the stirring blade 18 is a pounding blade for rice cake pounding and has a shape suitable for pounding rice cake material. In order to avoid mis-attachment of the stirring blades 17 and 18 different in shape to the cooking containers, attachment holes of the stirring blades 17 and 18 have different shapes in cross section and upper portions of the rotation shafts 71 and 82 of the cooking containers 7 and 8 have different shapes, the attachment holes of the stirring blades 17 and 18 corresponding to the rotation shafts 71 and 82 , respectively.
[0064] Referring to FIG. 4, in the automatic breadmaking apparatus 99 , the control unit 11 receives various kinds of information from the control display panel 3 , the lid switch 14 , the ambient temperature sensor 15 , the steaming temperature sensor 16 and the cooking container identification switch 21 . The control unit 11 includes the boiler drive circuit 115 for controlling the operation of the boiler 6 , the motor drive circuit 113 for controlling the operation of the motor 9 , the heater drive circuit 114 for controlling the operation of the baking heater 5 , the microcomputer 111 for controlling the operation of the motor drive circuit 113 , the heater drive circuit 114 and the boiler drive circuit 115 based on input information and the I/O circuit 112 for controlling input and output of information in the control unit 11 . The microcomputer 111 , in response to information input to the control unit 11 , controls the operation of the motor drive circuit 113 , the heater drive circuit 114 and the boiler drive circuit 115 and also controls indications displayed by various lamps such as the breadmaking operation lamp 36 on the control display panel 3 .
[0065] The operation of the automatic breadmaking apparatus 99 based on the control of the microcomputer 111 is now described by use of the flowchart of FIG. 10 illustrating contents of the control of the microcomputer 111 .
[0066] When power is tuned on, the operation waits for any one of the start key 31 , the immersing key 32 , the steaming key 33 and the pounding key 34 of the control display panel 3 to be activated by a user in Steps S 1 to S 4 .
[0067] The user needs to press the start key 31 for breadmaking and press the immersing key 32 , the steaming key 33 and the pounding key 34 sequentially at the end of each step for making rice cake. If bread is to be made, the cooking container 7 for breadmaking is required to be placed in the baking chamber 4 , and if rice cake is to be made, the cooking container 8 for making rice cake is required to be placed in the baking chamber 4 .
[0068] When the immersing key 32 is activated, an immersing step is carried out in Step S 5 in which glutinous rice is immersed for a necessary period so that the glutinous rice contains enough water. For preparation for this step, the user needs to wash the glutinous rice and put the glutinous rice in a container such as the cooking container 7 for breadmaking with a required amount of water. The immersing step is carried out for the glutinous rice to contain water prior to a steaming step in Step S 7 .
[0069] When the immersing step completes, the completion of the immersing step is indicated in Step S 6 , and the operation waits for the user to press a key.
[0070] When the steaming key 33 is activated, the steaming step is carried out in Step S 7 in which the boiler 6 is driven, thereby steaming the glutinous rice having contained water in the above-mentioned immersing step. For preparation for this step, the user needs to put the glutinous rice having contained water in the cooking container 8 for making rice cake and also put a required amount of water in the water vessel 61 of the boiler 6 .
[0071] When the steaming step completes, the completion of the steaming step is indicated in Step S 8 , and the operation waits for the user to press a key.
[0072] When the pounding key 34 is activated, a pounding step is carried out in Step S 9 in which the stirring blade 18 of the cooking container 8 is rotated by the motor 9 and the power transfer unit 10 to knead and pound the steamed glutinous rice in the cooking container 8 .
[0073] When the start key 31 is activated, an automatic operation of making bread is carried out in Step S 11 . For preparation for this step, the user needs to feed breadmaking ingredients (flour, water, yeast, etc.) in the cooking container 7 for breadmaking, select a desired menu and set a timer for a desired finish time. The automatic breadmaking apparatus 99 of this embodiment carries out different operations in the case where wheat flour is mainly used for the dough (for example, “loaf of bread” is selected from the kinds of bread in the menu display section 31 B) and in the case where the rice flour is mainly used for the dough instead of wheat flour (for example, “rice bread” is selected from the kinds of bread in the menu display section 31 B). In the former case, as shown in FIG. 11A, a kneading step, a primary rise step, a punching step, a dough setting step, a dough rounding step, a secondary rise step of fermenting the rounded dough, a baking step and a keep-warm step (not shown) are sequentially carried out in this order.
[0074] In the kneading step, the breadmaking ingredients are kneaded by turning the motor 9 on and off at preset intervals for four minutes and then continuously driving the motor 9 for ten minutes to rotate the stirring blade 17 . Thus the number of revolutions of the stirring blade 17 per unit time is suppressed by turning the motor 9 on and off for the starting four minutes of kneading for the purpose of avoiding the flying of powdery components contained in the breadmaking ingredients. The kneaded breadmaking ingredients turn into a dough state.
[0075] In the primary rise step, the ambient temperature within the baking chamber 4 is maintained at 32° C. by the baking heater 5 , and the dough is allowed to stand for 52 minutes. During the primary rise, the fermentation of the dough progresses, and the dough rises owing to gas enclosed in the dough.
[0076] In the punching step, the dough is punched for degasification by the stirring blade 17 rotated by continuous drive of the motor 9 for ten seconds. By this punching step, large accumulations of gas (gas bubbles) in the dough are eliminated, so that the dough becomes uniform.
[0077] In the dough setting step, the ambient temperature within the baking chamber 4 is maintained at 32° C. by the baking heater 5 , and the dough is allowed to stand for 37 minutes. By this step, the dough damaged by punching is laid to rest and uniformly rises.
[0078] In the dough rounding step, the dough is rounded by the stirring blade 17 rotated by continuous driving the motor 9 for eight seconds. Thereby the dough is well formed before baked.
[0079] In the secondary rise step, the ambient temperature within the baking chamber 4 is raised and maintained at 38° C. by the baking heater 5 , and the dough is allowed to stand for an appropriate time (30 to 70 minutes, for example, 60 minutes). Thereby the dough is more vividly fermented and rises sufficiently.
[0080] In the baking step, the ambient temperature within the baking chamber 4 is raised and maintained at 160° C. by the baking heater 5 , and the dough is allowed to stand for 47 minutes.
[0081] In the keep-warm step, the ambient temperature within the baking chamber 4 is slowly decreased from the previous baking temperature to 80° C. In this step, the baking heater 5 is controlled to turn on and off within a time period of 60 minutes at longest.
[0082] In the latter case (where the rice flour is used in place of wheat flour), as shown in FIG. 11B, a mixing step, a primary rise step, a kneading step, a secondary rise step, a baking step and a keep-warm step (not shown) are sequentially carried out in this order by an automatic breadmaking operation.
[0083] In the mixing step, the motor 9 is driven for three minutes to rotate the stirring blade 17 in order to mix the breadmaking ingredients. In the mixing step, the motor is turned on and off at particular intervals. Thereby the stirring blade 17 is rotated intermittently, and consequently, the number of revolutions of the stirring blade 17 per unit time decreases as compared with the case where the stirring blade is rotated continuously.
[0084] In the present specification, the term “kneading” means rotating the stirring blade 17 so that the breadmaking ingredients obtain the best viscosity for being baked. On the other hand, the term “mixing” means rotating the stirring blade 17 to mix the breadmaking ingredients for a short time so that the rice flour in the breadmaking ingredients is promoted to hydrate but the viscosity of the breadmaking ingredients does not rise. In the present invention, the breadmaking ingredients are referred to as “dough” after they are kneaded and lose their fluidity, but the breadmaking ingredients that are simply mixed and do not lose their fluidity are referred to as “breadmaking ingredients.”
[0085] In the primary rise step, the ambient temperature within the baking chamber 4 is maintained at 25° C. by the baking heater 5 , and the breadmaking ingredients are allowed to stand for 60 minutes. In the primary rise in FIG. 11A, the breadmaking ingredients in the cooking container 7 turn almost into the dough, while in the primary rise in FIG. 11B, the breadmaking ingredients in cooking container 7 remain breadmaking ingredients.
[0086] In the kneading step, the motor 9 is continuously driven for ten minutes to rotate the stirring blade 17 in order to knead the breadmaking ingredients. At the start of kneading in FIG. 11A, the motor 9 is intermittently driven, while in the kneading step in FIG. 11B, such intermittent driving is not performed because it is considered that the powdery components of the breadmaking ingredients are already unlikely to fly by kneading.
[0087] In the secondary rise step, the ambient temperature within the baking chamber 4 is raised and maintained at 38° C. by the baking heater 5 , and the dough is allowed to stand for an appropriate time period (30 to 70 minutes, for example, 50 minutes).
[0088] In the baking step, the ambient temperature within the baking chamber 4 is raised and maintained at 160° C. by the baking heater 5 , and the dough is allowed to stand for 55 minutes.
[0089] In the keep-warm step, the ambient temperature within the baking chamber 4 is slowly decreased from the previous baking temperature to 80° C. In this step, the baking heater 5 is controlled to turn on and off within a time period of 60 minutes at longest.
[0090] According to the sequence of FIG. 11B, the time until the completion of fermentation is shortened by nearly 30 minutes as compared with the sequence of FIG. 11A. Therefore, the fermentation can be finished before the rice flour releases moisture, and consequently, delicious bread can be made. Moreover, the bread can be made in a reduced time. Breadmaking becomes quicker and easier.
[0091] In the embodiment described above, the automatic breadmaking apparatus 99 provides excellent usability because it can be used for breadmaking, rice cake making and steam-cooking. Furthermore, regarding breadmaking, the automatic breadmaking apparatus 99 carries out different sequences for the breadmaking ingredients mainly containing wheat flour and for those mainly containing rice flour.
[0092] The breadmaking ingredients usable with the automatic breadmaking apparatus 99 may not contain wheat flour, may contain both wheat and rice flour and may contain rice flour, sugar, salt, fat, oil, dried yeast and/or skimmed milk powder. The breadmaking ingredients containing rice flour may contain gluten, may not contain gluten, and may contain a plurality of kinds of rice flour.
[0093] In the sequence of FIG. 11B, the stirring blade 17 is rotated in the mixing step and in the kneading step. The breadmaking ingredients are considered to have a lower viscosity in the mixing step than in the kneading step. For this reason, the number of revolutions of the stirring blade 17 (per unit time) is preferably smaller in the mixing step than in the kneading step. The number of revolutions of the stirring blade 17 is reduced in the mixing step as compared with that in the kneading step also because the powdery components of the breadmaking ingredients are more likely to fly in the mixing step than in the kneading step. The reduction of the number of revolutions of the stirring blade 17 is intended for ensuring that the powdery components are prevented from flying.
[0094] Also in the sequence of FIG. 11B, the breadmaking ingredients are stirred by the stirring blade 17 at a smaller number of revolutions for a shorter time in the mixing step than in the kneading step. That is for ensuring that the breadmaking ingredients containing rice flour instead of wheat flour first turn into the dough not in the mixing step but in the kneading step. If that is ensured, in the mixing step, the breadmaking ingredients may be stirred at the same number of revolutions but for a shorter time as compared with the kneading step or may be stirred at a reduced number of revolutions but for the same time period as compared with the kneading step.
[0095] The above-described embodiment should be construed as an example for the illustration purpose alone and should not be considered to limit the scope of the present invention. The scope of the invention is defined by the claims but not by the above explanation, and various changes and modifications will be included within the spirit and scope of the invention.
[0096] The present invention can be utilized for producing breadmaking apparatuses for baking delicious and softly risen bread with use of rice flour.
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An automatic breadmaking apparatus adapted to automatically carry out breadmaking operations from kneading to baking includes a housing, a container receivable in the housing into which breadmaking ingredients are fed, a stirrer for stirring the breadmaking ingredients fed in the container, a stirring control section for controlling an operation of the stirrer, a temperature control section for controlling temperature in the container, and a central control section for controlling the stirring control section and the temperature control section in accordance with a breadmaking sequence using rice flour.
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[0001] This is a continuation-in-part of U.S. application Ser. No. 09/175,007, filed Oct. 19, 1998.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention The present invention relates generally to a dental implant, and more particularly to a dental implant with a thread design and structure which provides for dramatically improved loading to thereby facilitate an immediate load implant or an implant with dramatically reduced healing time. The present invention also relates to a method of installing the above identified implant.
[0003] 2. Description of the Prior Art
[0004] Dental implants of various configurations currently exist in the art. These implants are installed into prepared bone sites and function as a device for anchoring a component such as a tooth or dental appliance in the patient's mouth. Examples of currently available dental implants are shown in U.S. Pat. No. 5,062,800 issued to Niznick, U.S. Pat. No. 5,368,160 issued to Leuschen, et al. and U.S. Pat. No. 5,582,299 issued to Laxnaru. Existing dental implant devices commonly include an implant having external threads for installation into a prepared bone site and a hollow interior with internal threads extending from its superior or top end downwardly into the interior of the main body of the implant. Such internal threads are used for connecting an implant mount during the installation process and for connecting a healing cap or a replacement tooth or other prosthesis when the installation is complete. During installation, the implant mount is connected with the implant via a threaded clamp screw. The implant mount interfaces with the implant through a hex connection which enables the implant to be rotated via rotation of the implant mount. It is common for the implant to be provided to the attending surgeon in a pre-mounted position with the implant mount connected to the implant by the clamp screw.
[0005] Installation of a dental implant in accordance with current procedures can be summarized as follows. After preparation of the bone site, a dental hand piece with a placement adaptor is positioned onto the implant mount via a hex or other connection. The implant is then positioned in the prepared bone site and installed by rotation of the implant mount, and thus the implant, in a forward or clockwise direction. The hand piece with attached placement adaptor is then removed from the implant mount and an open end wrench or other tool is positioned onto the hex end of the implant mount to remove the same. Because the interface between the threads of a conventional implant and the surrounding bone or tooth tissue is insufficient to resist the compressive forces resulting from normal chewing or biting action, it is necessary to allow the bone or tooth tissue in contact with such threads to heal before a replacement tooth or other prosthesis can be applied. In most cases, this period can be six months or more. Thus, following installation of a conventional implant and removal of the implant mount, a protective cover or healing screw is screwed into the internal threads of the hollow interior for the duration of the required healing time. In some cases the soft tissue surrounding the implant is extended and sutured over the healing screw, while in other cases the top of the implant is substantially flush with the surrounding tissue and the healing screw remains exposed during the healing period.
[0006] After the healing period has passed, the surgeon removes the protective screw and installs a healing cap. This healing cap is nonfunctional and remains in place while the tissue heals, generally 4-6 weeks. After this time period, the restoring doctor installs the replacement tooth or other prosthesis. The replacement tooth or other prosthesis commonly includes a mounting stem with external threads to be received by the internal threads of the hollow interior. Several drawbacks exist with respect to the current procedure. The primary drawback is that current procedures require two surgeries at intervals spaced by the required healing time: one surgery to install the implant, and a second surgery to remove the healing screw and install the healing cap and then later, the replacement tooth or prosthesis. The required healing time can be up to six months or longer. With conventional implants, the six month or more waiting time is needed because the external threads of the implant do not efficiently distribute the load and the bone is not strong enough immediately after installation to be fully loaded or to support the implant with a connected replacement tooth or other prosthesis. Thus, with current implants embodying current external designs, a healing period of up to six months or more is required after the first surgery (installation of the implant) to allow the tooth bone to grow around the implant and to heal.
[0007] Prior implant designs have existed that allowed a tooth to be placed on the implant immediately. However, these designs utilized osseointegration rather than the current bone implant connection. A further design utilized a threaded implant in combination with a series of tapping instruments to obtain the required compressive force resistance for immediately loading the tooth. Neither of these designs, however, has been widely accepted.
[0008] Accordingly, there is a need in the art for an improved dental implant with an improved thread configuration and an improved implant structure which eliminates the second surgery or dramatically reduces the time interval between the first surgery and placement of the final prosthesis.
SUMMARY OF THE INVENTION
[0009] In contrast to the prior art, the present invention relates to a dental implant which facilitates elimination of the second surgery to remove the healing cap and apply the prosthesis or which facilitates significant reduction of the time necessary between the first surgery and placement of the final prosthesis. More specifically, the present invention relates to a dental implant structure in which the ratio of the minor to major thread diameters (the core to thread ratio) is decreased, or the ratio of the major to minor thread diameters (the thread to core ratio) is increased. Specifically, these ratios are decreased and increased, respectively, to increase the thread strength of the implant to the point where healing time is eliminated or substantially reduced, thereby facilitating immediate or reduced time loading. The present invention further relates to a dental implant with an improved external thread design which dramatically improves the resistance of the implant to chewing or compressive forces, and thus similarly eliminates or substantially reduces the time period between implant installation and the loading of the implant. Still further, the implant of the present invention is designed to go into, but preferably not through, the cortical plate. Accordingly, the length of the implants of the present invention is preferably less than 20 mm, more preferably no longer than about 15 mm and most preferably about 10-15 mm in length.
[0010] To accommodate immediate loading of the implant of the present invention, the two piece abutment and cap screw of prior art implants are eliminated. Accordingly, in the present invention, the implant is provided with a unitary implant in which the threaded portion and the base or abutment portion for supporting the replacement tooth is a single piece structure in which such portions are integrally joined with one another.
[0011] One embodiment of the implant of the present invention is to eliminate the hollow interior of the implant and to significantly reduce the core to thread ratio below the standard 0.75. To accommodate the eliminated interior an outwardly extending top or prosthesis receiving post is provided above the neck of the implant to receive the replacement tooth or other prosthesis. It has been found that the reduction in the core to thread ratio results in an unexpectedly increased resistance to compressive forces such as chewing or biting to thereby facilitate immediate loading of the implant.
[0012] A further embodiment of the present invention includes providing the implant with an improved external thread design which includes first and second helical threads which are interleaved with one another and which exhibit different outside or major diameters. Preferably at least one of these helical threads is provided with a thread configuration in which the flat or the flatter thread side surface faces toward the distal or non-head end of the implant.
[0013] A still further embodiment of the present invention is to provide an implant less than 20 mm in length with the thread design described above.
[0014] Accordingly, an object of the present invention is to provide a dental implant which can be fully installed, together with the replacement tooth or other prosthesis, in a single surgery.
[0015] Another object of the present invention is to provide a dental implant which eliminates the hollow interior for attaching the prosthesis.
[0016] A further object of the present invention is to provide an immediate load dental implant to be installed into, but preferably not through, the cortical plate, thereby providing an implant of preferably less than 20 mm.
[0017] A still further object of the present invention is to provide a dental implant with a reduced core to thread ratio and more specifically, a core to thread ratio of no greater than 0.70.
[0018] A still further object of the present invention is to provide, independently or in combination with an implant of reduced core to thread ratio and/or an implant with a length of less than 20 mm, a unitary implant having an integral threaded portion and tooth supporting portions.
[0019] A still further object of the present intention is to provide a dental implant with an improved external thread configuration to facilitate immediate loading to reduce the interval between first and second surgeries.
[0020] A still further object of the present invention is to provide a dental implant structure by which the thread to core ratio can be significantly increased to a ratio of 1 . 40 or greater.
[0021] These and other objects of the present invention will become apparent with reference to the drawings, the description of the preferred embodiment and the appended claims.
DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a side view, partially in section, of a conventional dental implant.
[0023] [0023]FIG. 2 is an elevational side view of a conventional healing screw for use with the dental implant of FIG. 1.
[0024] [0024]FIG. 3 is an elevational side view of a replacement tooth for use with the dental implant of FIG. 1.
[0025] [0025]FIG. 4 is a side view, partially in section, of one embodiment of the dental implant in accordance with the present invention.
[0026] [0026]FIG. 5 is an enlarged sectional view of the thread configuration of the implant of the embodiment shown in FIG. 4.
[0027] [0027]FIG. 6 is an elevational bottom view from the distal end of the dental implant of FIG. 4.
[0028] [0028]FIG. 7 is an elevational top view from the proximal or head end of the dental implant of FIG. 4.
[0029] [0029]FIG. 8 is a side view, partially in section, of a second embodiment of the dental implant in accordance with the present invention.
[0030] [0030]FIG. 9 is an enlarged view of the thread configuration of the embodiment of the dental implant as shown in FIG. 8.
[0031] [0031]FIG. 10 is an elevational bottom view from the distal end of the dental implant of FIG. 8.
[0032] [0032]FIG. 11 is an elevational top view from the proximal or head end of the dental implant of FIG. 8.
[0033] [0033]FIG. 12 is a side view, partially in section, of a third embodiment similar to that of FIG. 8, but with a modified thread design.
[0034] [0034]FIG. 13 is a side view, partially in section, of a fourth embodiment of the dental implant of the present invention, which view is similar to that of FIG. 8, but with a further modified thread design.
[0035] [0035]FIG. 14 is an enlarged view of the thread pattern of the dental implant embodiment of FIG. 13.
[0036] [0036]FIG. 15 is an elevational side view, partially in section, of a replacement tooth for use with the implants of FIGS. 8, 12 and 13 .
[0037] [0037]FIG. 16 is a modified prosthesis receiving post for the embodiments of FIGS. 8, 12 and 13 .
[0038] [0038]FIG. 17 is a modified replacement tooth for use with the prosthesis receiving post design of FIG. 16.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0039] The present invention relates to improvements in a dental implant. In general, a dental implant provides support for a replacement tooth or other prosthesis and thus is anchored into a tooth root, bone or other tissue. The dental implant provides support for such replacement tooth or prosthesis at its proximal or superior end. A dental implant does not function to secure two or more pieces of tissue, bones or other elements together as in conventional bone screws, nor does it function to provide any significant resistance to pulling out force as in conventional tissue or bone screws.
[0040] Reference is first made to FIGS. 1, 2, and 3 showing a conventional dental implant and related structures known in the art. Specifically, FIG. 1 illustrates a conventional dental implant 10 having a main body portion 11 , a proximal or superior end 12 and a distal or inferior end 14 . The proximal end 12 is provided with a conventional hex configuration 15 to enable the implant to be rotated and installed into a pre-drilled hole in a tooth root or bone. The dental implant of FIG. 1 is provided with a hollow interior 16 which extends from the proximal end 12 into the main portion 11 of the implant for a substantial distance toward the distal end 14 . This hollow interior 16 is provided with internal threads. The exterior of the implant 10 is provided with threads 18 for securement to a tooth structure.
[0041] Conventional dental implants have a core to thread ratio greater than 0.70 with the standard being about 0.75 or greater. This translates into a thread to core ratio of less than about 1.40, with the standard being about 1.20 or less. The core to thread ratio is the ratio between the dimension at the innermost edge of the thread (the minor diameter) to the dimension at the outermost edge of the thread, while the thread to core ratio is the ratio of the major diameter to the minor diameter.
[0042] [0042]FIGS. 2 and 3 illustrate elements designed for use with the conventional dental implant of FIG. 1. Specifically, FIG. 2 illustrates a healing screw 17 having a proximal or head end 20 and an elongated stem portion 19 extending from the head 20 toward a distal end. The stem portion 19 is provided with external threads designed to be received by the internal threads of the hollow interior 16 (FIG. 1) and is substantially smaller in diameter than the proximal end 20 . The healing cap 17 is conventionally screwed into the hollow interior 16 of the implant 10 after installation of the implant and during the healing period for the surrounding bone or tooth tissue.
[0043] [0043]FIG. 3 illustrates a conventional replacement tooth 21 having an elongated externally threaded stem 22 at its distal end and a replacement tooth portion 24 at its proximal end. The external threads of the stem 22 are designed to mate with the internal threads of the interior portion 16 . The replacement tooth 21 is installed into the implant 10 of FIG. 1 after the necessary healing period has elapsed and the healing cap 17 (FIG. 2) has been removed.
[0044] General reference is next made to FIGS. 4 - 7 showing a first embodiment of a dental implant 25 in accordance with the present invention. The dental implant 25 includes a main body portion 26 with a proximal or superior end 28 and a distal or inferior end 29 . As illustrated best in FIGS. 4 and 6, the distal end 29 is provided with a plurality of cutting edges 32 to provide the implant with self tapping capabilities. The cutting edges 32 or other self-tapping structures as applied to dental implants are well known in the art and such structures are incorporated herein by reference. In the preferred embodiment, the distal end 29 of the implant 25 is also provided with a through-hole 34 for later bone growth, if desired. Such hole 34 , however, is not necessary to achieve the other benefits of the implant 25 .
[0045] As shown in FIGS. 4 and 7, the proximal end 28 is provided with a rotation head in the form of a hex end or portion 30 for engagement by a hand piece or other tool or adaptor for the purpose of rotating the implant 25 during installation. A hollow interior 31 extends from the proximal end 28 into the main portion 26 of the implant 25 for a substantial distance toward the distal end 29 . The hollow interior 31 is provided with internal threads to receive a conventional healing cap or replacement tooth such as as shown in FIGS. 2 and 3, respectively, or any other prosthesis or attachment intended for use with dental implants. In this embodiment, the diameter of the hollow interior 31 is reduced relative to that of conventional implants to accommodate the reduced core to thread ratio.
[0046] The exterior of the main body of the implant 25 as shown in FIG. 4 is provided with a plurality of external threads comprising a first series of helical threads 35 extending from the distal end 29 substantially to the proximal end 28 and a second series of helical threads 36 interleaved between the first series of helical threads 35 and also extending from the distal end 29 substantially to the proximal end 28 . In the preferred embodiment, the helical threads 35 and 36 have first and second outer diametrical dimensions which are different from one another. As shown generally in FIG. 4 and more specifically in FIG. 5, the outer or major diameter of the first series of helical threads 35 is greater than the outer or major diameter of the second series of helical threads 36 .
[0047] With reference to FIG. 5, each of the first series of helical threads 35 includes an outer edge 38 extending helically around the implant 25 and defining the thread diameter or major diameter of the threads 35 . The specific size of this outer or major diameter, which is twice the radius “R 01 ” shown in FIG. 5 as the distance between the edge 38 and the implant centerline 33 , will depend of the particular size of the implant. Conventional implants normally include implants with diameters of 3 mm to 6 mm, with most standard implants being 4 mm or 5 mm. Implants are conventionally provided in lengths from 10 mm to 15 mm and specifically in lengths of 10 mm, 11.5 mm, 13 mm and 15 mm.
[0048] The helical threads 35 also include an inner edge 39 . The inner edge 39 defines the core diameter or minor diameter of the thread 35 which, as shown in FIG. 5, is twice the distance “R i ” between the edge 39 and the centerline 33 . The core diameter 39 defines the innermost portion of the thread 35 . Like the outer edge 38 , the inner edge 39 of the thread extends helically around the implant 25 . The core to thread ratio or the minor to major diameter ratio of thread 35 is determined by comparing the minor diameter defined by twice the distance “R i ” to the major diameter defined by twice the distance “R 01 ”. Preferably this ratio R i /R 01 is about 0.70 or less and more preferably about 0.60 or less. The range of core to thread ratios for implants in accordance with the present invention is preferably 0.40 to 0.70, more preferably 0.45 to 0.65 and most preferably 0.50 to 0.60. These ratios are based on a major diameter of 4 mm and a minor diameter of about 2.25 mm for a 4 mm implant, and a major diameter of 5 mm and a minor diameter of about 3 mm for a 5 mm implant.
[0049] With these core to thread ratios, it has unexpectedly been found that the resistance of the implant to compressive forces is dramatically increased. This increase is significantly greater than what one would expect by comparing the relative thread surface areas of the implant of the present invention with those of conventional implants with a standard core to thread ratio of about 0.75.
[0050] In a preferred embodiment, the outer edge 38 terminates in a flat surface generally parallel to the longitudinal axis of the implant as shown. Although it can, if desired, terminate substantially at a point, it is preferred that the outer edge 38 terminate in a flat portion as shown having a dimension “A 1 ” of less than about 0.2 mm and more preferably between about 0.03 and 0.15 mm.
[0051] The particular height H 1 of the thread 35 defined by the distance between the outer edge 38 and the inner edge 39 will vary with the particular size of the implant, the amount of torque desired to install the implant and the compressive force resistance desired.
[0052] The thread 35 also includes a pair of side surfaces extending helically from the distal end 29 of the implant to the proximal end 28 . These side surfaces include a distal or distal facing surface 40 and a proximal or proximal facing surface 41 . As shown best in FIG. 5, these surfaces 40 and 41 form angles DA 1 and PA 1 , respectively, with a line extending perpendicular to the longitudinal or center axis 33 of the implant. Although these two angles DA 1 and PA 1 can be the same, it is preferred that the angle DA 1 be smaller than the angle PA 1 (or that the angle PA 1 be larger than the angle DA 1 ). More specifically, it is preferred that the angle DA 1 be less than about 45°, more preferably less than about 25°, and most preferably less than about 10°. In contrast, it is preferred that the angle PA 1 be between about 45 and 5°, more preferably between about 40 and 10°, and most preferably between about 35 and 20°. With this structure, it is preferred that the surface 40 , which comprises the flatter surface or smaller angle face the distal end of the implant as shown.
[0053] The thread design 36 is similar to that of the thread 35 except that its outer or major diameter defined by twice the distance “R 02 ” between the outer edge 42 and the centerline 33 is less than the major diameter of the thread 35 . Similar to the thread 35 , the inner dimension of the thread 36 is defined by the inner edge 39 . The core to thread ratio, or minor to major diameter ratio, of the thread 36 is defined as the ratio of its minor diameter (twice the distance “R i ”) to its major diameter (twice the distance “R 02 ”). This core to thread ratio is expected to be greater than the core to thread ratio of the thread 35 since the denominator of the ratio is less. However, even this ratio is preferably less than the standard ratio of about 0.75. It is contemplated, however, that the core to thread ratio of the smaller thread in a thread pattern of multiple thread diameters 1 could be greater than the standard core to thread ratio of 0.75 without deviating from the present invention.
[0054] In determining core to thread ratio in a multiple thread diameter pattern in accordance with the present invention, the major diameter of the largest thread is used. Thus, in the embodiment of FIGS. 4 and 8, the preferred values of the core to thread ratio as set forth above with respect to the thread 35 (the largest thread) are applicable.
[0055] Similar to the thread 35 , the outer edge 42 of the thread 36 is provided with a flat portion extending helically around the implant. Although this outer portion 42 can terminate at a point, it preferably terminates at a flat portion with a dimension A 2 of less than about 0.1 mm and more preferably between about 0.3 and 0.1 mm
[0056] Also, similar to thread 35 , the second helical thread 36 includes a pair of sides extending helically along the length of the implant. Specifically, these sides include a distal or distal facing side 44 and a proximal or proximal facing side 45 . These sides 44 and 45 form angles DA 2 and PA 2 with a line extending perpendicular to the longitudinal or center axis 33 of the implant, respectively. Although these angles can be the same, it is preferred for the angle DA 2 of the distal side 44 to be smaller than the angle PA 2 of the proximal side 45 (or the angle PA 2 to be larger than the angle DA 2 ). Preferably the angle DA 2 of the distal side 44 is less than 45°, more preferably less than about 25° and most preferably less than about 10°. The angle PA 2 of the proximal side 45 is preferably between about 45 and 5°, and more preferably between about 35 and 10°.
[0057] The distance between the threads 35 and 36 measured from the top outer edge of the thread 35 to the top outer edge of the thread 36 is defined by the distance W 1 , while the distance between the threads 36 and 35 measured from the top outer edge of the thread 36 to the top outer edge of the thread 35 is defined by the distance W 2 . These distances relate to the pitch of the threads or the number of threads per unit length. Preferably, the distances W 1 , and W 2 are such as to provide a pitch for the threads 35 of about 8-20 threads per inch and a similar pitch for the threads 36 of about 8-20 threads per inch. More preferably, the thread pitch should result in 10-18 threads per inch and most preferably about 12 threads per inch. Although the pitch of the threads 35 and 36 is preferably constant throughout the length of the implant, the pitch can be designed to vary, if desired.
[0058] In the preferred embodiment, a 13 mm implant has about 4 to 10 turns of the thread 35 . More preferably, a 13 mm implant has about 6 to 8 turns of the thread 35 . This translates to a thread 35 density pitch of about 12 to 16 threads per inch.
[0059] Although the implant of the present invention can be of various lengths, it is preferably of a length that will penetrate the cortical plate, but preferably not go through it. Thus, the preferred implant length in accordance with the present invention is less than 20 mm. More preferably, the length is no greater than 15 mm, and most preferably the length is about 10 to 15 mm. For purposes of the present invention, the length of the implant is that portion comprised of the threads.
[0060] Reference is next made to FIGS. 8, 9, 10 and 11 illustrating a second embodiment of a dental implant 47 of the present invention. Specifically, the embodiment of the FIG. 8 includes a main implant portion 46 having first and second helical threads 50 and 51 , respectively, extending from the distal end 48 toward the proximal end 49 . The main body portion 46 and threads 50 and 51 of the embodiment of FIG. 8 are substantially the same as that of the embodiment of FIG. 4. Accordingly, the elevational distal end view of FIG. 10 of the embodiment of FIG. 8 is substantially the same as the distal end view of FIG. 6. The enlarged thread configuration illustrated in FIG. 9 is also similar to that shown in FIG. 5 with respect to the embodiment of FIG. 4. Specifically, the first and second helical threads 50 and 51 of the embodiment of FIG. 8 extend helically along a substantial length of the implant and are interleaved between each other. Further, although not specifically described, the core to thread ratios of the threads 50 and 51 and their respective configurations and dimensions are similar to those described and shown above with respect to FIG. 5. Further, each of the threads 50 and 51 include distal or distal facing sides 55 and 58 , respectively, and proximal or proximal facing sides 56 and 59 , respectively. The angles which these sides form with a line extending perpendicular to the longitudinal axis or center line of the implant is similar to that disclosed with reference to FIG. 5.
[0061] The embodiment of FIG. 8 differs from that of FIG. 4 in that an extended neck 43 is provided between the threaded portion and the proximal end 49 , a head or prosthesis receiving post 52 is provided to the proximal end 49 of the implant and the hollowed out interior portion 31 of the embodiment of FIG. 4 is eliminated. Further, the proximal end of the head or post 52 is provided with a structure 54 for rotating the implant 47 during installation. In the preferred embodiment, this structure 54 comprises a pair of flats on opposite sides of the post 52 . The structure 54 is designed to mate with a hand piece or other tool or adaptor. However, this structure can be any structure which enables the implant to be rotated. It is also contemplated that a portion of the head or post 52 can be provided with a conventional hex end to receive an appropriate tool for rotation.
[0062] As shown best in FIG. 8, the head 52 includes a circumferential groove 53 near its upper end. This groove is intended to receive a rubber loop to assist in installation of the implant. A plurality of grooves 57 are also provided for use when constructing impressions or temporaries.
[0063] It is contemplated that with the embodiment of FIG. 8, a replacement tooth or other prosthesis such as that illustrated in FIG. 15 would be connected to the post 52 . As shown in FIG. 15, the replacement tooth includes a conventional tooth exterior 60 and an interior conforming substantially to the exterior figuration of the post 52 and portion 54 of FIG. 8. It is contemplated that with the embodiment of FIG. 8, the replacement tooth of FIG. 15 would be secured to the post 52 through an appropriate adhesive. The neck 43 can be of varying heights depending on the nature of the tissue and the particular prosthesis used. Preferably, the height of the neck 43 is between about 0.5 and 8 mm and most preferably between about 1 and 5 mm.
[0064] The embodiment shown in FIG. 12 is an embodiment similar to that of FIG. 8 except that the threads 64 of the implant of FIG. 12 are of the same diameter and are symmetrical. The core to thread ratio of the threads 64 , however, are substantially the same as that of the embodiment of FIG. 4. Specifically, the core to thread ratios are preferably 0.70 or less and more preferably 0.60 or less. The preferred ranges of such ratios are 0.40 to 0.70, with more preferred and most preferred ratios being 0.45 to 0.65 and 0.50 to 0.60, respectively. FIG. 12 also includes a modified prosthesis receiving post comprising the post 63 extending outwardly from the neck 43 and a hexagonal end 54 to facilitate rotation of the implant.
[0065] The embodiment of FIG. 13 is similar to that of the embodiment of FIG. 12 in that the threads 66 are of equal outer diameter, but is dissimilar to that of FIG. 12 in that the threads are not symmetrical. The details of this thread configuration are shown in FIG. 14. As shown in FIG. 14, the distal or distal facing side 68 of the threads 66 forms an angle DA 3 with a line perpendicular to the longitudinal axis or center line 33 of the implant, while the proximal or proximal facing side 69 of the threads 66 forms an angle PA 3 . In the embodiment of FIGS. 13 and 14, the angle DA 3 is less than the angle PA 3 (or the angle PA 3 is greater than the angle DA 3 ), with the preferred values of those angles being similar to those described above with respect to FIG. 5.
[0066] [0066]FIG. 16 illustrates an alternate prosthesis receiving post for the implant embodiments of FIGS. 8, 12 and 13 . In the embodiment of FIG. 16, the head or post portion 52 is provided with an internal recess 70 . This recess 70 is provided with internal threads which are intended to receive external threads from a replacement tooth such as that illustrated in FIG. 17. In FIG. 17, the replacement tooth includes a main replacement tooth portion 71 and an elongated stem portion 72 having external threads matching the internal threads of the internal portion 70 of FIG. 16. As shown, the stem portion 72 is positioned entirely within the tooth portion 71 . To install the replacement tooth of FIG. 17 on the implant of FIG. 16, the stem 72 is positioned into the interior portion 70 and rotated until tight.
[0067] Having described the detailed structure of the preferred embodiment of the present invention, the use of the dental implant and the method aspect of the present invention can be understood best as follows: First, a dental implant is provided which includes a proximal end, a distal end and an externally threaded shaft. The shaft preferably includes a core to thread ratio as specified above. The shaft further includes first and second helical threads which are interleaved with one another and embody first and second thread diameters, with one of the thread diameters being different than the other. The implant also preferably includes a prosthesis receiving post integrally positioned at the proximal end of the implant and extending outwardly from the proximal end to receive a prosthesis. The method further includes drilling or boring a hole into a tooth root or bone at a desired location and then inserting the distal end of the implant into the hole and rotating the dental implant to a desired degree of installation. Preferably, the implant is not installed through the cortical plate. Finally, a replacement tooth or other prosthesis is mounted or attached to the prosthesis receiving post either via a threaded connection, adhesives, or the like. This installation of the replacement tooth or prosthesis is preferably performed immediately. Thus, the preferred method is a single surgery method in which both the installation of the implant and the installation of the prosthesis are completed in a single office visit.
[0068] Although the description of the preferred embodiment has been quite specific, it is contemplated that various modifications could be made without deviating from the spirit of the present invention. Accordingly, it is intended that the scope of the present invention be dictated by the appended claims rather than by description of the preferred embodiment.
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A dental implant having an external thread configuration and/or a structure which facilitates a single step dental implant/prosthesis installation or which significantly reduces healing time between surgeries. The invention also relates to a method for installing such a dental implant.
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This application is a continuation of application Ser. No. 08/021,137 filed Feb. 23, 1993, and now abandoned.
FIELD OF THE INVENTION
The present invention relates to an image analysis system for processing and/or analyzing an image which is provided through image input devices such as a scanner, a video camera, a video tape recorder, and so on. The present system may further understand the content or meaning of an image through high level processing.
BACKGROUND OF THE INVENTION
Conventionally, an input image provided through image input devices such as a scanner, a video camera, and so on is firstly converted from analog form to digital through an analog-to-digital converter, then processed, analyzed, or understood by using a digital computer and/or a digital circuit.
FIG. 6 shows a typical prior art (Page 194, FIG. 1B "Special computer architectures for pattern processing, CRC Press, Inc. 1982). In the figures, the numeral 1 is an image input unit, 3 is a digital computer, 20 is a frame memory, and 99 is an image signal input terminal. The image input unit 1 carries out the analog-to-digital conversion for an input image signal applied to the input terminal 99. A frame of an image signal in digital form thus converted is stored in the frame memory 20. The computer 3 carries out the processing for the digital images stored in the frame memory 20 by using a computer program stored in the computer 3.
FIG. 7 shows another prior art (Page 7 FIG. 1.6, "Digital image processing, Addison-Wesley Publishing Company, Inc. 1977). In the figure, the numeral 21 is an image processing circuit, 22 is a connection interface. An image signal has voluminous information, as it is an information having a spatial extension, and in case of a moving picture, it has a time extension (for instance 30 frames in each second). When an image signal is processed by using a general purpose computer, it takes a long time for the processing, although the general purpose computer has the flexibility for the content of the processing which is described by software of a computer program. In order to solve this problem, a special LSI (large scale integrated circuit), and/or a special processing circuit has been developed for carrying out a fundamental operation in image processing. The image processing circuit 21 has such a special LSI and/or a special processing circuit. Some examples of the fundamental processing are a point operation, a neighboring operation by using 3×3 pixels (for instance, accumulation of products), and a fast Fourier transform. The fundamental processing directly handles a value of each pixel, but does not understand the content of the image. The connection interface 22 couples the computer 3 with the image processing circuit 21 so that the computer 3 controls the operation of the image processing circuit 21, and/or receives the result of the processing.
The prior art of FIGS. 6 and 7 process an input signal sequentially in the order of an input of image frames. In other words, after the processing for a frame is finished, the processing for a succeeding image frame is carried out. Even when a plurality of image processing circuits and/or calculators are used for high speed processing, image frames are spacially divided and each frame is processed by each image processing circuit, and/or a plurality of pixels are processed simultaneously. Therefore, the processing is carried out in the order of frames in the sequence of arrival. When a set of parameters for a processing is changed, the processing for each set of parameters must be carried out for each set of parameters.
Therefore, a prior image processing system is not flexible, and it is slow in processing operation.
In the case of FIG. 6 which uses a general purpose computer and describes the content of processing by computer program, it may carry out both a simple image processing and a complex image processing, it has the disadvantages that the processing speed is slow and it is almost impossible to process a moving image like a television signal on a real time basis.
In the case of FIG. 7, the high speed processing may be possible if a special circuit matches with the processing. However, as a special circuit is limited to only a fundamental processing, when a high-level processing including analysis and/or understanding of an image is intended, we must use a general purpose computer. If we use a DMA (direct memory access), or GPIB for an interface with a computer to transmit image data, it takes a long time at the interface portion.
SUMMARY OF THE INVENTION
It is an object, therefore, of the present invention to overcome the disadvantages and limitations of a prior image processing system by providing a new and improved image processing system.
It is also an object of the present invention to provide an image processing system having a plurality of image processing units which operate simultaneously for high speed processing by properly distributing input images to those image processing units and controlling processing content in each image processing units.
It is also an object of the present invention to provide an image processing system which handles both a simple fundamental processing, and a complex high-level processing.
The above and other objects are attained by an image processing system comprising; an input terminal for accepting image signal in analog form; an image input unit coupled with the input terminal for analog-to-digital conversion for the image signal; a frame identification designator coupled with the image input unit for supplying frame identification to each image frame at an output of the image input unit; a plurality of image processing units coupled with the frame identification designator, for receiving an image frame which has a specified identification; a control device coupled with the image processing units for controlling each image processing unit; each of the image processing units comprising; a frame identification selector for taking an image frame selectively so that a specific image frame having a frame identification equal to the identification of the frame identification selector is taken; an image processing module for carrying out image processing for an image frame taking by the frame identification selector.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features, and attendant advantages of the present invention will be appreciated as the same become better understood by means of the following description and accompanying drawings wherein;
FIG. 1 is a block diagram of an image processing system according to the present invention,
FIG. 2 is a block diagram of a frame identification selector in FIG. 1,
FIG. 3 is another block diagram of a frame identication selector in FIG. 1,
FIG. 4 is a block diagram of an image processing module in FIG. 1,
FIG. 5 is a block diagram of another embodiment of the image processing system according to the present invention,
FIG. 6 is a block diagram of a prior art of an image processing system, and
FIG. 7 is a block diagram of another prior art of an image processing system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a block diagram of an image analysis system according to the present invention. In the figure, the numeral 1 is an image input unit, 2 is an image processing assembly which has a plurality of image processing units, 3 is a control computer, 4 is a frame identification designator, 5 (5-1 - - - 5-n) is an image processing unit, which has a frame identification selector 6 and an image processing module 7, 10 is a bothway communication path, and 99 is an image input terminal. An image signal applied to the image input unit 1 through the input terminal 99 may be a moving picture supplied by a television camera or a VTR (video tape recorder), and/or a still picture supplied by an image scanner.
The image input unit 1 carries out A/D conversion (analog-to-digital conversion) together with quantization for an image signal in analog form applied to an input terminal 99, and provides an output image signal in digital form. When an input image signal is an interlace type, it may be converted to a non-interlace type signal by combining two field pictures into one frame picture.
The frame identification designator 4 provides a frame identification to each image frame. A frame identification is an integer number from 1 to N, where N is a predetermined integer, for instance N=30. A frame identification increments one by one, and when it reaches N, next frame identification returns to 1. Therefore, a frame identification has a period of N. The upper limit N of the frame identification is supplied by an external circuit (not shown), or by a control computer 3.
The image processing assembly 2 carries out the actual processing for an input digital image signal under the control of the control computer 3, which controls the operation of the image processing assembly 2 and receives the result of the processing. The control computer 3 may be an ordinary personal computer, a work station, or a board type computer. The image processing assembly 2 is coupled with the control computer 3 through the bothway communication path 10 for exchanging program and a data.
The image processing assembly 2 has a plurality of image processing units 5-1 through 5-n. The value of n may be any integer, as long as they are mounted in the assembly 2. Each unit 5-1 through 5-n may be a separate and different unit, but it would be better that all the units have the same architecture are mounted in a single housing considering the simple structure of hardware and easy control. Each unit comprises a frame identification selector 6 and an image processing module 7.
FIG. 2 shows a block diagram of a frame identification selector 6. In the figure, the numeral 61 is a frame identification separator, 62 is a frame identification memory, 63 is a coincidence circuit, and 64 is a gate circuit. The frame identification separator 61 functions to takes a frame identification out of the header portion of an image frame which is forwarded from the image input unit 1 through the frame identification designator 4. The frame identification memory 62 stores a tag which designates each image processing board so that it processes an image frame having a frame identification equal to the tag. The content of the frame identification memory 62 may be set by an external switch (not shown), or it may store a set of tags beforehand. The coincidence circuit 63 compares the frame identification separated by the separator 61 out of the image frame with the tag which is supplied by the memory 62. When the frame identification coincides with the tag, the coincidence circuit 63 opens the gate circuit 64 so that the image frame is forwarded to the image processing module 7, and when the frame identification does not coincides with the tag, the gate 64 is closed so that the related frame is not forwarded to the image processing module 7.
FIG. 3 shows a block diagram of another embodiment of a frame identification selector 6. The feature of FIG. 3 is the presence of a number set 65, and other portions of FIG. 3 are essentially the same as those of FIG. 2. The number set 65 and the frame identification memory 62 in FIG. 3 are coupled with a local control 73 which is described later. The number set 65 determines a specific number to each image processing unit, for instance, when n number of units are provided, each of them is numbered from 1 to n, respectively. The number determined by the number set 65 is forwarded to the local control 73. The local control 73 determines a specific tag based on the number provided in the number set 65, depending upon content of processing, then the local control 73 provides it to frame identification selector 6. The tags provided by the local control 73 are stored in the frame identification memory 62.
FIG. 4 shows a block diagram of the image processing module 7, which actually processes an image frame. In the figure, the numeral 71 is a frame memory, 72 is an image processing operator or a processor, 73 is a local control, and 74 is a digital-to-analog converter (D/A). The frame memory 71 stores a frame of input image supplied through the frame identification selector 6 until the predetermined processing in the image processing operator 72 for the current frame finishes, and the memory stores the result of the processing in the operator 72. The image processing operator 72 carried out a predetermined processing for a frame of image stored in the frame memory 71. The local control 73 is coupled with the image processing operator 72 and the control computer 3 through the bothway communication path 10, and functions to determine the contact of processing and the processing mode in the operator 72, and transfer the result of the processing to the control computer 3, under the control of the control computer 3. The local control 73 also functions to determine an address of an image processing unit by providing a tag to the image processing unit. The D/A converter 74 converts a content of the frame memory 71 to an analog form, and the converted analog signal is forwarded to an image monitor, or a video tape recorder (not shown). The D/A converter 74 may be omitted if only parameters of the processing result are requested but no frame of image is necessary, although it is essential if the processing result is visually monitored.
The image processing operator 72 may be an LSI or a specific calculation circuit which is commercially available for low-level processing in pixel levels for image processing purposes. A typical image processing LSI, which is commercially available, "HRU-TAICHI-CORE" provided by Ezel-Sharp-Semiconductor Corporation, Japan. The low-level processing is defined here to be simple systematic processing which does not consider the meaning and/or the content of an image, for instance, the low-level processing includes gray-level conversion, edge detection, filtering (low pass filter process), and thinning operation. These low-level processings are carried out by a conventional image processing circuit 21 in FIG. 7, and a block of pixels (for instance, 3×3 pixels) are processed for above low-level processings. A high-level processing which includes recognition and/or understanding of an image is of course possible in the present invention, and that high-level processing is described later.
The image processing units in FIG. 1 operate independently from one another. In one modification, each processing units may operate so that a processing result of a first processing unit is supplied to another processing unit by coupling image processing operators and/or local controls with each other.
In FIG. 1, where a plurality of image processing units are provided, the operation is as follows. Each image processing unit is determined which frame identification number the image processing unit processes, and the content of the processing by each image processing module is determined.
When only one image processing module is provided, the processing is carried out for each frame sequentially.
When a plurality of image processing modules are provided, the operation is as follows.
First, when all the image processing units take the same frame as one another, each frame is applied to all the image process units at the same time. Therefore, if the content of the processing, and/or the parameters of the processing depend upon each image processing unit, each frame is processed for a plurality of processing contents simultaneously.
Secondly, when each image processing unit takes a different frame, for instance, a first unit takes a first frame, a second unit takes a second frame, et al, a plurality of frames are processed concurrently in a plurality of image processing units. In that case, the processing speed is n times as that when only one image processing unit is used, where n is number of image processing units. In that case, each image processing unit begins the processing when the related frame reaches the unit, therefore, the image processing units do not operate at the same time for a plurality of frames. The result of the processing is obtained sequentially in the order of the input of the frame identification.
Alternatively, n number of image processing modules are grouped into a plurality of groups, so that the content of the processing and/or the parameters of the processing depend upon each group. The frame to be processed in each group may be the same as each other, or different from each other.
As described above, according to the present invention, a frame to be processed in an image processing module, and/or content to be processed may be designed flexibly. Therefore, the change of processing content does not need the change of hardware structure. Further, the processing speed is improved through simultaneous operation of a plurality of image processing units.
Another embodiment of the present invention which carries out both low-level processing and high-level processing is described.
FIG. 5 shows a block diagram of another embodiment of the present invention. In the figure, the numeral 8 is a processor network, 9 is a switch, 11 through 15 are a bothway communication path. A local control 73 in an image processing module 7 in an image processing unit 2 is coupled with a computer 3 through a bothway communication path 10, and also coupled with a switch 9 through bothway communication paths 11-13. The switch 9 is coupled with the processor network 8 through a bothway communication path 14. The processor network 8 is coupled with the computer 3 through a bothway communication path 15. It is supposed that bothway communication paths 11-13, 14, and 15 are a specific bus, which has enough communication ability with high bit rate. Alternatively, some of bothway communication paths are substituted with a communication function installed in a special processor described later.
The processor network 8 comprises a plurality of processor groups, each of which has at least one processor. Each processor may be a commercially available microprocessor, or a digital signal processor (DSP) as far as it has digital calculation function and external communication/control function. Preferably, operational program of a processor in the processor network 8 is supplied by the computer 3 through download operation in view of the flexibility. When the download of a program by the computer 3 is impossible, each processor in the processor network 8 has a ROM (read only memory), which stores the program for operating the processor. The processors are coupled with one another in a network so that the communication between the processors is possible. The INMOS transputer (T-800) manufactured by SGS-Thomson Electronics Co,. in France is, for instance, used as a processor and a local control 73 in the processor network 8, since it has a communication function called a link.
Some embodiments are possible for providing a network which has a plurality of processors. Some of them are a pipe line system, and a hierarchical structured system. These structures are conventional, and the inner structure of a network is also conventional.
The switch 9 connects selectively the bothway communication paths 11-13 which are coupled with the image processing units 5-1 through 5-n, with the bothway communication path 14 which is coupled with the processor network 8. In a simple case, the switch 9 connects each image processing unit to each processor in the processor network 8 on the one-by-one basis with the fixed relations. In general, the switch 9 functions to connect flexibly the image processing units to the processor network depending upon the number of image processing units, and the number of processors in the processor network, and the object of the processing.
The embodiment of FIG. 5 has the feature that a plurality of image processing units 5-1 through 5-n in the embodiment of FIG. 1 are coupled with the processor network 8 through the bothway communication paths 11-13, and 14, and the switch 9. This structure enables the high-level processing of an image.
An image processing operator 72 in FIG. 4 provides a pixel level processing to an input image frame. This processing is a so-called low-level processing, which is a basis for extracting a feature in an image frame, and/or measuring an image frame. On the other hand, the processor network 8 carries out a high-level processing including recognition and/or understanding of an image frame to the processing result of the image processing units 5-1 through 5-n. The content of a high-level processing may be designed by a computer program installed on each processor. As the processor network 8 is coupled with the image processing units 5-1 through 5-n through the bothway communication paths 11--14 and the switch 9, the processing result in the image processing units may be forwarded directly to the processor network 8, thus, the efficiency of a high-level processing is improved. The flow of information is not restricted from the image processing units to the processor network, but also the opposite direction is possible. Therefore, it is possible to modify a processing algorithms and/or a set of processing parameters for an input image frame, depending upon a processing result of high-level processing in the processor network 8.
It should be appreciated that a high-level image processing has been carried out in a prior art by using a general purpose computer, which is coupled with a low-level image processing circuit as shown in FIG. 7. In that structure, a general purpose computer is independent from an image processing circuit, and therefore, the coupling is not dense, and the total processing including both a low-level processing and a high-level processing has been difficult. On the other hand, the embodiment of FIG. 5 carries out both a low-level processing and a high-level processing, keeping the flexibility of operation by using computer software.
As described above, the present invention has a feature having a plurality of image processing units, which process either a plurality of input image frames concurrently, or a plurality of processing items for a single input image frame. Thus, the total processing speed is improved. Further, the embodiment of FIG. 5 has a processor network 8 for a high-level processing, and an image processing assembly 2 for a low-level processing, and means for directly coupling the former with the latter with high bit rate communication path, so that not only a low-level processing but also a high-level processing which includes recognition and/or understanding of an image are carried out with high efficiency.
The present invention is applicable to an image analysis system in the field which needs image processing and/or image recognition, including image communication field, industry field, and medical field.
From the foregoing it will now been apparent that a new and improved image processing system has been found. It should be understood of course that the embodiments disclosed are merely illustrative and are not intended to limit the scope of the invention. Reference should be made to the appended claims, therefore, rather than the specification as indicating the scope of the invention.
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A moving image with a plurality of continuous frames is processed by using a plurality of image processing units (5-1 through 5-n), which operate simultaneously. A frame identification designator (4) attaches an identification number cyclically to each frame of the input image signal. A frame identification selector (6) in each image processing unit inputs an image frame selectively based upon the identification number, and transfers the selected frame to a corresponding image processing module. The image processing units (5-1 through 5-n) typically carry out either the same processing on respective image frames, or a plurality of processing to a single frame. An additional processor network (8) may be coupled with the image processing units for high-level processing including recognition and/or understanding of an image.
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BACKGROUND OF THE INVENTION
This invention is directed to an optically clear silicone microemulsion formed with very little input of mechanical energy for mixing the components. More particularly, a ternary composition of water, a volatile cyclic or linear methyl siloxane (VMS), and a short-chain or low molecular weight silicone polyether, spontaneously provides optically clear microemulsions when combined with only hand agitation.
It is well documented (U.S. Pat. No. 4,999,398) that emulsions, especially silicone emulsions, are opaque, cloudy, and tend to separate on standing. Thus, the desirability of microemulsions, which contain micro-particles in the droplet phase, providing a measure of clarity.
As used herein, the term emulsion or macroemulsion means a dispersion of one immiscible liquid in another, in the form of droplets, with diameters approximately in the range of 100-1,000 nanometers (0.1-1.0 microns/1,000-10,000 angstroms Å). In contrast, a microemulsion means a transparent, thermodynamically stable, dispersion of two or more immiscible liquids and a surfactant.
Microemulsions are clear or transparent because they contain particles smaller than the wavelength of visible light, which is typically on order of about 10-100 nanometers. Microemulsions may contain oil droplets dispersed in water (O/W), water droplets dispersed in oil (W/O), or they may be in the form of a bicontinuous structure. They are characterized by an ultra-low interfacial tension between the oil and water phases.
A microemulsion can be recognized by several of its inherent characteristics which are that (i) it contains oil, water, and a surfactant; (ii) there is a high concentration of surfactant relative to oil; (iii) the system is optically clear; (iv) the phases do not separate by centrifugation; and (v) the system forms spontaneously.
Thus, for purposes of my invention, an emulsion is considered as containing particles having an average diameter of more than 100 nanometers (0.1 microns/1,000 angstroms Å), whereas a microemulsion contains particles having an average diameter of less than 100 nanometers (0.1 microns/1,000 angstroms Å). Clarity or transparency is controlled to a great extent by the particle size of the dispersed phase. The scattering of light is dependent on the particle size. Therefore, clear or transparent compositions appear to be a single phase without droplets or particles when viewed with the naked eye, as defined hereafter.
While Bailey in U.S. Pat. No. 3,299,112 describes emulsions formed from water, a silicone oil, and a silicone polyether, Bailey's emulsions are not clear; and require input of substantial mechanical energy to prepare. Furthermore, in contrast to my invention, the ternary system in the '112 patent is not a microemulsion; the silicone oil is not a volatile cyclic VMS; and where Bailey does describe a linear silicone oil, it is not a volatile linear silicone. Thus, the silicone oil in Bailey corresponds to R" 3 SiO(R" 2 SiO) x SiR" 3 where x is 10-1,000. My corresponding volatile linear VMS have an "x" of 0-5, well below the range in Bailey. In fact, I discovered that where "x" exceeds 5, the emulsions tend not to be clear.
In addition, emulsions are recognized as inherently unstable systems separating with time. In contrast, my microemulsions form spontaneously and are stable indefinitely. The order of addition of the components does not influence their formation, and simple hand shaking in the temperature range of their stability is sufficient to cause the microemulsions to form.
My spontaneously formed clear microemulsions have particular value in the personal care arena. Because of the unique volatility characteristics of the VMS component of my ternary system, it can be used alone, or blended with other cosmetic fluids, to form a variety of over-the-counter personal care products.
Thus, it is useful as a carrier in antiperspirants and deodorants, since it leaves a dry feel, and does not cool the skin upon evaporation. It is lubricious and will improve the properties of skin creams, skin care lotions, moisturizers, facial treatments such as acne or wrinkle removers, personal and facial cleansers, bath oils, perfumes, colognes, sachets, sunscreens, pre-shave and after-shave lotions, shaving soaps, and shaving lathers. It can be used in hair shampoos, hair conditioners, hair sprays, mousses, permanents, depilatories, and cuticle coats, to enhance gloss and drying time, and provide conditioning benefits. In cosmetics, it will function as a leveling and spreading agent for pigments in make-ups, color cosmetics, foundations, blushes, lipsticks, eyeliners, mascaras, oil removers, color cosmetic removers, and powders. It is useful as a delivery system for oil and water soluble substances such as vitamins. When incorporated into sticks, gels, lotions, aerosols, and roll-ons, my ternary composition imparts a dry, silky-smooth, payout.
In addition, because my spontaneously formed clear microemulsions exhibit a variety of advantageous and beneficial properties such as (i) clarity, (ii) very small particle size, (iii) ultra-low interfacial tensions, (iv) the ability to combine properties of water and oil in a single homogeneous fluid, (v) shelf stability, and (vi) ease of preparation; they have wide application, but especially in antiperspirants, deodorants, in perfumes as a carrier, and hair conditioning.
BRIEF SUMMARY OF THE INVENTION
It is an object of my invention to form a clear microemulsion by simply combining (i) water; (ii) a volatile cyclic methyl siloxane or volatile linear methyl siloxane; and (iii) a silicone polyether.
What I have accomplished is significant, because I discovered how to make clear products without involving the use of high shear, heretofore required to obtain the small particle size necessary to achieve clarity.
These clear microemulsions form spontaneously in the sense that they do not require energy input by means of mixing and shear devices. Thus, turbines, impellers, colloid mills, homogenizers, or sonolators, are not required to form these systems. It is only necessary that the appropriate amounts of the three components be added to a suitable container, and the container hand shaken. Of course, the components can be mixed or sheared with more energy input, and the microemulsions will still be obtained, but no advantage results from such additional energy usage.
These and other objects of my invention will become apparent from a consideration of the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a ternary phase diagram of the system comprising water, octamethylcyclotetrasiloxane (D 4 ), and the silicone surfactant, for determining composition ranges of microemulsions prepared according to Example XIII of my invention. The compositions are defined by the shaded area depicted in FIGURE 1.
In FIGURE 1, each of the corners represents 100 percent of the component labelled there. The side of the triangle directly opposite each corner represents zero percent of that component. Lines parallel to the opposite side represent increasing amounts of that component as they become closer to the corner. Any line drawn from the corner of Component A to the opposite side represents varying the amount of Component A at a constant ratio of the other two components.
The composition of any point within the shaded area is determined by drawing lines parallel to each of the three sides through the point. The amount of each component is then read from the intersection of each line with the side of the triangle which corresponds to that component, i.e. the side beginning at 100 at each component's corner.
DETAILED DESCRIPTION
My ternary composition contains water, a volatile cyclic or linear methyl siloxane (VMS), and a short-chain or low molecular weight silicone polyether. Those three components can be combined to form clear compositions without the addition of other materials.
Thus, the composition should be free of non-essential ingredients such as salts; co-surfactants; monohydroxy alcohols; and diols and triols such as ethylene glycol and glycerol. The elimination of such non-essential ingredients is especially beneficial and advantageous, as it obviates the need for refractive index matching, often resorted to in the past to achieve clear or transparent products.
The three components can be combined in any given order of addition. While heat enhances solubility, lowers surface tension, and reduces viscosity, its application is not required. Room temperature (20°-25° C./68°-77° F.) is sufficient in most cases.
The oil component of my ternary composition is a volatile methyl siloxane (VMS), which is a low viscosity silicone fluid corresponding to the average unit formula (CH 3 ) a SiO.sub.(4-a)/2 in which a has an average value of two or three. The fluid contains siloxane units joined by .tbd.Si--O--Si.tbd. bonds. Representative units are monofunctional "M" units (CH 3 ) 3 SiO 1/2 and difunctional "D" units (CH 3 ) 2 SiO 2/2 . The presence of trifunctional "T" units CH 3 SiO 3/2 results in the formation of branched cyclic volatile methyl siloxanes. The presence of tetrafunctional "Q" units SiO 4/2 results in the formation of branched linear volatile methyl siloxanes.
Linear VMS have the formula (CH 3 ) 3 SiO{(CH 3 ) 2 SiO} x Si(CH 3 ) 3 , and cyclic VMS have the formula {(CH 3 ) 2 SiO} y , in which x is 0-5, and y is 3-6. Preferably, the volatile methyl siloxane has a boiling point less than 250° C. and a viscosity of 0.65-5.0 centistokes (mm 2 /s).
Some representative volatile methyl siloxanes are: ##STR1##
The cyclic volatile methyl siloxanes (II) have been assigned the International Nomenclature Cosmetic Ingredient (INCI) name "CYCLOMETHICONE" by The Cosmetics, Toiletries and Fragrance Association, Inc., (CTFA) Washington, D.C. Cyclic and linear methyl siloxanes are clear fluids, essentially odorless, non-toxic, non-greasy, non-stinging, and non-irritating to skin. VMS leave substantially no residue after thirty minutes at room temperature (20°-25° C./68°-77° F.) when one gram is placed at the center of No. 1 circular filter paper of 185 millimeters diameter, supported at its perimeter in open room atmosphere. Volatile methyl siloxanes may be used alone or mixed together. Mixtures result in solutions having evaporating behaviors different from individual fluids.
Representative linear volatile methyl siloxanes (I) are hexamethyldisiloxane (MM) with a boiling point of 100° C., viscosity of 0.65 mm 2 /s, and formula Me 3 SiOSiMe 3 ; octamethyltrisiloxane (MDM) with a boiling point of 152° C., viscosity of 1.04 mm 2 /s, and formula Me 3 SiOMe 2 SiOSiMe 3 ; decamethyltetrasiloxane (MD 2 M) with a boiling point of 194° C., viscosity of 1.53 mm 2 /s, and formula Me 3 SiO(Me 2 SiO) 2 SiMe 3 ; dodecamethylpentasiloxane (MD 3 M) with a boiling point of 229° C., viscosity of 2.06 mm 2 /s, and formula Me 3 SiO(Me 2 SiO) 3 SiMe 3 ; tetradecamethylhexasiloxane (MD 4 M) with a boiling point of 245° C., viscosity of 2.63 mm 2 /s, and formula Me 3 SiO(Me 2 SiO) 4 SiMe 3 ; and hexadecamethylheptasiloxane (MD 5 M) with a boiling point of 270° C., viscosity of 3.24 mm 2 /s, and formula Me 3 SiO(Me 2 SiO) 5 SiMe 3 .
Representative cyclic volatile methyl siloxanes (II) are hexamethylcyclotrisiloxane (D 3 ) a solid with a boiling point of 134° C. and formula {(Me 2 )SiO} 3 ; octamethylcyclotetrasiloxane (D 4 ) with a boiling point of 176° C., viscosity of 2.3 mm 2 /s, and formula {(Me 2 )SiO} 4 ; decamethylcyclopentasiloxane (D 5 ) with a boiling point of 210° C., viscosity of 3.87 mm 2 /s, and formula {(Me 2 )SiO} 5 ; and dodecamethylcyclohexasiloxane (D 6 ) with a boiling point of 245° C., viscosity of 6.62 mm 2 /s, and formula {(Me 2 )SiO} 6 .
Representative branched volatile methyl siloxanes (III) and (IV) are heptamethyl-3-{(trimethylsilyl)oxy}trisiloxane (M 3 T) with a boiling point of 192° C., viscosity of 1.57 mm 2 /s, and formula C 10 H 30 O 3 Si 4 ; hexamethyl-3,3,bis {(trimethylsilyl)oxy} trisiloxane (M 4 Q) with a boiling point of 222° C., viscosity of 2.86 mm 2 /s, and formula C 12 H 36 O 4 Si 5 ; and pentamethyl {(trimethylsilyl)oxy} cyclotrisiloxane (MD 3 ) with the formula C 8 H 24 O 4 Si 4 .
One preferred VMS component of my ternary system is octamethylcyclotetrasiloxane (CH 3 ) 2 SiO! 4 . It has a viscosity of 2.3 centistokes (mm 2 /s) at 25° C., and is referred to as "D 4 " since it contains four difunctional "D" units (CH 3 ) 2 SiO 2/2 shown as: ##STR2##
Four "D" units combine to form octamethylcyclotetrasiloxane shown in either formula below: ##STR3##
In the literature, D 4 is often called CYCLOMETHICONE or TETRAMER. It has a higher viscosity (2.3 cs) and is thicker than water (1.0 cs), yet octamethylcyclotetrasiloxane needs 94% less heat to evaporate than water.
Another preferred VMS component of my ternary system is decamethylcyclopentasiloxane (D5) often referred to as PENTAMER. It is shown structurally below: ##STR4##
A benefit offered by using VMS compounds is that many local, state, federal, and international regulations, have restricted the use of certain chemicals, but VMS is a suitable replacement. Thus, the Environmental Protection Agency (EPA) determined that volatile methyl siloxanes such as octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, dodecamethylcyclohexasiloxane, hexamethyldisiloxane, octamethyltrisiloxane, and decamethyltetrasiloxane, were acceptable substitutes for the CFC-113 chlorofluorocarbon (C 2 Cl 3 F 3 ) and methylchloroform (MCF). This determination is limited to cleaning in closed systems, for metal cleaning, electronic cleaning, and precision cleaning applications, under the EPA's Significant New Alternatives Policy (SNAP).
In addition, the EPA excluded VMS as a volatile organic compound (VOC). Thus, they added VMS to a list of compounds in 40 CFR 51,100(s) excluded from the definition of VOC, on the basis that VMS compounds have negligible contribution to tropospheric ozone formation. They pointed out that exempting VMS from regulation as an ozone precursor contributes to achievement of several important environmental goals, in that VMS might be used as a substitute for compounds listed as hazardous air pollutants (HAP). As they explained, that met the need to develop substitutes for ozone depleting substances (ODS), and attained National Ambient Air Quality Standards for ozone under Title I of the Clean Air Act.
The other component of my ternary system, in addition to water and VMS, is a short-chain or low molecular weight silicone polyether. Representative polyether structures are: ##STR5##
A cyclic polyether of the type shown below can also be used. ##STR6##
In these structures, R1 represents an alkyl group containing 1-6 carbon atoms such as methyl, ethyl, propyl, butyl, pentyl, and hexyl; R2 represents the radical --(CH 2 ) a O(C 2 H 4 O) b (C 3 H 6 O) c R3; x has a value of 0-3; y has a value of 1-3; z has a value of 0-2; m has a value of 3-5; n is one; a has a value of 3-6; b has a value of 4-20; c has a value of 0-5; and R3 is hydrogen, a methyl radical, or an acyl radical such as acetyl. Preferably, R1 is methyl; b is 6-12; c is zero; and R3 is hydrogen.
Compositions according to my invention may contain 5-70% by weight of surfactant, but most preferably, they contain about 15-30% by weight of the surfactant. The balance of the composition is oil and water, with the proportions of oil and water generally falling between 40:60 to 80:20, or 0.4 to 0.8 as defined below for Ratio 1.
For purposes of my invention, the criteria used to determine optical clarity is whether text can be read with the naked eye through a two centimeter diameter bottle filled with the microemulsion.
As noted in the textbook Microemulsions Theory and Practice, Edited by Leon M. Prince, Academic Press, Inc., Pages 7-10, New York (1977), the "Visual recognition of microemulsions should not be taken lightly. In fact, the microemulsion chemist should train himself carefully in this art. Use of sunlight rather than an artificial source of light is recommended. The eye is better than a microscope because the limit of resolution of a light microscope in blue light is only about 0.1 μm so that droplets smaller than 0.14 μm cannot be seen".
The following examples show my invention in more detail.
EXAMPLE I
I formed optically clear microemulsions spontaneously at temperatures ranging between 47°-62° C. by merely adding to a container, 50 parts of de-ionized water, 50 parts of octamethylcyclotetrasiloxane (D4), and 25 parts of silicone polyether. No mixing, stirring, shearing, or input of mechanical energy for agitating the three ingredients was required. The polyether corresponded to the compound: ##STR7## where R1 was methyl, x was zero, y was one, and R2 was --(CH 2 ) 3 (OC 2 H 4 ) 8 OH. I was able to read text through a two centimeter diameter bottle filled with the microemulsions. I determined that the microemulsions contained particles having an average diameter of less than 100 nanometers (0.1 microns).
EXAMPLE II
I repeated Example I and formed clear microemulsions spontaneously at temperatures ranging between 60°-68° C. by merely combining in a container, 50 parts of de-ionized water, 50 parts of decamethylcyclopentasiloxane (D5), and 25 parts of silicone polyether. The optical clarity was the same as obtained in Example I.
EXAMPLE III
I repeated Example I and formed clear microemulsions spontaneously at temperatures ranging between 44°-60° C. by merely combining in a container, 60 parts of de-ionized water, 40 parts of octamethylcyclotetrasiloxane (D4), and 17.65 parts of silicone polyether. The optical clarity was the same as obtained in Example I.
EXAMPLE IV
I repeated Example III including the use of salt which is a non-essential ingredient. I formed clear microemulsions spontaneously at temperatures ranging between 20°-30° C. by merely combining in a container, 50 parts of an aqueous solution containing 15% sodium chloride, 50 parts of octamethylcyclotetrasiloxane (D4), and 17.65 parts of silicone polyether. The optical clarity was the same as obtained in Example III.
EXAMPLE V
I repeated Example IV and formed clear microemulsions spontaneously at temperatures ranging between 22°-41° C. by merely combining in a container, 30 parts of an aqueous solution containing 15% sodium chloride, 70 parts of octamethylcyclotetrasiloxane (D4), and 25 parts of silicone polyether. The optical clarity was the same as obtained in Example IV.
EXAMPLE VI
I repeated Example II and formed clear microemulsions spontaneously at temperatures ranging between 30°-85° C. by merely combining in a container, 50 parts of de-ionized water, 50 parts of decamethylcyclopentasiloxane (D5), and 66.67 parts of silicone polyether. The optical clarity was the same as obtained in Example II.
The following four examples illustrate preparation of clear antiperspirants. In Examples VII-X, an antiperspirant active was incorporated into my clear silicone microemulsion without input of mechanical energy for mixing the components.
EXAMPLE VII
I repeated Example I and formed clear microemulsions spontaneously at temperatures ranging between 42°-58° C. by merely combining in a container, 50 parts of an aqueous solution containing 25% of the antiperspirant active Aluminum Chlorohydrate (ACH-303), 50 parts of octamethylcyclotetrasiloxane (D4), and 25 parts of silicone polyether. The optical clarity was the same as obtained in Example I.
EXAMPLE VIII
I repeated Example VII and formed clear microemulsions spontaneously at temperatures ranging between 36°-69.6° C. by merely combining in a container, 50 parts of an aqueous solution containing 25% of the antiperspirant active Aluminum-Zirconium Tetrachlorohydrex-Gly (ACH-370), 50 parts of octamethylcyclotetrasiloxane (D4), and 28.2 parts of silicone polyether. The optical clarity was the same as obtained in Example VII.
EXAMPLE IX
I repeated Example VII and formed clear microemulsions spontaneously at temperatures ranging between 30°-46° C. by merely combining in a container, 50 parts of an aqueous solution containing 50% of the antiperspirant active Aluminum Chlorohydrate (ACH-303), 50 parts of octamethylcyclotetrasiloxane (D4), and 21.95 parts of silicone polyether. The optical clarity was the same as obtained in Example VII.
EXAMPLE X
I repeated Example VII and formed clear microemulsions spontaneously at room temperature by merely combining in a container, 63 parts of an aqueous solution containing 25% of the antiperspirant active Aluminum Chlorohydrate (ACH-303) and 15% of sodium chloride, 37 parts of octamethylcyclotetrasiloxane (D4), and 20.5 parts of silicone polyether. The optical clarity was the same as obtained in Example VII.
Other antiperspirant actives such as Aluminum Sesquichlorohydrate salts can be used in Examples VII-X. Suitable antiperspirants products can be formulated containing a maximum use level of antiperspirant active of 20% by weight AZG and 25% by weight ACH, on an anhydrous basis.
The following examples illustrate preparation of compositions according to my invention using a linear volatile methyl siloxane instead of a cyclic volatile methyl siloxane.
EXAMPLE XI
I repeated Example I and formed clear microemulsions spontaneously at temperatures ranging between 30°-70° C. by merely combining in a container, 50 parts of de-ionized water, 50 parts of hexamethyldisiloxane (MM), and 42.9 parts of silicone polyether. The optical clarity was the same as obtained in Example I.
EXAMPLE XII
I repeated Example XI and formed clear microemulsions spontaneously at temperatures ranging between 43°-56° C. by merely combining in a container, 50 parts of de-ionized water, 50 parts of hexamethyldisiloxane (MM), and 17.7 parts of silicone polyether. The optical clarity was the same as obtained in Example I.
Table I provides a summary of Examples I-XII. In Table I, Ratio 1 is the amount of oil divided by the amounts of oil and water. Ratio 2 is the amount of surfactant divided by the amounts of oil, water, and surfactant. Percent Surfactant is obtained from the relationship (Ratio 2) divided by (1-Ratio 2)×100.
TABLE I______________________________________ TemperatureExample (°C.) Ratio 1 Ratio 2 % Surfactant______________________________________I 47-62 0.5 0.2 25.0II 60-68 0.5 0.2 25.0III 44-60 0.4 0.15 17.6IV 20-30 0.5 0.15 17.6V 22-41 0.7 0.2 25.0VI 30-85 0.5 0.4 66.7VII 42-58 0.5 0.2 25.0VIII 36-69.6 0.5 0.22 28.2IX 30-46 0.5 0.18 22.0X 20-25 0.5 0.22 28.2XI 30-70 0.5 0.3 42.9XII 43-56 0.5 0.15 17.6______________________________________
As can be seen in Table I, compositions according to my invention can be prepared at temperatures generally in the range of 20°-85° C. They contain 5-70% by weight of surfactant, most preferably, about 15-30% by weight of the surfactant; with the balance being oil and water. The proportions of oil and water generally fall between 40:60 to 80:20, or 0.4 to 0.8 as defined above for Ratio 1.
EXAMPLE XIII
I formed a number of optically clear microemulsions spontaneously at room temperature (22° C.). In this example, compositions representative of my invention were prepared, wherein the mixing ratio of the three components comprising water, oil, and surfactant, was within the shaded area in FIGURE 1 of the drawing, i.e. the area surrounded by the lines connecting points A, B, C, D, and E. I formed these microemulsions in the same manner as in Example I. Thus, I merely added the three ingredients to a container. No mixing, stirring, shearing, or input of mechanical energy for agitating the three ingredients was required. The polyether corresponded to the same compound used in Example I. I was again able to read text through a two centimeter diameter bottle filled with these microemulsions. They contained particles having an average diameter of less than 100 nanometers (0.1 microns).
EXAMPLE XIV--COMPARISON
I repeated Example I and formed a number of emulsions at room temperature. However, in this COMPARISON EXAMPLE, I used a silicone oil equivalent to the silicone oils described in Bailey's U.S. Pat. No. 3,299,112. Thus, Bailey's silicone oil is said to correspond to R" 3 SiO(R" 2 SiO) x SiR" 3 with x being 10-1,000. I followed the teaching in Bailey, but was not able to read text through a two centimeter diameter bottle filled with these Bailey emulsions. As noted in the BACKGROUND OF THE INVENTION, my invention in one embodiment involves using a volatile linear VMS having an "x" of 0-5, well below the range in Bailey. In this COMPARISON EXAMPLE, I verified that where "x" exceeds 5, the compositions are not clear.
Other variations may be made in the compounds, compositions, or methods described, without departing from the essentials of my invention, the forms of which are exemplary, and not limitations on its scope as defined in the claims.
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A method of spontaneously forming a highly stable clear microemulsion by combining (i) water; (ii) a volatile cyclic methyl siloxane or volatile linear methyl siloxane; and (iii) a silicone polyether surfactant. The amounts of each component are such that the composition is in the form of a microemulsion. The volatile methyl siloxane is present in the microemulsion in the form of particles having an average diameter of less than about 100 nanometers. The microemulsion is useful in personal care products.
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CROSS REFERENCE TO RELATED INVENTION
[0001] This invention is related to an invention for a Double Pendulum Gravimeter and Method of Measuring Gravity Using the Same, described in U.S. application Ser. No. ______, filed concurrently herewith and assigned to the assignee hereof. The subject matter of this application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a pendulum, and more particularly, to a new and improved pendulum arm in the form of a flexure which is made of energy-conserving material, such as quartz, and which has a structure that is capable of reproduction in multiple substantially identical units, all of which exhibit substantially identical length, flex, and resonant operating characteristics. Further still, the present invention relates to a new and improved method of construction of such a pendulum arm flexure.
BACKGROUND OF THE INVENTION
[0003] A pendulum is formed by a mass or “bob” that is connected to one end of a pendulum arm. The other end of the pendulum arm is pivotally connected to a stationary structure at a point of suspension or a center of motion. Energy imparted to the bob causes it to swing back and forth in an arc of oscillation at the point of suspension. Gravity sustains the oscillation of the bob until friction dissipates the oscillation energy of the swinging bob.
[0004] The time required for the pendulum bob to swing from one maximum amplitude end point in the arc of oscillation back to that same point is the period (T) of the swing. The period (T) of the swing, the gravity (g) and the length of the pendulum arm (L) are related to one another in an ideal pendulum by the following equation (1):
[0000] T= 2 π[L/g] 1/2 (1)
[0000] Knowing or measuring two of the three variables length (L), gravity (g) or period (T) permits the other variable to be calculated. In this manner, a pendulum may be used as a measurement device for determining gravity (g), or precise time intervals (T), or the frequency (f) of the oscillation of the pendulum. The period (T) and the frequency (f) are inversely related to one another by the following well known equation (2):
[0000] f= 1/ T (2)
[0005] It is desirable to minimize the oscillation energy loss associated with the swinging pendulum. Oscillation energy losses have the effect of changing the period (T) and/or increasing the frequency (f). A changing period (T) or frequency (f) makes it very difficult to calculate with precision the quantity which is to be measured with the pendulum. Adding energy to replace that energy lost to friction is very difficult in a pendulum, because the added energy may create aberrations in the swing of the pendulum which in turn affect the ability to precisely measure the desired variable. While energy loss in a pendulum cannot be avoided altogether, minimizing the energy loss has the effect of enhancing the accuracy of measurement.
[0006] One significant source of energy loss in a pendulum is the friction at the point of suspension where the pendulum arm connects to the stationary structure. The friction from the movement of the pendulum arm relative to the stationary structure dissipates energy. Even a knife-edge point of suspension creates enough friction to adversely affect the period (T) and frequency (f) in a precision pendulum.
[0007] One known technique of diminishing energy loss at the point of suspension is to prevent the pendulum arm from moving relative to the stationary structure. To do so, the pendulum arm must be formed as a resilient flexure which is rigidly connected to the stationary structure at the point of suspension. The other end of the flexure is rigidly connected to the pendulum bob. The rigidly connected ends of the flexure do not move relative to the objects to which they are connected, so there is no frictional loss associated with relative movement at these points. Instead, the flexure bends back and forth as the bob swings in its arc of oscillation.
[0008] One known pendulum flexure is formed from a resilient, energy conserving material, such as quartz (fused silica) or other similar amorphous material. Flexing the material in one direction temporarily stores energy as intermolecular or van der Waals forces within the resilient material of the flexure. When the flexure flexes in the opposite direction, the stored energy is released. In this manner, a significant quantity of the oscillation energy is preserved, minimizing the loss of oscillation compared to the frictional losses from relative mechanical movement.
[0009] The known pendulum arm flexure is formed of quartz or other energy-conserving material. Examples are described in two theses: A Pendulum Gravimeter for Measurement of Periodic Annual Variations in the Gravitational Constant, by William F. Hoffman, Princeton University, January 1962; and A Pendulum Gravimeter for Precision Detection of Scalar Gravitational Radiation, by David R. Curott, Princeton University, May 1965. The quartz pendulum arm flexures described in these theses are formed by heating the center section of a solid quartz rod until it achieves a viscous and flowable state, and then stretching the viscous center section to draw it out to a long, small diameter fiber extending between the larger unchanged ends of the rod. The rod transitions or necks down from the full diameter ends to the small diameter center fiber. The transitions occur in an unpredictable manner according to the uniformity of heat distribution in the center section of the quartz rod, the amount of heat energy in the center section prior to stretching, the rate at which the solid rod is stretched, and the viscosity of the heated center portion from which the fiber is formed, among other variables. The fiber itself is not of a uniform diameter, because the stretching occurs in an uncontrolled manner. The necked down transition portions between the full diameter ends of the rod and the center fiber are also variable in characteristics, due to the transitions occurring in an uncontrolled manner.
[0010] As a consequence of these uncontrolled variables, the length (L) of the pendulum arm is not predictable, and the flex characteristics of the flexure are also unpredictable. The necked down transition portions do not precisely demarcate points which establish the length (L) of the fiber which forms the pendulum arm. The thinnest portions of the necked down transition portions adjacent to the fiber may flex slightly along with the fiber, thereby varying the length (L) of the pendulum arm. Furthermore, the nonuniform diameter or thickness of the fiber itself will have different flexure characteristics.
[0011] These idiosyncratic aspects of known prior art quartz pendulum arm flexures are not of principal concern in those pendulum devices which utilize only a single pendulum supported by a single flexure. The operating characteristics of the pendulum device are adapted to the unique characteristics of the single flexure. However, in pendulum devices which require two flexures to support a single bob, or in pendulum devices which use two separate pendulums operating at the same oscillation frequency, it is important that multiple pendulum arm flexures have substantially the same length, flex and resonant operating characteristics. Pendulum arm flexures having substantially the same length, flex and resonant operating characteristics achieve predictable oscillatory behavior. Using pendulum arm flexures which have significantly different length, flex and resonant operating characteristics result in undesirable modes of movement of a single pendulum supported by two flexures. The undesirable modes of movement consume additional energy and adversely affect the desired operation of the pendulum. In addition, in double or multiple pendulum devices, significantly different length, flex and resonant operating characteristics of multiple pendulum arm flexures create substantial difficulties in attempting to coordinate and synchronize the motions of multiple pendulums, or may make synchronized operation achievable only when accompanied by substantial and undesirable energy loss.
SUMMARY OF THE INVENTION
[0012] The pendulum arm flexure of the present invention is made from quartz or other energy-conserving material, and has a definite length (L) and a substantially uniform diameter fiber extending between opposite ends to which holders are attached. As a consequence of these characteristics, the length, flex and resonant operating characteristics of the flexure are predictable and therefore reproducible in multiple substantially identical ones of the pendulum arm flexures, each of which has substantially identical operating characteristics. Two of these substantially identical pendulum arm flexures may be used effectively to suspend a single bob in single pendulum device. Multiple ones of these substantially identical pendulum arm flexures may be used to suspend the bobs of multiple pendulums in a multiple pendulum device. The definite and determinable operating characteristics of the pendulum arm flexure of the present invention minimize or eliminate undesirable modes of motion which consume additional oscillating energy of the pendulum. The definite and determinable operating characteristics of the pendulum arm flexure reduce the need, and components required, to add energy to an oscillating pendulum, thereby simplifying the operation of the pendulum. The present invention also involves a method of constructing such a pendulum arm flexure having these desirable characteristics.
[0013] In accordance with these considerations, one principal aspect of the invention is a pendulum arm flexure for supporting a pendulum bob from a support structure. The flexure comprises an elongated fiber having opposite ends, and a holder connected at each opposite end of the elongated fiber. One holder is adapted to rigidly connect the pendulum arm flexure to either the pendulum bob or the support structure, and the other holder is adapted to rigidly connect the pendulum arm flexure to the other one of the pendulum bob or the support structure. Each holder includes an inner end adjacent to the fiber, and the fiber extends continuously between the inner ends of the holders. The inner end of each holder has a larger cross-sectional size than the cross-sectional size of the adjacent fiber. The inner end of each holder transitions abruptly in cross-sectional size relative to the cross-sectional size of the connected fiber. The fiber has a precise length measured between the abrupt transitions at the inner ends of the opposite holders. The fiber has resiliency characteristics which permit flexing along the length of the fiber between the inner ends of the holders during oscillation of the pendulum. Each holder has rigidity characteristics which prevent flexing of the holder at its inner end during oscillation of the pendulum. The fiber is formed of energy conserving material which temporarily stores energy expended in flexing the fiber in one direction as intermolecular force and then releases the stored energy when the fiber flexes in the opposite direction.
[0014] Other aspects of the pendulum arm flexure include some or all the following described features. The fiber has a substantially uniform cross-sectional size between the inner ends of the opposite holders. The resiliency characteristic of the fiber is substantially uniform along the length of the fiber between the inner ends of the holders. An electrically conductive coating covers the fiber and each holder. Each holder is integrally connected to the fiber, such as by integral fusion. The fiber and both holders are separately formed before each holder and the fiber are integrally fused together. The fiber and both holders are formed of the same material, which is preferably capable of viscously flowing upon the application of sufficient heat, such as a glass or quartz material.
[0015] Another principal aspect of the invention is a method of constructing a pendulum arm flexure which supports a pendulum bob from a support structure, in which the pendulum arm flexure comprises an elongated fiber having opposite ends and a holder located at each opposite end of the elongated fiber, with each holder adapted to connect the pendulum arm flexure to one of the pendulum bob or the support structure. The method comprises forming first and second holders separately from one another and from an elongated fiber, connecting the first holder to one end of the fiber and connecting the second holder to the other end of the fiber at a predetermined distance from the first holder to establish the length of the pendulum arm flexure which will undergo oscillation.
[0016] Other subsidiary aspects of the construction method include some or all of the following described features. Each holder is integrally connected to the ends of the separate fiber, by for example, fusing each holder and the fiber. The holders and the fiber are formed of the same material, such as quartz, which is capable of fusion upon the application of sufficient heat. Each holder is formed to include an opening within which to receive the one end of the fiber, the end of the fiber is inserted into the opening of each holder, and the holder and the end of the fiber inserted the opening are fused to integrally connect each holder to each end of the fiber. The holder and the end of the fiber are fused by the application of heat sufficient to melt the holder and the fiber while directing a stream of cover gas over the fiber adjacent to the inner end of each holder to cool the fiber and prevent melting of the fiber adjacent to the holder. The fiber is formed to have a substantially uniform cross-sectional size along its length between the holders. A center section of a rod of material from which the fiber is formed is heated sufficiently to make the center section of the rod viscous and flowable, and opposite ends of the rod are moved away from one another at a substantially constant rate to draw the viscous center section of the rod into an elongated and substantially uniform and reduced cross-sectional length of material, from which the fiber is obtained. Opposite ends of the rod are moved away from one another at a substantially constant rate by suspending the rod vertically above a hollow tube of electrically conductive material, attaching a magnet to the lower end of the vertically suspended rod, and moving the end of the heated rod into the tube at a substantially constant rate established by eddy currents induced in the electrically conductive tube which create a magnetic force that counteracts force from the magnet and causes the magnet to move downward at a substantially constant rate. The exterior of the flexure may be coated with an electrically conductive material.
[0017] A more complete appreciation of the present invention and its scope may be obtained from the accompanying drawings, which are briefly summarized below, from the following detailed description of presently preferred embodiments of the invention, and from the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective block and generalized component illustration of a double pendulum device which incorporates multiple ones of the pendulum arm flexures of the present invention.
[0019] FIG. 2 is a perspective view of one pendulum arm flexure shown in FIG. 1 and which incorporates the present invention.
[0020] FIG. 3 is an enlarged axial section view of one end of the pendulum arm flexure shown in FIG. 2 .
[0021] FIG. 4 is an enlarged axial section view of the end of the pendulum arm flexure shown in FIG. 3 , prior to fusing a fiber in a retainer portion of a holder to form the integral flexure shown in FIGS. 2 and 3 .
[0022] FIG. 5 is a partial enlarged axial section view similar to FIG. 4 , showing a holder and an end of a fiber prior to inserting the end of the fiber into the holder and prior to integrally fusing those components together to create the flexure shown in FIGS. 2 and 3 .
[0023] FIG. 6 is a perspective view of a prior art pendulum arm flexure with respect to which the present invention is an improvement.
[0024] FIG. 7 is a perspective view of a rod from which the prior art pendulum shown in FIG. 6 is constructed.
[0025] FIG. 8 is an enlarged axial section view of one end of the prior art pendulum arm flexure shown in FIG. 6 .
[0026] FIG. 9 is a generalized perspective view of a glass lathe holding a tube and a rod upon which actions are performed to construct the pendulum arm flexure shown in FIGS. 2-5 .
[0027] FIGS. 10A-10J are perspective, axial section, enlarged and partial sequential views which illustrate actions performed on the tube and the rod shown in FIG. 9 to construct a holder shown in FIGS. 4 and 5 of the pendulum arm flexure shown in FIGS. 2 and 3 .
[0028] FIGS. 11A-11C are perspective, axial section, enlarged and partial sequential views which illustrate actions performed to construct a fiber of the pendulum arm flexure shown in FIGS. 2-5 .
[0029] FIGS. 12A-12C are perspective, axial section, enlarged and partial sequential views which illustrate actions performed on the holder illustrated in FIGS. 10A-10J and the fiber illustrated in FIGS. 11A-11C , to connect the holder and the fiber as shown in FIGS. 2 and 3 .
[0030] FIG. 13A is a partial view similar to FIG. 3 , showing an electrically conductive coating applied to the exterior of the pendulum arm flexure shown in FIGS. 2 and 3 . FIGS. 13B and 13C are generalized illustrations of actions taken to apply the electrically conductive coating shown in FIG. 13A .
DETAILED DESCRIPTION
[0031] Four pendulum arm flexures 20 , each of which incorporates the present invention, are used in a double pendulum device 22 shown in FIG. 1 . The double pendulum device 22 may be a gravimeter used to measure gravity (g), or a clock used to measure intervals of time (T) or to establish a frequency (f). An example of a double pendulum device 22 used as a gravimeter is described in the above cross-referenced US patent application.
[0032] The double pendulum device 22 includes a first pendulum 24 and a second pendulum 26 . The first pendulum 24 comprises a pendulum bob 28 and two pendulum arm flexures 20 which suspend the pendulum bob 28 from a pendulum suspension structure 30 . The second pendulum 26 comprises a pendulum bob 32 and two pendulum arm flexures 20 which suspend the pendulum bob 32 from a pendulum suspension structure 34 . One end of each pendulum arm flexure 20 , the upper end 36 as shown in FIG. 1 , is connected to one of the pendulum suspension structures 30 or 34 . The other end of each pendulum arm flexure 20 , the lower end 38 as shown in FIG. 1 , is connected to one of the bobs 28 or 32 . In this manner, two pendulum arm flexures 20 support each pendulum bob 28 and 32 from each pendulum suspension structure 30 and 34 . Both pendulum suspension structures 30 and 34 are connected to a support post 40 which extends from and forms part of a rigid base 42 of the device 22 .
[0033] The upper ends 36 of the two flexures 20 associated with each pendulum 24 and 26 are rigidly connected to the suspension structures 30 and 34 . The lower ends 38 of the two flexures 20 associated with each pendulum 24 and 26 are rigidly connected to respectively opposite ends of the bobs 28 and 32 . The points of connection of the upper ends 36 of the flexures 20 to the pendulum suspension structures 30 and 34 , and the points of connection of the lower ends 38 of the flexures 20 to the bobs 28 and 32 , cause the pendulums 24 and 26 to swing or oscillate in a common plane of oscillation. Preferably, the pendulums 24 and 26 oscillate 180° out of phase with one another, meaning that when the pendulum 24 reaches its maximum amplitude point in its arc of oscillation on the left (as shown), the pendulum 26 reaches its maximum amplitude in its arc of oscillation on the right (as shown), and vice versa. The maximum amplitude points of the pendulum bobs 28 and 32 in their arcs of oscillation are sensed by amplitude sensors 44 and 46 , respectively, both of which are attached to the base 42 . Although the bobs 28 and 32 are shown supported below the suspension structures 30 and 34 , the flexures 20 could also be suspend the bobs above suspension structures in appropriate circumstances.
[0034] The length, flexure and resonant operating characteristics of the pendulum arm flexures 20 are substantially identical in accordance with the present invention, as discussed in greater detail below. The weight and center of mass distribution of the pendulum bobs 28 and 32 are also substantially identical. Consequently, the pendulums 24 and 26 experience substantially identical natural or resonant oscillation characteristics. The substantially identical natural resonant oscillation characteristics of each pendulum 24 and 26 causes one pendulum 24 or 26 to oscillate at a frequency (f) or period (T) which is substantially identical to the frequency or period of the other pendulum 26 or 24 .
[0035] When oscillating at their natural resonant frequencies, the pendulums 24 and 26 conserve the maximum amount of oscillation energy. Stated alternatively, the pendulums 24 and 26 minimize the loss of oscillation energy when operating at their natural resonant frequencies. The natural resonant frequency energy storage and loss characteristic of any resonant system is defined by a term referred to as “Q”. When operating at a high Q, a resonant system conserves the maximum amount of the resonant energy and minimizes the loss of oscillating energy.
[0036] The pendulums 24 and 26 preferably have substantially identical high Q's and natural resonant frequencies. The pendulums 24 and 26 swing in substantially identical arcs of oscillation, maintain substantially identical maximum amplitude points, and do so while losing a minimum amount of oscillation energy from the unavoidable frictional energy loss associated with any moving mechanical system. These desirable characteristics result in major part from the consistent, predictable and reproducible characteristics of each pendulum arm flexure 20 .
[0037] More details concerning each pendulum arm flexure 20 are shown in FIGS. 2-5 . The pendulum arm flexure 20 comprises a holder 50 at each end 36 and 38 of the flexure 20 . The holders 50 are adapted to connect the ends 36 and 38 to a pendulum bob (e.g, 28 or 32 , FIG. 1 ) and to a suspension structure (e.g., 30 or 34 , FIG. 1 ). A fiber 52 extends between the opposite ends 36 and 38 of the holders 50 . The fiber 52 is formed from material, such as quartz (fused silica), which provides a high degree of energy conservation due to the storage and release of intermolecular forces when the material is mechanically flexed or bent and then released to resume its initial non-flexed position. Preferably, the holders 50 are also formed of the same type of material as the fiber 52 . A further desirable characteristic of this type of energy-conserving material is a capability to become viscous, flow and melt upon the application of sufficient heat, as discussed below.
[0038] The fiber 52 has a substantially uniform diameter and substantially uniform material characteristics along its length between the holders 50 . The fiber 52 flexes when the pendulum swings in its arc of oscillation. The holders 50 do not flex to any significant degree when the pendulum swings in its arc of oscillation, because the holders 50 are themselves rigid and rigidly connected to the pendulum suspension structures 30 and 34 and to one of the pendulum bobs 28 and 32 .
[0039] Each holder 50 has a uniform diameter tubular portion 54 located at its outer end. A middle portion 56 of each holder 50 is formed as a hollow frustoconical-shaped or necked-down transition which extends inward from the tubular portion 54 toward an inner tubular retainer portion 58 of each holder 50 . The retainer portion 58 extends inward from the transitional portion 56 and connects to the fiber 52 . Initially, before the fiber 52 is connected to the tubular retainer portion 58 , a small axial opening 60 extends from an inner end 62 of the retainer portion 58 into the transitional portion 56 ( FIGS. 4 and 5 ). An outer end 64 of the fiber 52 is inserted into the axial opening 60 ( FIG. 4 ). The retainer portion 58 is heated until it and the outer end 64 of the fiber 50 melt and fuse together into an integral solid mass 66 ( FIG. 3 ). The integral fusion of the end 64 of the fiber 52 and the retainer portion 58 makes the end 64 of the fiber 52 integrally and rigidly a part of the holder portion 50 . In this manner, the fiber 52 is rigidly and integrally joined to each holder 50 , as shown in FIG. 3 .
[0040] Due to its integral connection to the retainer portion 58 of the holder 50 , the outer end 64 of the fiber 52 is not able to flex relative to the retainer portion 58 or relative to the holder 50 . Flexing of the fiber 52 is only possible beginning at the point where the fiber 52 adjoins the inner end 62 of the retainer portion 58 and along the length of the fiber 52 to the point adjoining the inner end 62 of the retainer portion 58 of the holder 50 at the opposite end of the flexure 20 . The fiber 52 flexes only between the inner ends 62 of the retainer portions 58 of the opposite holders 50 ( FIG. 2 ), due to the rigid connection of the holders 50 to the pendulum bobs and to the suspension structures.
[0041] The specific positions of the inner ends 62 of the holders along the length of the fiber 52 precisely define the effective oscillation length (L) of the pendulum arms along which flexure occurs. The length of the pendulum arm (L) is precisely and definitely established by a center portion 68 of the fiber 52 extending between the distinct inner ends 62 of the retainer portions 58 of the oppositely positioned holders 50 . The length of the center portion 68 of the fiber 52 between the opposite ends 62 of the retainer portions 58 is precisely set before fusing the end 64 of the fiber 52 and the retainer portion 58 of the second holder 50 of the flexure 20 . The length (L) of the pendulum is controlled by the extent to which the center portion 68 is exposed after inserting and fusing the end 64 of the fiber 52 in the axial opening 60 . Controlling the length (L) of the flexure 20 in this manner allows multiple ones of the pendulum arm flexures 20 to be constructed having substantially identical lengths (L).
[0042] In contrast to the precise and controllable length (L) of the fiber 52 of the flexure 20 ( FIG. 2 ), a known prior art flexure 70 , shown in FIGS. 6 and 8 , exhibits an effective oscillation length (L) which is significantly indeterminable. The prior art flexure 70 is formed from a single integral rod 72 of quartz material, shown in FIG. 7 . A center portion 74 of the rod 72 is heated until it becomes viscous and flowable, which allows cylindrical ends 76 of the rod 72 to be separated and pulled in opposite directions, thereby drawing the viscous center portion 74 into two opposite frustoconically shaped transitional portions 78 between which a considerably smaller diameter center fiber 80 extends. The center fiber 80 continues in a portion 82 which diminishes further in diameter from the transitional portion 78 , until ultimately a center portion 84 of the fiber 80 reaches a somewhat consistent diameter over some indeterminate length. The entire prior art flexure 70 is formed simultaneously in this manner.
[0043] The two transitional portions 78 are variable and nonuniform in their thickness and length characteristics. The diminishing-diameter portions 82 of the center fiber 80 are also variable and nonuniform in their thickness and length. The variability in thickness arises from the lack of precise control in drawing the viscous center portion 74 of the rod 72 into the transitional portions 78 , the portion 82 and the center fiber 84 . Most importantly, however, the variable transitional portions 78 and the diminishing-diameter portions 82 do not precisely establish the beginning and ending points at which the fiber 80 flexes. Flexure may occur in some indeterminate location within the transitional portions 78 and/or in the diminishing-diameter portions 82 . Without such a specific point at which the fiber 80 is allowed to flex, it is impossible to determine with precision the effective length (L) of the flexure 70 during oscillation, as shown graphically in FIG. 6 .
[0044] Another category of problems associated with the prior art flexure 70 is that its resonant oscillatory characteristics are substantially indeterminable. The flexible transitional portions 78 and the diminishing-diameter portions 82 of the fiber 80 vary in thickness or diameter, and that variability introduces different flexure characteristics in those portions 78 and 80 compared to the more uniform flexing characteristics of the center portion 84 of the fiber 80 . The variability in thickness of the flexing portions 78 and 82 of the flexure 70 create different mechanical flex characteristics, which leads to variability in the natural resonant frequency characteristics of the flexure 70 . These variable characteristics make it very difficult or impossible to predict the oscillating characteristics of the prior art flexure 70 .
[0045] A prior art pendulum arm flexure 70 of the type shown in FIG. 6 will perform satisfactorily in a pendulum which utilizes only a single such flexure 70 to support a pendulum bob. In those circumstances, the flexure and natural resonant frequency operating characteristics of the flexure 70 are simply measured, and then the remaining aspects of the pendulum are adapted to the measured characteristics of the flexure 70 . In other words, the operating characteristics of the pendulum device are adapted to the unique characteristics of the pendulum arm flexure. In the case of a single flexure-single bob pendulum device, consistency in the characteristics of the pendulum arm flexure is not necessarily essential.
[0046] On the other hand, a prior art pendulum arm flexure 70 is not satisfactory for use where multiple pendulum arm flexures are used to support a single pendulum bob, or where multiple pendulums must oscillate in synchronization with one another, or where the pendulum device requires or depends upon predictable length, flex and natural resonant frequency operating characteristics of the pendulum arm flexure. To obtain optimal performance in such situations, each pendulum arm flexure should have substantially identical and predictable length (L) and natural resonant frequency operating characteristics. Without such substantially predictable characteristics, the oscillation of a single pendulum bob supported by two flexures will not oscillate in the desired manner with minimum loss of oscillation energy, and/or the two pendulums will not oscillate in synchronization with one another with minimum loss of oscillation energy. Excessive energy loss becomes a substantial and significant problem in the use of these prior pendulum devices.
[0047] The pendulum arm flexure 20 of the present invention solves these problems by having a substantially predictable effective length (L) and predictable flexure and natural resonant frequency characteristics. As a consequence, the present invention permits the construction of multiple substantially identical pendulum arm flexures 20 on a repeatable, predictable and consistent basis, thereby assuring that the pendulum devices in which multiple ones of those flexures 20 are utilized will operate as desired with minimal loss of oscillating energy.
[0048] A method of constructing each pendulum arm flexure 20 to yield consistent and predictable characteristics entails separately constructing two holders 50 and a single fiber 52 ( FIGS. 4 and 5 ) and then joining them together to form the flexure 20 ( FIG. 2 ). FIGS. 10A-10J illustrate the construction of one holder 50 . The other holder 50 of the flexure 20 is formed in the same manner. FIGS. 11A-11C illustrate the construction of a single fiber 52 . FIGS. 12A-12C describe joining the two holders 50 to the fiber 52 to form the flexure 20 ( FIG. 2 ). FIGS. 13A-13C describe placing an electrically conductive coating on the exterior of the flexure 20 ( FIG. 2 ).
[0049] Construction of the holder 50 commences, as shown in FIG. 9 , by fusing an end of a quartz tube 90 to a solid quartz rod 92 . The fusion preferably occurs while the tube 90 and the rod 92 are held in chucks 94 and 96 of spindles 98 and 100 , respectively, of a conventional glass lathe 102 . The spindles 98 and 100 are sometimes referred to as the headstock and tailstock of the lathe, respectively. The spindles 98 and 100 rotate coaxially about a single working axis of the lathe 102 , and the chucks 94 and 96 hold one or two workpieces and rotate them about that working axis. As shown in FIG. 9 , the tube 90 and rod 92 constitute the workpieces. One of the spindles is movable longitudinally along the working axis, to move the workpiece held by that spindle axially relative to the workpiece held by the other spindle. The flexure 24 is preferably constructed by actions performed by using the glass lathe 102 , as described in connection with FIGS. 10A-10J and 12 A- 12 C.
[0050] The ends of the tube 90 and the rod 92 are brought into contact with one another, by movement of the spindle 100 toward the spindle 98 . Heat from a heat source such as an methane-oxygen flame or a laser is directed onto the contacting ends and adjacent portions of the tube 90 and the rod 92 . Sufficient heat is applied to melt and fuse together the contacting ends of the tube 90 and the rod 92 , causing the tube 90 and the rod 92 to be integrally connected to one another. The heat for fusing the tube 90 and the rod 92 together is applied while the tube 90 and the rod 92 are rotated by the spindles 98 and 100 , thereby uniformly distributing the heat and uniformly fusing together the ends of the tube 90 and the rod 92 . The fused-together tube and rod are thereafter allowed to cool to room temperature.
[0051] Next, as shown in FIG. 10A , heat from a methane-oxygen flame or laser is applied to heat a center portion 104 of the fused-together ends of the tube 90 and rod 92 . The heat is applied while the fused-together tube 90 and rod 92 are rotating in the glass lathe 102 ( FIG. 9 ), thereby evenly distributing the heat throughout the center portion 104 . Sufficient heat is applied to make the center portion 104 viscous and flowable.
[0052] Thereafter as shown in FIG. 10B , the opposite ends of the fused together tube 90 and rod 92 are moved axially away from one another by separating the spindles 98 and 100 from one another ( FIG. 9 ), thereby extending the length of the viscous center portion 104 of the tube 90 and simultaneously drawing it radially inward into a frustroconically shaped necked down tube portion 106 and a frustroconically shaped necked down solid portion 108 . The necked down tube portion 106 is hollow to the location where the tube 90 was fused to the rod 92 ( FIGS. 9 and 10 ), and the necked down solid portion 108 is complete integral material since it was formed from the rod 92 . The necked down portions 106 and 108 are thereafter allowed to cool to room temperature.
[0053] The necked down tube portion 106 is then heat worked to thicken a shoulder area 110 of the necked down portion 106 and to reduce the internal diameter of an axial opening 112 through a neck area 114 of the necked down portion 106 , as shown in FIG. 100 , while the tube 90 and rod 92 rotate in the glass lathe 102 ( FIG. 9 ). Applying heat to the necked down tube portion 106 while rotating it in the glass lathe causes the viscous glass to accumulate in the shoulder area 110 and in the neck area 114 , due to surface tension of the viscous material. Consequently, the amount of material in a shoulder area 110 and in the neck area 114 increases. The increased material in the neck area 114 reduces the diameter of the axial opening 112 . The configuration shown in FIG. 100 is allowed to cool to room temperature.
[0054] The necked down tube portion 106 is then cut away from the necked down solid portion 108 , as shown in FIG. 10D . Cutting is accomplished by scoring the neck area 114 with a diamond cutter 116 at a location 118 on the neck area 114 adjacent to the end of the necked down solid portion 108 while the tube 90 and rod 92 rotate in the glass lathe 102 ( FIG. 9 ), and then applying axial separation force from the spindles 98 and 100 ( FIG. 9 ) to separate the neck area 114 from the necked down solid portion 108 at the scored location 118 . The location for scoring the neck area 114 and separating the necked down portions 106 and 108 should be measured from the shoulder area 110 to extend about 30-50% more than the desired final axial length of the retainer portion 58 ( FIGS. 4 and 5 ). The separated necked down tube portion 106 is thereafter used to create one holder 50 ( FIGS. 4 and 5 ) as further described below.
[0055] Next, as shown in FIG. 10E , heat is applied to the neck area 114 of the necked down tube portion 106 , until the neck area 114 becomes viscous. The viscous material in the heated neck area 114 accumulates and reduces the length of the neck area 114 and increases the thickness of the walls of the neck area 114 to reduce the inside diameter of the axial opening 112 through the neck area 114 , as shown in FIG. 10F . The heat is applied to accumulate the viscous material in the neck area 114 until the diameter of the axial opening 112 is reduced to the desired diameter of the final size of the axial opening 60 in the retainer portion 58 ( FIGS. 4 and 5 ). In a preferred embodiment described herein, the desired diameter of the axial opening 112 is approximately 50 microns (W. Preferably a video camera with visual enlargement and measurement capabilities is used to visualize the effects and gauge the diameter of the axial opening 112 as the heat is applied.
[0056] Thereafter, as shown in FIG. 10G , the necked down tube portion 106 with its shortened and reduced internal diameter neck area 114 ( FIG. 10F ) is reattached by heat fusion to the necked down rod portion 108 from which it was previously separated ( FIG. 10D ). Attachment in this manner allows the necked down tube portion 106 with its shortened and reduced internal diameter neck area 114 to be cut at the desired length of the retention portion 58 ( FIGS. 4 and 5 ).
[0057] Cutting the shortened and reduced internal diameter neck area 114 of the necked down tube portion 106 to the desired length of the retention portion 58 ( FIGS. 4 and 5 ) is illustrated in FIG. 10H . The desired length is measured at location 120 , and the rotating neck area 114 is scored lightly with very light contact from the diamond cutter 116 , while the attached necked down tube portion 106 and the necked down rod portion 108 rotate in the glass lathe. A small amount of liquid, preferably water, is applied at the scored location 120 , and the spindle 100 of the glass lathe 102 ( FIG. 9 ) is moved slightly axially relative to the spindle 98 to separate the necked down tube portion 106 from the necked down rod portion 108 at the scored location 120 .
[0058] The end 122 of the separated neck area 114 is thereafter heat or flame polished, as shown in FIG. 10I . The heat from the polish gathers any slight projections or irregularities of material resulting from mechanically separating the necked down tube portion 106 from the necked down rod portion 108 ( FIG. 10H ). Any slight projections or irregularities surrounding the reduced internal diameter axial opening 112 are thereby removed, to prevent those slight projections from inhibiting the insertion of the fiber 52 into the axial opening 60 when the flexure 20 is constructed ( FIGS. 4 and 5 ). As a result of the actions described in conjunction with FIG. 10I , the neck area 114 of the necked down tube portion 106 assumes the final configuration of the retainer portion 58 of the holder 50 ( FIGS. 3-5 ). The thickened shoulder area 110 of the necked down tube portion 106 has previously assumed the final configuration ( FIG. 10C ) of the transitional portion 56 of the holder 50 ( FIGS. 2-5 ).
[0059] The holder 50 is completed by cutting the tube 90 with a wet saw 124 at a position 126 spaced along the cylindrical tube 90 from the transitional portion 56 or the shoulder area 110 , as shown in FIG. 10J . The cut end of the cylindrical tube at position 126 is heat or flame polished to eliminate any slight projections resulting from wet sawing the tube 90 . Eliminating any such slight projections in this manner has eliminates stress concentration points which might cause the holder 50 to break.
[0060] Construction of the fiber 52 of the flexure 20 ( FIGS. 2-5 ) commences with use of a small diameter solid quartz rod 130 , shown in FIG. 11A . The rod 130 has a diameter of about 1 mm and is of a manageable length of approximately 100 mm, for example. The rod 130 has been ultra sonically cleaned for approximately 10 minutes in a 2% micro-90 solution, and then rinsed in tap water. Next, the rod is rinsed in de-ionized water and then hot air dried. The rod is then etched for three minutes in a 25% hydrofluoric acid solution, followed by a tap water rinse, a de-ionized water rinse and then air dried. Once prepared in this manner, the rod 130 is subjected to the actions which form part of it into the fiber 52 .
[0061] An upper end 132 (as shown) of the rod 130 is connected by a conventional clamp 134 to a stationary structure 136 , or otherwise held in a stationary position, while the remainder of the rod 130 hangs vertically downward from the upper stationary-supported end 132 . Another conventional clamp 138 is attached to a lower end 140 (as shown) of the rod 130 . A relatively small magnet 142 which produces substantial magnetic flux, such as a conventional rare earth magnet, is connected to the clamp 138 . The lower end 140 of the vertically suspended rod 130 , the lower clamp 138 and the magnet 142 are located vertically above a center opening 144 of a vertically oriented tube 146 . The electrically conductive tube 146 is electrically conductive and is formed from relatively low electrical resistance material such as copper or aluminum.
[0062] Heat from a methane-oxygen flame or from a laser is applied along a middle section 150 of the rod 130 between its ends 132 and 140 , as shown in FIG. 11A . The heat uniformly heats the middle section 150 of the rod 130 until it becomes viscous and flowable. Gravity acts on the viscous middle section 150 and the lower end 140 of the rod 130 , on the clamp 138 and on the magnet 142 , causing the viscous middle section 150 of the rod 130 to stretch as shown in FIG. 11B . The lower end 140 of the rod 130 , the clamp 138 and the magnet 142 move downward into the center opening 144 of the tube 146 under the influence of gravity.
[0063] The magnetic flux from downward moving magnet 142 induces eddy currents in the conductive tube 144 . The eddy currents flow circumferentially around the conductive tube 144 , and create a magnetic flux and upward oriented magnetic force within the tube which opposes the magnetic flux of the magnet 142 , thereby creating an oppositional force to resist the downward movement of the magnet 142 under the influence of gravity. The magnitude of eddy currents induced in the tube 144 is related to the speed at which the magnet 142 descends within the tube. The amount of oppositional magnetic force created by the eddy currents in the tube 144 increases with the speed of descent of the magnet 142 . At a sufficient rate of descent, the oppositional force from the eddy currents interact with the magnetic flux from the magnet 142 to counterbalance the gravitational force on the viscous middle section 150 and the lower end 140 of the rod 130 , on the clamp 138 and on the magnet 142 , causing the speed of the descent of the magnet 142 , the clamp 138 and the lower end 140 of the rod 130 to stabilize at a constant downward velocity.
[0064] The viscous middle section 150 of the rod 130 stretches at a constant rate once the constant downward velocity of the magnet 142 , the clamp 138 and the lower end 140 of the rod 130 are stabilized in their downward descent rate. At some point in the constant downward descent after the viscous middle section 150 has stretched considerably, the middle section 150 cools and its viscosity decreases enough to increase the mechanical resistance to further downward descent, causing the lower end 140 of the rod 130 and the clamp 138 and the magnet 142 to slow and ultimately gently terminate further descent within the tube 144 .
[0065] The constant rate of descent of the lower end 140 of the rod 130 , the clamp 138 and the magnet 142 within the conductive tube 144 stretches the middle section 150 of the rod 130 at a constant rate while the middle section 150 remains viscous. The constant rate stretching of the middle section 150 of the rod 130 has the effect of drawing down the viscous middle section 150 to a substantially constant diameter along its length. Transitional portions of the middle section 150 adjacent to the ends 132 and 140 of the rod 130 experience a reduction in diameter, but those transitional portions are not part of the constant diameter section 150 and are not used to form the fiber 52 of the flexure 20 ( FIGS. 1-5 ). The constant diameter middle section 150 is drawn down to approximately 30μ in diameter for use as the fiber 52 , in the preferred example of the flexure 20 described herein.
[0066] By starting with similar rods 130 ( FIG. 11A ), which have the same initial diameter and which have been subjected to the same preconditioning described above, multiple middle sections 150 having substantially the same diameter are created from each of the similar rods 130 . The middle sections 150 each have substantially the same diameter as a result of using the same magnet 142 moving downward within the same tube 144 to achieve a constant rate of descent and constant rate of stretching of the middle section 150 . In this manner, multiple similar fibers 52 are created for each of multiple similar flexures 20 ( FIGS. 1-3 ).
[0067] Next, as shown in FIG. 11C , the constant diameter middle section 150 is cut at a position 152 near one end of the constant diameter middle section 150 , preferably with a scissors. A video camera with microscopic expansion and measuring capabilities is used to select the position 152 at which the constant diameter middle section 150 is cut. The position 152 is selected to avoid including any portion of the larger diameter transitional portions between the ends 132 and 140 and the constant diameter center section 150 . A piece 154 of the constant diameter middle section 150 remains connected to one of the ends 132 or 140 (end 132 is shown in FIG. 11C ). As is explained below, leaving the piece 154 connected to the end 132 facilitates construction of the flexure 20 ( FIGS. 2-5 ). A part of the piece 154 becomes a fibers 52 for four one or more flexures 20 ( FIGS. 2-5 ).
[0068] Construction of the flexure 20 commences by chucking a holder 50 ( FIG. 10J ) into one of the spindles of the glass lathe ( FIG. 9 ). The end 132 of the rod 130 to which the piece 154 remains connected ( FIG. 11C ) is chucked into the other one of the spindles of the glass lathe ( FIG. 9 ). The cut end of the uniform diameter piece 154 ( FIG. 11C ) constitutes the end 64 of the fiber 52 ( FIGS. 4 and 5 ).
[0069] The end 64 of the constant diameter piece 154 is inserted into the axial opening 60 of the holder 50 , as shown in FIG. 12A . The end 64 of the piece 154 is extended substantially completely through the axial opening 60 in the retainer portion 58 of the holder 50 . Heat from a hydrogen-oxygen flame or a laser, for example, is applied to the exterior of the retainer portion 58 to fuse the retainer portion 58 and the end 64 into the single integral mass 66 ( FIG. 3 ).
[0070] Simultaneously with the application of the heat, a stream 156 of cover gas, such as argon or helium, is directed from a nozzle 158 onto the piece 154 at a position directly adjoining the inner end 62 of the retainer portion 58 of the holder 50 . The stream 156 of cover gas cools the piece 154 adjacent to the end 62 to prevent the piece 154 from becoming sufficiently viscous so that the larger mass 66 of the molten retainer portion 58 and end 64 do not draw material from the piece 154 outside of the end 62 . In this manner, the stream 156 of cover gas ensures that the diameter of the piece 154 adjacent to the end 62 of the retainer portion 58 remains constant in diameter and is not diminished in diameter when the retainer portion 58 and the inner end 64 of the piece 154 are integrally fused together. Consequently, the diameter of the piece 154 fiber 52 immediately adjacent to the inner end 62 of the holder 50 remains the same diameter as the fiber 52 at other locations along the length of the fiber 52 .
[0071] Next, as shown in FIG. 12B , a portion 160 is cut out of the piece 154 , thereby separating the end 132 and transitional portion ( FIG. 12A ) from the piece 154 . The portion 160 has sufficient length to form the fiber 52 of the flexure 20 ( FIGS. 2-5 ) and to form the end 64 of the fiber 52 ( FIG. 4 ). The remaining portion of the piece 154 and the connected end 132 are removed from the chuck of the spindle of the glass lathe, for later use in fabricating another fiber 52 for another flexure 20 , if the length of the remaining piece 154 is sufficient for that purpose.
[0072] Thereafter, as shown in FIG. 12C , another holder 50 is inserted in the chuck of the spindle of the glass lathe. The end of the portion 160 is inserted into the axial opening 60 of the second holder 50 . The extent of insertion precisely establishes the length of the fiber 52 between the inner ends 62 of the holders 50 ( FIG. 2 ). A video camera with microscopic expansion and measuring capabilities is used to establish the precise length of the fiber 52 . The actions described above in connection with FIG. 12A , including the application of the stream 156 of cover gas from the nozzle 158 , are repeated to fuse the end 64 of the portion 160 and the retainer portion 58 of the second holder 50 into the integral mass 66 ( FIG. 3 ), thereby completing the formation of the flexure 20 ( FIGS. 1-3 ).
[0073] Construction of the flexure 20 is completed by applying a thin conductive layer 162 of electrically conductive material, such as gold palladium, to the exterior of the holder 50 and the fiber 52 of the flexure 20 , as shown in FIG. 13A . The conductive layer 162 electrically connects the flexure 20 to one of the pendulum suspension structures 30 or 34 , which are connected through the post 40 to the base 42 ( FIG. 1 ). In essence, the flexures 20 are electrically connected to the same common reference potential as the surrounding components, thereby draining any electrostatic charge that might otherwise accumulate on the flexures 20 during use. An accumulation of static charge on the flexure will electrostatically attract and repel the flexure with respect to adjoining structures and thereby adversely influence the oscillation characteristics of the pendulum. Adverse influences on the oscillation of the pendulum create inaccuracies in the quantity being measured by the pendulum device.
[0074] The conductive layer 162 is applied as discussed in connection with FIGS. 13B and 13C . To begin, as shown in FIG. 13B , the flexure 20 is placed inside a chamber 164 . An oxygen plasma is directed onto the flexure 20 within the chamber 164 . The oxygen plasma oxidizes any hydrocarbon impurities on the surface of the flexure 20 , turning those impurities into carbon dioxide and thereby leaving the flexure 20 clean. A clean surface of the flexure is essential to achieving good adherence of the layer 162 ( FIG. 13A ).
[0075] Next, as shown in FIG. 13C , the clean flexure is placed in a sputter coating chamber 166 . The conductive layer 162 is sputter coated or deposited in the conventional manner onto the quartz or other energy-conserving material of the clean flexure 20 . The electrically conductive layer 162 is very thin in depth and uniform in thickness, for example a few microns, a few hundred angstroms, or a few molecules in depth. Despite the relative thinness of the layer 162 , its thickness is sufficient to prevent any electrical charge from accumulating on the flexure.
[0076] The electrically conductive layer 162 is sufficiently thin and flexible to avoid adversely influencing the flex characteristics of the flexure 20 . As a result, the flex and oscillating characteristics of the flexure 20 are established principally by the flex characteristics of the quartz or other energy-conserving material which forms the fiber 52 ( FIG. 2 ). The electrically conductive layer 162 also remains adherent and sufficiently flexible to avoid cracking or separating during oscillation of the pendulum. The electrically conductive layer 162 does not diminish the strength or integrity of the quartz or other energy-conserving material from which the flexure 20 is formed. The metallic conductive layer 162 should not be highly stressed, create excessive tension on the exterior of the fiber 52 and/or create nucleations on the underlying quartz or other energy-conserving material, because such effects weaken the fiber 52 and makes it prone to break after a time of oscillation. Any stresses from the conductive layer 162 should be compatible with and comparable to the stresses occurring within the quartz or other energy conserving material of the fiber 52 during oscillation. Preferably, the electrically conductive coating is gold palladium. A conductive layer which is not satisfactory for long-term oscillation is tin oxide.
[0077] Forming the flexure 20 with the structure described and in the manner described results in a substantial improved flexure compared to the known prior art flexures used in pendulums.
[0078] The length of the fiber 52 between the inner ends 62 of the two oppositely positioned retainer portions 58 of the holders 50 is precisely established by use of the microscopic expansion and measuring capabilities of the video camera, when the second holder 50 is fused as described in connection with FIG. 12C . In this manner, the precise oscillation length (L) of the fiber 52 is established.
[0079] The use of the stream 156 of cover gas ( FIG. 12A ) maintains the constant diameter of the fiber 52 between the inner ends 62 of the retainer portions 58 of the holders 50 ( FIG. 2 ). Consequently, the fiber 52 is not weakened at the point where it is fused to the holder 50 . The fiber 52 is not more prone to fail from the mechanical stress of vibration at the location where it is fused to the holder 52 , since the diameter of the fiber 52 remains undiminished at this position.
[0080] Similarly, since the diameter of the fiber 52 remains constant at the position adjoining the inner ends 62 of the retainer portions 58 , the uniform diameter of the fiber 52 along its entire length establishes substantially similar flex and natural resonant frequency operating characteristics. Furthermore, these natural resonant frequency operating characteristics are similar among multiple flexures 20 constructed in the manner discussed above, due to the substantially constant and uniform diameter fibers 52 obtained from substantially uniform diameter middle sections 150 ( FIGS. 11B and 11C ) of multiple rods 130 which have been processed in a substantially similar manner as described above.
[0081] The retainer portions 58 of each of the holders 50 are of sufficient mass and rigidity to prohibit any flexure. Consequently, only the fiber 52 flexes between the inner ends 62 of the retainer portions 58 of the holders 50 at opposite ends of the flexure 20 ( FIG. 2 ). The natural resonant frequency operating characteristics of the pendulum results substantially only from the characteristics of the fiber 50 , allowing the natural resonant frequency and length characteristics to be predetermined and made uniform among multiple ones of the flexures 20 .
[0082] The flexure of the present invention prevents the accumulation of electrostatic charges. Aberrations in the oscillation of the pendulum due to the accumulation of static charge are avoided, and as a consequence, the quantity (e.g., gravity) measured by the pendulum is more accurate.
[0083] The method of constructing the pendulum armed flexure 20 as discussed above involves uniform, precise and repeatable actions. As a consequence, multiple pendulum arm flexures having substantially identical length, flex and natural resonant frequency operating conditions can be produced on a controllable, precise and repeatable basis. The substantially identical characteristics allow two pendulum arm flexures to be used effectively to suspend a single bob in a single pendulum device, and/or allow multiple similar pendulums to be used effectively in multiple pendulum devices. Undesirable modes of motion are avoided by using multiple pendulum arm flexures having substantially identical length, flex and natural resonant frequency operating characteristics. The loss of oscillation energy is avoided by using multiple pendulum arm flexures according to the present invention.
[0084] The significance of these and other improvements and advantages will become apparent upon gaining a full appreciation of the present invention. Preferred embodiments of the invention and many of its improvements have been described with a degree of particularly. The detail in describing the preferred examples is not necessarily intended to limit the scope of the invention. The scope of the invention is defined by the following claims.
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A pendulum arm flexure which supports a pendulum bob for oscillation has predictable and reproducible characteristics. Holders retain a specific predetermined length of uniform diameter elongated fiber at ends of the fiber and permit flexing only along a defined length of the fiber between the holders during oscillation. Energy conserving material of the fiber temporarily stores and releases energy when flexing.
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BACKGROUND OF THE INVENTION
In the dyeing of yarn, it is known to support a plurality of yarn packages on each of a plurality of vertically disposed spindles. Several yarn packages are loaded on each spindle and placed under compression. A retainer is placed against the last package loaded on each spindle to maintain the yarn packages under compression during dyeing.
The spindles are hollow and have a plurality of openings along their length providing communication between the interior of the spindle and the interior of the dye kettle. During the dyeing, dye liquor is forced upwardly through the hollow spindles and outwardly through the openings and through the yarn packages on each spindle. The process is reversed while dyeing so that the liquor is forced from the interior of the dye kettle through the yarn packages, through the openings in the spindles, and downwardly through the hollow spindles and out of the dye kettle. The packages of yarn are relaxed during the dyeing process.
Some prior art mechanisms for securing yarn packages in a compressed condition on the spindles require an operator to place a pressure plate on the end package and then thread a nut-like fastener on top of each spindle. This requires an interruption of the carrier loading cycle and subjects the operator to the risk of serious injury by having his hand and arm within the compression unit for a minimum of five seconds while manipulating the nut to a tightened position over approximately two inches of threaded stud.
Prior attempts to eliminate the inefficient production and the dangerous manipulation of the nut-like fastener have been only partially successful. See, for example, U.S. Pat. No. 3,777,516 issued Dec. 11, 1973 to Gerhard Tigges entitled CLOSING DEVICE IN PARTICULAR FOR DYEING SPINDLES. The Tigges device still requires manipulation of threaded members and consequent inefficiency in production. See also U.S. Pat. No. 3,731,502 issued May 8, 1973 to John M. Stearns et al. entitled RELEASABLE LOCKING ASSEMBLY. The Stearns et al. locking assembly requires special tooling and is not adaptable to existing spindles.
The dyeing of the yarn using pressurized dye liquor forces successive inward and outward flow of the dye liquor through each of the spindles in the dye kettle. The failure to contain the dye liquor beneath the top pressure plate is another shortcoming in the prior art with which the present invention is concerned. Sealing devices of the prior art are inefficient because they all allow some leakage and because most of them are expensive and complex mechanisms requiring time consuming manipulation to function.
SUMMARY OF THE INVENTION
The lock and seal of the present invention includes an internally threaded spindle nut which is threadably registrable with the externally threaded stud on top of the conventional dye spindle. The spindle nut portion of this invention is threadably connected to the threaded stud on the conventional dye spindle in advance of the dyeing operation and, unlike the prior art spindle nut, remains connected to the spindle after the dyeing is completed for use in successive dyeing operations. The present spindle nut of this invention becomes, in effect, a part of the dye spindle.
The spindle nut includes the cam portion of an automatic lock. A sealing mechanism utilizes a pressure plate like that used in the prior art for compressing yarn packages on a dye spindle. The sealing mechanism includes a top ring which has a plurality of inwardly projecting locking pins spaced above the pressure plate and positioned for instant and positive locking engagement with the cams on the spindle nut permanently threaded to the dye spindle. A compression spring and sealing tubes extend between the pressure plate and the top ring of the sealing assembly.
With the spindle nut and its integral cams permanently joined to the dye spindle for use in repeated dyeing operations, a plurality of yarn packages are positioned on the dye spindle in the usual manner. Thereafter, the yarn packages are compressed together on the spindle in the usual manner and the top ring of the sealing assembly is simply dropped over the cammed portion of the spindle nut and the pressure plate is automatically locked against the compressed yarn packages. Downward movement of the top ring relative to the spindle nut brings the inwardly projecting locking pins into engagement with guide cam surfaces on the upper end of the spindle nut. These upper cam surfaces first engaged by the locking pins guide the pins downwardly into engagement with positioning cams spaced below the guide cams. The pressure plate is thus united with the spindle nut throughout the dyeing operation as the positioning cam directs the pins on the ring into locking engagement with the lower edge of the guide cam responsive to upward movement of the pressure plate and the top ring by the compressed yarn packages.
When the dyeing of the yarn is completed and the fluid pressure within the dye kettle is diminished, the pressure plate may be quickly removed from the spindle by manually rotating the top ring until the pins register with spaces between the guide cams, permitting the top ring and its attached pressure plate to be lifted upwardly and removed from the spindle nut with a single simple motion of slightly rotating and lifting the top ring and pressure plate relative to the spindle nut.
The escape of dye liquor while dyeing is minimized by a plurality of concentric tubes extending between the top ring and the pressure plate. One of the tubes is connected to the pressure plate and is movable into sealing engagement with the top ring responsive to upper movement of the pressure plate by the compressed yarn. Another tube is connected to the pressure plate and extends in closely spaced relation or in engagement with a plurality of laminar ridges spaced beneath the positioning cams on the spindle nut. The pressurized dye liquor is progressively retarded as it flows between the spaced ridges and the tube so that only a minimum amount of dye liquor is permitted to escape about the spindle nut during the dyeing operation.
It is an object of the present invention to provide an effective locking mechanism for dye spindles which automatically locks the pressure plate against upward movement beyond a predetermined point without the manipulation of any type of mechanism by the operator, and which automatically releases the pressure plate when the operator slightly rotates the ring and lifts the ring and its attached pressure plate relative to the spindle nut.
It is another object of the invention to provide a sealing mechanism for retarding the escape of pressurized dye liquor from about the dye spindle during the dyeing operation, and which sealing mechanism becomes automatically operable without attention from an operator upon the pressure plate being positioned over the carrier spindle and restrained against upward movement beyond a predetermined point.
It is a still further object of the invention to provide a lock and seal which functions to lock the pressure plate on a carrier spindle and retard the upper flow of dye liquor without any moving parts requiring the attention of an operator.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental view, with parts broken away, illustrating a dye spindle and the spindle nut of this invention in elevation and the lock ring and seal mechanism of this invention operatively connected thereto and shown in section;
FIG. 2 is an elevational view of a prior art dye spindle, with parts broken away;
FIG. 3 is a view similar to FIG. 1 but showing the threaded connection of the spindle nut with the dye spindle in dotted lines;
FIG. 4 is an elevational view of the spindle nut, illustrating the cam portion of the lock and illustrating the spaced annular laminar ridges which serve as part of the seal;
FIG. 5 is a top view of the spindle nut shown in FIG. 4;
FIG. 6 is a plan view of the lock ring and pins which cooperate with the cams shown in FIG. 4 to lock the pressure plate on the spindle;
FIG. 7 is a sectional view taken substantially along the line 7--7 in FIG. 5;
FIG. 8 is a plan view of the pressure plate;
FIG. 9 is an elevational view of the pressure plate shown in FIG. 8;
FIG. 10 is an enlarged sectional view, with parts broken away, illustrating the cooperation of the laminar ridges with the inner tube to retard the escape of dye liquor;
FIG. 11 is an elevation of the cam portion of the spindle nut; and
FIG. 12 is a profile of the annular cams shown in FIG. 11.
DETAILED DESCRIPTION OF THE INVENTION
Referring more specifically to the drawings, a conventional dye spindle with which the present invention is used is broadly illustrated at 20. In practice, a plurality of such dye spindles are submerged in a dye kettle with each spindle supporting a plurality of yarn packages held on the spindle under compression. A pressure plate 21 engages the last yarn package loaded on each spindle and the pressure plate is held against upward movement relative to the spindle by a desired means. Referring to FIG. 2, the prior art dye spindle 20 is shown removed from the environment of FIG. 1. The spindle 20 is hollow and has a plurality of holes 22 providing communication between the interior of the hollow spindle 20 and the interior of the dye kettle, when in use. Dye liquor is forced under pressure upwardly through the hollow spindle and outwardly through the holes 22 in the walls of the spindles to permeate the yarn carried by the spindle as it passes into the dye kettle. The process is reversed while dyeing to force the dye liquor from the interior of the dye kettle through the yarn and inwardly through the holes 22 and then downwardly and outwardly from the hollow spindles to complete the dyeing operation.
As illustrated in FIG. 2, each of the hollow dye spindles 20 has an elongated threaded stud or boss 23 formed integral with the spindle 20 and projecting upwardly therefrom in the drawings. The threaded boss 23 was originally provided for reception of a similarly threaded nut N (FIG. 2) which was manually threaded on the boss 23 during a pause in the dyeing operation while a compression unit applied pressure to compress the yarn and a worker positioned the pressure plate against the last package loaded and laboriously threaded the nut N on the boss 23.
The present invention utilizes the prior dye spindle 20 and its threaded boss 23 but the nut N of the prior art which was laboriously threaded on the boss 23 prior to each dyeing operation and laboriously removed at the completion of dyeing to get the dyed yarn off of the spindle has been discarded in favor of the present spindle nut, broadly indicated at 24, and which may be permanently threaded on the boss 23 of the dye spindle 20 to remain with the spindle indefinitely through successive dyeing operations.
A plurality of yarn packages, not shown, and the pressure plate 21 are positioned on the carrier spindle 20 after it has been equipped with the spindle nut 24 and the pressure plate and yarn packages are compressed tightly against one another by appropriate equipment as before. However, it is no longer necessary to laboriously thread a nut in place to hold the pressure plate and the yarn packages on the spindle.
Instead, according to this invention, the pressure plate 21 is attached to a lock ring 25 by a spring 26. The lock ring 25 includes a plurality of inwardly projecting lock pins 27. The spindle nut 24 includes a lock portion comprising a plurality of circumferentially spaced guide cams 30 and a positioning cam 31 projecting outwardly from the surface 29 of the spindle nut 24. There are six guide cams 30 on the spindle nut 24 in the illustrated embodiment of the invention and the positioning cam 31 is illustrated as an annular cam spaced below the guide cams 30.
The inner diameter of the ring 25 between the points A and B in FIGS. 6 and 7 is large enough to freely pass over the cams on the spindle nut 24. The pins 27 extend inwardly of the ring 25 a distance sufficient that opposed pins in FIG. 6 are spaced apart far enough to freely pass over the surface of the spindle nut 24 but the opposed pins are spaced sufficiently close to each other that the pins engage the operative or working surfaces of the cams. Thus, when the lock ring 25 with its pressure plate 21 attached thereto is dropped over a spindle nut 24 on a dye spindle 20, the pins 27 engage a tapered surface 28 at the top of the spindle nut 24 which aligns the pins with the surface 29 of the nut 24. The pins then move downwardly across the surface 29 to working surfaces 32 on the triangularly-shaped cams 30 (FIGS. 4 and 12) and the working surfaces 32 guide the pins at an angle across the body surface 29 of the spindle nut 24 to a vertical working surface 33 on each cam 30. The vertical working surface 33 of each cam 30 guides the pins 27 vertically downwardly into engagement with an inclined working surface 34 on positioning cam 31. The working surface 34 extends downwardly and terminates at a point 35 in a valley beneath the working surface 32 previously traversed by the pin 27. The valley 35 is at the juncture of downwardly inclined surface 34 with an upwardly inclined surface 36 on positioning cam 31. Upwardly inclined surface 36 extends from valley 35 to its juncture with a plateau 37 spaced beneath the lower working surface 38 of the corresponding cam 30.
FIG. 12 illustrates the profile of cams 30 and the positioning cam 31 and it will be noted that whether the working surfaces 34 and 36 on positioning cam 31 extend up or down depends on the direction of travel around the nut 24. The pins 27 may move down either working surface 32 or working surface 32A of any cam 30. Both of the surfaces 32 and 32A guide pins 27 to a downwardly inclined surface 34. Surface 32 guides pins 27 to an inclined surface 34 extending to a valley 35 beneath the same cam 30 traversed by pin 27, while inclined surface 32A on each cam 30 guides pins 27 to an inclined surface 34 extending to a valley 35 beneath an adjacent cam 30 to that traversed by pin 27.
The vertical surface 33 extends beneath the lower working surface 38 on each cam 30 and terminates at a point 40 defined by the surface 33 and a working surface 41 extending upwardly from the point 40 to the lower working surface 38. It will be noted that each of the valleys 35 in the positioning cam 31 is positioned beneath the upwardly inclined working surface 41 on the one cam 30 above that valley and that the vertical working surface 33 on that one cam 30 is spaced from the adjacent cam 30 and overlies the inclined working surface 34 on the cam 31 which terminates in the valley beneath said one cam.
A typical path of a pin 27 is illustrated in FIG. 12 by successive positions 27A through 27F. Of course, in actual practice a single pin 27 may traverse either surface 32 or 32A of only a single cam 30 and the corresponding portion of the cam 31 therebeneath, but for this illustration it is assumed the pin traverses surface 32. Still referring to FIG. 12, 27A illustrates the position of the pin 27 as it begins to move down the surface 32. The pin continues to move down inclined surface 32 to the position of 27B near the lower end of surface 32. The pin then moves through the space 42 between the cams 30 as indicated at 27C. The pin continues to drop vertically until it reaches position 27D on the inclined surface 34 on cam 31, which guides the pin to position 27E in the valley 35 spaced inwardly of the point 40 on the cam 30 traversed by the pin. The expansion of the yarn packages against the pressure plate moves the lock ring 25 and its pins 27 upwardly from the position of 27E to the inclined wall 41 on cam 30. The pin stops as at 27F at a predetermined locking point 43 defined by the juncture of inclined surface 41 with lower surface 38 of its cam 30 to lock the pressure plate and yarn packages on the spindle until the force on the pressure plate is released.
THE SEAL
The locking of the pressure plate 21 to the spindle 20 automatically and simultaneously positions the seal of this invention about the upper end of the spindle where it functions to significantly retard the flow of dye liquor upwardly about the spindle, without any attention from the operator. Referring now to FIGS. 1 and 3, the pressure plate 21 is fastened to the lock ring 25 by the spring 26. The lower end of the spring 26 is welded as at 51 to the pressure plate 21 and the upper end of the spring 26 is welded as at 52 to the lock ring 25. A first sealing tube 53 is welded as at 54 to the pressure plate 21 and extends upwardly therefrom in the drawings beyond the spindle 20 and toward the lock ring 25. The upper edge of the sealing tube 53 is shown in abutting relation to a depending flange 55 of lock ring 25 but the tube 53 is not connected with the ring 25. It is urged into abutting and sealing relation with flange 55 by force exerted against the pressure plate 21 by the compressed yarn column during the dyeing operation.
Seated against and secured to opposed surfaces of flange 55 on lock ring 25 are an inner sealing tube 56 and an outer positioning tube 57. The inner sealing tube 56 and the outer positioning tube 57 are spaced on either side of the first sealing tube 53, and the lower ends of the tubes 56, 57 extend beyond the spindle nut 24 into juxtaposition with the spindle 20 but are spaced from the pressure plate 21 when it is in its uppermost position as shown in FIGS. 1 and 3.
The spindle nut 24 includes a seal portion comprising a plurality of laminar ridges 60 formed integral therewith and projecting circumferentially from a surface 50 of the nut 24. There are four laminar ridges 60 in the illustrated embodiment of the invention and each ridge 60 is closely spaced from the inner sealing tube 56 to define a narrow orifice 61. The laminar ridges 60 cooperate with the inner tube 56 to form an effective seal against the escape of dye liquor under pressure during the dyeing operation. Pressurized dye liquor is forced upwardly through the orifice 61A between the lower most laminar ridge 60A in FIG. 10 into the relatively large expansion area 62A above ridge 60A and between ring 56 and surface 50 of the spindle nut 24. Movement of the pressurized liquid from the orifice 61A into the expansion area 62A causes rapid expansion of the fluid and a corresponding decrease in the energy or head of the liquid.
It is to be understood that the drawing in FIG. 10 is illustrative of the actual spacing of the inner sealing tubes 56 from the ridges 60. The inner sealing tube 56 is in fact spaced from the ridges sufficiently to enable the tube 56 to pass freely over the top of the spindle 20 as the lock ring 25 traverses the cams 30 on the spindle nut. The ridges 60 are of the same diameter as the spindle 20, as shown in FIGS. 1 and 3. A space or orifice 61 of 10 about 0.005 of an inch (0.127 mm) has been found to provide sufficient clearance and a suitably sized orifice.
In the illustrated embodiment the expansion area 62 between the ridges 60 and between the sealing tube 56 and surface 50 of the cam lock measures about one eighth of an inch (0.317 cm) in each direction. The effectiveness of the seal provided by the juxtaposition of the laminar ridges 60 and the inner sealing tube 56 is demonstrated by known physical principles: (1) Pressurized fluid loses head or energy when it flows through a restricted space or orifice, as at 61; (2) the fluid loses head or energy when it flows from an orifice (61) into an enlarged area such as the expansion area 62; (3) fluid loses head or energy as it moves upwardly; and (4) fluid loses head or energy because of friction generated between the molecules of the fluid and because of the friction generated by contact of the fluid with the surfaces which contain the fluid. Each of these four components resulting in the loss of head or energy is repeated several times as the pressurized dye liquor moves upwardly through the several orifices 61 and expansion areas 62A-62D. The passage of fluid through the lowermost orifice 61A and into the enlarged area 62A reduces the head or energy available to pass through the next orifice 61B. There is increasing loss of head or energy as the dye liquor passes through successive orifices and expansion areas 61B, 62B, 61C, 62C, 61D and 62D. Consequently there is very little energy available to force dye liquor upwardly and very little dye liquor able to escape through the uppermost orifice 61E defined by the tube 56 and the annular cam 31 on the spindle nut 24.
The most significant components for the loss of head or energy as the dye liquor passes upwardly are the passage of the fluid through the orifices and into the expansion areas. It is calculated that the passage of the fluid through each of the described orifices consumes about five percent of the head or energy of the fluid and the rapid expansion of the fluid in the described expansion areas 62 consumes about fifty percent of the head or energy. It can thus be seen that the passage of the fluid through these successive orifices and expansion areas consumes over ninety-seven percent of the energy by the time the fluid reaches orifice 61E. It is contemplated that the sizes of the orifices and expansion areas may be changed within the spirit of the invention, and the percentages of head loss may change accordingly.
The small loss of dye liquor through the seal of this invention is competitive with the loss of dye liquor through any known seal heretofore used with carrier spindles in the dyeing of yarn. The efficiency of the present seal is at least as good as the prior known seals and the quick and effortless placement of the seal in operative position simultaneously with the locking of the compressed yarn packages on the spindle is a significant advance in the art.
There is thus provided a combination lock and seal which is operative with no moving parts to simultaneously lock the packages on the spindle in a compressed state and to seal the top of the spindle against significant loss of dye liquor. Realizing that the spindle nut of this invention becomes a permanent part of the spindle and remains in place for successive dyeing operations, the positioning of the pressure plate and the sealing mechanism on the spindle nut after the spindle is loaded requires only a fraction of the operator's time that has been previously required to lock the packages on the spindle and seal the top of the spindle with prior known mechanisms.
Although specific terms have been employed in the drawings and specification, they are used in a descriptive sense only and not for purposes of limitation.
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A spindle nut remains attached to a dye spindle for repeated dye operations and includes radially projecting cam surfaces for successively guiding and locking a lock ring against outward movement relative to the spindle nut at the beginning of successive dye operations. A pressure plate engages the outermost yarn package on the dye spindle and a tube is fixed to the pressure plate and extends outwardly about the spindle toward the lock ring at the beginning of each dye operation, terminating in spaced relation from the lock ring. The pressure obtained during each successive dye operation moves the pressure plate outwardly until the tube engages the lock ring to hold the yarn packages on the spindle during dyeing. At the end of each dyeing operation, the pressure plate and yarn packages are removed from the spindle after rotating the lock ring a partial revolution to disengage it from a locking cam surface on the spindle nut and position the lock ring for easy removal from the spindle nut by lifting it axially from the spindle nut.
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FIELD OF THE INVENTION
The present invention relates to an improved container for the vacuum evaporation of metal.
BACKGROUND OF THE INVENTION
Vacuum deposition is a common method for coating metals such as aluminum, copper, zinc, and tin onto various substrates of metal, glass, and plastic. The metal is typically vaporized by means of electric resistance heating in a metallic or ceramic container or vessel generally referred to in the art as a “boat” or a metallization boat. The boat is connected to a source of electrical power within an evacuated chamber and heated to a controlled operating temperature sufficient to cause a metal charge placed in contact with the boat to vaporize.
In the vacuum metallization process, the metal melt in a metallization boat is heated to a very high temperature, in many instances to a temperature higher than typically seen in casting operations, 1200° C. and above. This means that the metal melt will be much more aggressive and behave as a corrosive acid, lowering the life of the metallization boats. Additionally, when the operation is carried out with repetitive heating, cooling, and exposure to molten metals during that span, the life of the boats is further reduced.
One important factor to longer boat life is the wettability of the slag build-up in the cavity of the boat. After a few hours in operation, a slag begins to build up around the edge of the metal puddle in the boat. The slag is the by-product of the reaction of the molten metal with the refractory boat, and is typically non-wetting to the metallizing metal. It inhibits the spreading of the metal puddle, thus increases the operating temperature and further reduces the useful life of the boat. Improved wetting of the boat and/or slag surface is believed to be an important factor in increasing the average life of metallization boats.
Another factor impacting boat life is the resistance to corrosion by the molten aluminum. During metallization, the molten aluminum corrodes the surface of the boat, typically resulting in deep grooves running from the anterior to the posterior of the boat and penetrating into the boat's depth. These grooves over time, effect the spreading of the aluminum melt, affecting the deposition uniformity on the metallized substrate. Additionally, the grooves can cause the spattering of the liquid aluminum due to excessive accumulation of the aluminum in the grooves. Aluminum spatter causes holes in the metallized substrate. At the point where there is non-uniformity in the metallized substrate or there are holes in the boats due to metal spatter, the boats are typically replaced. Therefore, minimizing the depth of grooves, or slowing the formation of grooves over the evaporation surface can lead to longer useful boat life.
PCT Publication No. WO 2005/049881A1 discloses a metallization boat with improved wettability, which indirectly can lead to longer boat life. The boat has a plurality of grooves having a depth of 0.03 to 1 mm, a length of more than 1 mm, a width of 0.1 to 1.5 mm, and a distance between the grooves of less than 2.0 mm.
FIG. 23 is a top view showing a metallization boat in the prior art (as discussed in U.S. Pat. No. 6,645,572) having multiple grooves, with a number of grooves with a length-wise orientation as the direction of conduction of the boat, and the rest of the grooves having most of their length running parallel to the direction of conduction of the boat.
There is still a need to further increase the useful life of metallization boats by mitigating the severity and pattern of groove formation over the metallization surface. Applicants have found that increasing the depth, and/or the width, and/or the spacing between the grooves in metallization boats leads to less severe grooving over the metallization surface, and a more uniform grooving pattern, while maintaining the improved wettability, thus extending the useful service life of the boats over the prior art.
BRIEF SUMMARY OF THE INVENTION
The invention relates to a refractory container for evaporating metals having an evaporation surface in contact with molten metal with a direction of conduction parallel to a length axis of the refractory boat and a plurality of grooves in the evaporation surface, with the grooves each having at least one of a depth of at least 1.2 mm, a width of at least 1.75 mm, and an interval spacing of at least 2.2 mm, and with at least two of the plurality of grooves having at least a portion of length at an angle of 10 to 170° to the direction of conduction of the refractory boat.
The invention further relates to a method to extend service life in refractory boats, by creating a plurality of grooves in the evaporation surface in contact with molten metal, for the grooves to have at least one of a depth of at least 1.2 mm, a width of at least 1.75 mm, and an interval spacing of at least 2.2 mm, and for at least two of the plurality of grooves to have a portion of length to position at an angle of 10 to 170° to the direction of conduction of the refractory boat.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the metallization boat of the invention.
FIG. 2 is a perspective view showing a second embodiment of the invention with intersecting grooves being placed relatively far apart.
FIGS. 3 and 4 are top evaporation surface views of the metallization boats of FIGS. 1 and 2 , respectively.
FIGS. 5-12 are top views showing different embodiments of the boat of the invention.
FIGS. 13-22 are perspective views showing different shapes of the boat of the invention.
FIG. 23 is a top view showing a metallization boat in the prior art.
FIGS. 24 a , 25 a , 26 a , and 27 a are photographs showing the groove patterns in comparative boats and the boats of the present invention.
FIGS. 24 b , 25 b , 26 b , and 27 b are photographs showing the groove patterns in comparative boats and the boats of the present invention, after 8 hours of metallization.
FIGS. 28 a , 29 a , 30 a , 31 a are photographs showing the patterns in comparative boats (with longitudinal grooves and without grooves) and the boat of the present invention prior to metallization.
FIGS. 28 b , 29 b , 30 b , 31 b are photographs of the boats of FIGS. 28 a - 31 a , respectively, after 5 hours of metallization.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the terms “first,” “second,” and the like do not denote any order or importance, but rather are used to distinguish one element from another, and the terms “the”, “a” and “an” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Furthermore, all ranges disclosed herein are inclusive of the endpoints and are independently combinable.
As used herein, approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially,” may not to be limited to the precise value specified, in some cases.
As used herein, the term “metallization boat” may be used interchangeably with “refractory boat,” “evaporation boat,” “evaporation vessel,” “evaporator boat,” or simply “vessel” or “boat,” referring to a heating source for metallization.
As used herein, the direction of conduction means the longitudinal direction parallel to the major (length) axis of a metallization boat.
A. Composition of the Boat of the Invention: As to the composition of the metallization boat of the invention, in one embodiment, the metallization boat comprises an electrically conductive component such as titanium diboride, zirconium diboride, titanium nitride, silicon carbide, chromium carbide, and mixtures thereof; a non-conductive component such as boron nitride, aluminum nitride, silicon nitride, nitride of a rare earth metal compound, alumina, silica, boric oxide, boron oxynitride, oxide of a rare earth metal compound, oxide of an alkaline earth metal, and mixtures thereof. The boron nitride is either hexagonal boron nitride or amorphous boron nitride, or its mixtures. The composition of mixed materials has a density of at least about 90% of theoretical density (% TD). Such compositions are described in various patents and publications including U.S. Pat. Nos. 3,544,486; 3,915,900; 4,528,120; 5,604,164; and US Patent Publication Number 2005-0065015, which references are expressly incorporated herein by reference.
In one embodiment of the invention, the boat comprises mixed materials of 10-60 wt. % BN, 0 to 60 wt. % of at least one of a nitride of the elements Al, Si, Ti, Fe, Co, Ni and mixtures thereof; and 30-70 wt. % of at least one electronically conductive material selected from the group of borides of Ti, Zr, Al, Cr and mixtures thereof, and carbides of Si, Ti, and Cr. In one example, the boat comprises 10-60 wt. % BN, 0 to 60 wt. % of at least AlN or SiN, and 30 to 70 wt. % of at least titanium diboride, zirconium boride, aluminum boride, chromium boride, silicon carbide, titanium carbide, and chromium carbide.
In one embodiment, the boat consists essentially of a refractory boride, predominantly titanium diboride, one or more refractory nitrides, predominantly, boron nitride and/or aluminum nitride, and about 0.10 to 25 wt. % of at least one of a metal compound, a transition metal compound, an alkali metal compound, a rare earth metal compound of a boride, an oxide, a carbide, a nitride and mixtures thereof.
In one embodiment, the rare earth metal compound consists essentially of yttrium oxide. In a second embodiment, the alkali metal compound consists essentially of calcium oxide. In a third embodiment of the invention, the metal compound consists essentially of aluminum oxide. In a fourth embodiment, the transition metal compound consists essentially of iron boride. In a fifth embodiment the boat comprises: a) titanium diboride and boron nitride; or titanium diboride, boron nitride and aluminum nitride; b) a metal selected from molybdenum, tungsten, tantalum and niobium; and c) an oxide such as CaO, MgO, Al 2 O 3 , TiO 3 , compounds of these oxides and rare earth metal oxides such as Y 2 O 3 , YAG(Al 5 Y 3 O 12 ), YAP(AlYO 3 ), and YAM(Al 2 Y 4 O 7 ). In one example, the container boat consists essentially of 45-65 wt. % of boron nitride; 35-65 wt. % of titanium diboride; and 0.10 to 10 wt. % of a rare earth metal compound such as an oxide, a carbide, a nitride, and a mixture thereof. In another example, the container boat further contains up to 10 wt. % aluminum nitride, or at least one of a calcium oxide, aluminum oxide, magnesium oxide, and titanium dioxide.
B. Forming a Densified Body: In one embodiment, the refractory boat is prepared by molding the mixture comprising the various components to form a green body having a TD of at least 50%, and then die pressing the body. In one embodiment, the green body heated to a densification temperature of at least about 1400° C. and at a pressure of about 100 to 300 Mpa for a TD of at least 90%. In one embodiment wherein the pressure is applied onto all sides of the green body, e.g., in an autoclave, for a densified body having uniform density distribution and uniform isotropic microstructure. In another embodiment, the green body is isostatically hot pressed at a temperature of 1800 to 2200° C. and a pressure of 1 to 100 Mpa. In yet another embodiment, the hot pressing is done after uniaxial pressing or cold isostatic pressing of 0.5 to 200 Mpa.
In one embodiment, the green body is densified through pressureless sintering at a temperature above 1000° C. In another embodiment, the green body is formed in a process such as slip casting, tape casting, fugitive-mold casting, or centrifugal casting.
C. Forming Metallization Boat having Patterned Top Surface: After the sintering process, the densified body is formed into a suitable shape of a boat by various means including a manual means using tools known in the art such as band saws, grinders, and the like, or alternate means such as Electro Discharge Machining (EDM), Electro Discharge Grinding (EDG), laser, plasma, ultrasonic machining, sand-blasting, and water jet, etc. In one embodiment, the machining is done according to a predetermined computer controlled pattern (“CNC”) to maintain the desired configuration depending on the final metallization application, i.e., the dimensions of the boat, the formation of the cavity in the top surface, and the patterning of the top surface of the boat.
In one example of a boat, the densified body is machined into a boat having a length of 50 to 200 mm, width of 10 to 35 mm, and a depth or thickness of 8 to 30 mm with a cavity of 45 to 120 mm, a width of 7 to 32 mm, and a cavity depth of 0.5 to 4 mm. In another embodiment, the boat has dimensions of 41.275 mm (1⅝″), a width of 14.2875 mm ( 9/16″), and a depth of 26.9875 mm (1 1/16″). The cavity of this boat has dimensions of 34.925 mm (1.375″) by 11.1125 mm (0.4375 inch) by 3.175 mm (0.125 inch).
Depending on the applications, the boat of the invention may be of various shapes and forms as illustrated in the figures. In one embodiment, the boat is of a rectangular shape and with a rectangular cross-section as shown in FIGS. 1-2 , 15 and 17 . In another embodiment, the boat has an elliptical cross-section as shown in FIG. 13 , an inverted triangle cross-section as shown in FIG. 16 , a T-shape for a cross-section as in FIG. 14 , an inverted U or hat-shape cross-section as in FIG. 18 , an inverted isosceles trapezoid shape for a cross-section as in FIG. 19 , and an isosceles trapezoid shape for a cross section in FIG. 20 . In another embodiment as shown in FIG. 21 , the boat has a rectangular cross-section for the two ends but a mid-section with an inverse isosceles trapezoid shape for increased cooling surface area. In another embodiment as shown in FIG. 22 for increased cooling surface area purpose, the boat has a rectangular cross-section for the two ends but a middle section having an isosceles trapezoid shape for a cross-section.
In one embodiment of the invention, the boat of the invention comprises a smooth surface onto which grooves are formed. In another embodiment, the boat has at least one cavity in the top surface, with the grooves being formed on the surface of the cavity. In another embodiment, the boat has a plurality of cavities in the surface for simultaneous vapor-deposition of two or more low melting metals, for example. The grooves of the invention may be formed on at least one or multiple cavities. The cavity may be of various shapes, forms, and dimensions as illustrated in FIGS. 13 , 15 , 16 , 17 , and 18 . For boats with multiple cavities, the cavities may be of the same or different shapes, forms, and dimensions.
In one embodiment, the cavity has an elliptical shape for its cross section as in FIG. 15 . In another embodiment, the cavity has an inverted isosceles trapezoid shape as shown in FIG. 16 . In yet another embodiment, the cavity has a bow shape with a maximum depth in the center of the boat cavity as illustrated in FIG. 17 . In a fourth embodiment, the cavity is of equal shallow depth as in FIG. 13 . In a fifth embodiment, the cavity is relatively deep relative to the thickness of the boat as shown in FIG. 18 .
In one embodiment, the cavity and/or top surface of the boat (for the evaporation of molten metal) is coated with a layer which functions as a wetting enhancement coating and/or a corrosion resistant coating. The coating can be applied by brush painting, brush coating, spraying, rolling, dipping, and the like. The coating may comprises an electrically conductive component composition as disclosed in U.S. Pat. No. 6,645,572, or a non-electrically conductive composition, selected from compounds of an oxide such as CaO, MgO, SiO2, ZrO2, B2O3, Al 2 O 3 , TiO 2 , hafnium oxide, compounds of these oxides and rare earth metal oxides such as Y 2 O 3 , YAG(Al 5 Y 3 O 12 ), YAP(AlYO 3 ), and YAM(Al 2 Y 4 O 7 ), or a nitride such as calcium nitride, TiN, BN, AlN, Si3N4, and mixtures thereof, or one of a metal alkoxide, a silicon alkoxide, an alumina solution, and a silica solution. A non-electrically conductive composition is meant a composition that has a resistivity at room temperature of greater than 1500 micro-ohm-cm, and a resistivity of greater than 4500 micro-ohm-cm at operating temperature.
In one embodiment, the coating is a non-electrically conductive composition comprising at least one of an oxide, a nitride, a boride, a carbide, a silicide and mixtures thereof. In another embodiment, the coating comprises a suspension of a fine powder of at least one of BN, AlN, iron boride, TiB 2 , TiC, ZrC, HfC, VC, NbC, TaC, Cr 3 C 2 , Mo 2 C, WC in water, acetone, alumina sol, and the like, including compounds derivatives and mixtures thereof. In a third embodiment, the non-electrically coating is a BN paint commercially available from sources such as General Electric Company and Zyp Coatings, Inc. In a fourth embodiment, the electrically conducting coating comprises a paste comprising TiB 2 powder in glycerol as a binder. In a fifth embodiment, TiB 2 powder is sprinkled onto the surface of the boat, and then irradiated by a YAG laser.
In another embodiment, the coating is an oxide thin film layer selected from metal alkoxides and silicon alkoxides. In a second embodiment, the coating layer comprises alumina sol (bohmite alumina colloidal solution) or silica sol (e.g., tetra-ethoxy silane TEOS or tetramethoxy silane TMOS). In a fourth embodiment, the coating is a mixture of TiC and alumina sol.
The boat of the invention comprises a plurality of grooves formed on the boat surface or boat cavity as illustrated in FIGS. 1-12 . The grooves may be stand-alone as separate grooves (e.g., parallel groves in FIGS. 5 , 6 , 7 , 9 , and 10 ), they may be interconnected (see FIGS. 1 , 2 , and 8 ), or a combination of stand-alone and interconnected grooves on the surface ( FIGS. 11 and 12 ).
As defined herein, a “groove” is a channel running across one dimension of the cavity (width or length), e.g., a line or a curve, or a self-terminating channel on the cavity surface with random geometry or having the shape of a circle ( FIG. 12 ), square, rectangle, triangle, diamond ( FIG. 11 ), ellipse, etc. The grooves are formed on the boat surface or the surface of the cavity by known automatic or manual mechanical means such as using grinders, drills, via Electro Discharge Machining (EDM), Electro Discharge Grinding (EDG), laser, plasma, ultrasonic machining, sand-blasting, and water jet, etc.
In one embodiment, the grooves are circular in shape as shown in FIG. 12 . In another embodiment, the grooves are of random geometry as shown in FIGS. 5 , 6 , 8 , and 9 . In a third embodiment, the grooves are in the form of straight lines as shown in FIGS. 1-4 , 7 and 10 . In a fourth embodiment, the grooves are in the form of random lines as shown in FIG. 6 . In a fifth embodiment, the grooves are formed in a direction not parallel to the conduction direction (i.e., not aligned with the major axis of the boat). In a sixth embodiment, at least 50% of the grooves intersect with one another. In a seventh embodiment, there is no intersection of the grooves as illustrated in FIGS. 5 and 6 .
In one embodiment, the grooves having at least a portion of the length at an angle of 10 to 170 degrees to the conduction direction (the length axis of the boat) as illustrated in FIG. 7 . By at least “a portion of the length” is meant at least 20% of the length of the groove length. In another embodiment, at least 40% of the length of the groove length is at an angle of 10 to 170 degrees to the conduction direction.
In another embodiment, the grooves are from 20 degrees to 160 degrees to the conduction direction as illustrated in FIG. 10 . In a third embodiment, at least 10% of the grooves are at an angle of 10 to 170 degrees to the conduction direction as illustrated in FIG. 8 . In a fourth embodiment, at least 50% of the grooves are at an angle of 10 to 170 degrees to the conduction direction as illustrated in FIG. 8 .
In one embodiment, the grooves are interconnected as illustrated in FIG. 8 . In another embodiment, at least 25% of the grooves are interconnected as illustrated in FIGS. 11-12 .
In one embodiment, only the grooves are coated or filled with a wetting enhancement and/or corrosion resistant coating layer as previously described for coating a boat surface in contact with molten metal, e.g., an electrically conductive composition, or a non-electrically conductive composition. A non-electrically conductive composition is meant a composition that has a resistivity at room temperature of greater than 1500 μ-Ωcm, and a resistivity of greater than 4500 μ-Ω-cm at operating temperature.
Examples include BN, AlN, TiB 2 , TiC, ZrC, HfC, VC, NbC, TaC, Cr 3 C 2 , Mo 2 C, WC, derivatives and mixtures thereof, metal alkoxides, silicon alkoxides, and mixtures thereof, to be applied onto the grooves by brush painting, brush coating, spraying, rolling, dipping, etc.
Applicants have found that by minimizing the depth of grooves, or controlling formation of grooves over the evaporation surface, boat life can be surprisingly extended, i.e., in specifying for the grooves each to have at least one of: a) a depth of at least 1.2 mm; b) a width of at least 1.75 mm, and c) an interval spacing of at least 2.2 mm.
In one embodiment, the boat of the invention is characterized as having grooves with a depth of at least 1.2 mm and a width of at least 1.75 mm. In another embodiment, the grooves have a depth ranging from 1.5 to 5 mm. In a second embodiment, a depth of at least 1.5 mm. In a third embodiment, a width of at least 2 mm.
In one embodiment, the boat of the invention has a depth of 1.0 mm, a width of 1 mm, and an interval spacing of 2.5 mm. In another embodiment, the boat is characterized by having adjacent grooves being spaced at least 1 mm (0.039″) apart (for grooves in the form of random or straight lines) as illustrated in FIGS. 1-4 . In another embodiment, the grooves of depth 1.5 mm are spaced at least 2 mm (0.079″) apart. In another embodiment, the grooves of width 1 mm are spaced at least 2.5 mm apart. In yet another embodiment, the centers of adjacent grooves having 1.2 mm depth with a circular, triangular, square, rectangular, or elliptical shape are at last 1 mm apart.
In one embodiment, the grooves are of uneven depth to promote the wettability of the molten metals, e.g., the grooves in the center of the cavity of the boat being deeper than the grooves near the edges of the boat. In one embodiment, the grooves have a depth difference of at least 50%, i.e., the deepest grooves are at least 50% deeper than the shallowest grooves.
Examples are provided herein to illustrate the invention but are not intended to limit the scope of the invention.
EXAMPLES 1-4
In all examples, evaporator boats commercially available from GE Advanced Ceramics of Strongsville, Ohio, under the trade name “VaporStar” were used. The boats were machined for an overall dimensions of 30 mm wide, 10 mm thick, and 150 mm long. Grooves of various dimensions were machined on the surface of the boats such that the grooves were at 45 degrees to the longitudinal axis of the boat, creating an interconnected pattern. The grooves were machined using a sandblasting technique, for the following dimensions for the grooves.
TABLE 1
Initial boat
Groove
thickness
Width
Groove Depth
Groove Spacing
Example
(mm)
(mm)
(mm)
(mm)
SM-1
10.2
0.5
0.1
1.0
SM-2
10.2
1.0
0.6
2.0
SM-3
10.0
2.0
1.5
4.0
SM-4
10.2
1.0
0.9
5.0
FIGS. 1-2 are perspective views and FIGS. 3-4 are top views of the boats of the invention in Examples 3-4. Examples 1 and 2 are comparative examples illustrating the grooved boats of the prior art. FIGS. 24( a )- 27 ( a ) are photographs of the top views of the grooved sections of the boats in Examples 1-4 before metallization.
The evaporation boats made from the Examples were tested in a vacuum chamber at ˜1×10^−4 millibar. The boats were heated by a direct passage of current and brought to a temperature of 1500° C. through direct heating. Aluminum for metallization was supplied continuously via an aluminum wire fed near the middle area of the grooved pattern. The wire feed was at 9.5 grams per minute for eight 1-hour intervals, for a total time of metallization of 8 hours. Between each 1-hour metallization interval, the boats were cooled and lightly brushed using a soft-plastic bristle brush. The brushing was to replicate the typical cooling, venting, and cleaning of boats during substrate roll changes in actual applications. During metallization, the boat temperature was controlled to maintain an even spreading and evaporation of molten aluminum over the metallization surface of the boat.
As the test progresses, the aluminum spreading was stable and consistent for all of the boats. It was noted that the aluminum caused more severe length-wise grooving in the boats of comparative examples 1-2, as compared to less severe and more uniform grooving in examples 3-4 of the invention. After 8 hours of metallization, the boats were photographed and the deepest point of the groove was measured using a drop-gage.
In Table 2, the “Min. thickness after run.” is the thickness of the boat at the deepest point of grooving after the 8-hour metallization period. The “Max. wear depth after run” is the depth of wear starting from the base of the initially machined grooves, i.e. the initial minimum thickness minus the thickness after metallization. The “Wear depth as % of ini. thickness” is computed as the percentage of “Max wear depth after run” over the initial minimum thickness.
TABLE 2
Wear
Min.
Max. wear
depth as %
Initial boat
Groove
Groove
Groove
Initial min.
thickness
depth after
of initial
Example
thickness
width
depth
spacing
thickness
after run
run
thickness
SM-1
10.2
0.5
0.1
1.0
10.1
5.0
5.1
49%
SM-2
10.2
1.0
0.6
2.0
9.7
4.4
5.3
46%
SM-3
10.0
2.0
1.5
4.0
8.5
4.8
3.7
22%
SM-4
10.2
1.0
0.9
5.0
9.3
5.3
4.0
30%
FIGS. 24( b )- 27 ( b ) are photographs of the top views of the boats in Examples 1-4 after 8 hours of metallization. As seen in the pictures, the boats of the invention held up quite well with less-severe and more uniform grooving leading to additional life left in the boats—expected to be useable for at least 4 more hours. The metallization boats with the groove dimensions of the prior art corroded more quickly as seen in the picture, with some of the grooves penetrating deeply and extensively in a length-wise direction of the boats.
EXAMPLES 5-8
In these examples, evaporator boats commercially available from GE Advanced Ceramics of Strongsville, Ohio, under the trade name “VaporStar” were also used. The boats were machined for an overall dimensions of 10 mm×40 mm×132 mm.
The top surface of the boats in FIGS. 29( a ), 30 ( a ), and 31 ( a ) were wet-sanded with 320 grit sand paper. The top surface of the boat of FIG. 28( a ) was ground with a standard grinding wheel to generate a 0.25 mm deep ground cavity. Grooves of about 1 mm wide, 1 mm deep, and about 4 mm apart were manually machined in the top surface of the boat of FIG. 30( a ) using a Dremel tool to create intersecting patterns of an approximate 45° angle to the electrical conduction direction. Grooves were manually machined in the top surface of the boat of FIG. 31( a ) using a Dremel tool to create a groove pattern of the prior art, having longitudinal grooves of about 1 mm deep, 1 mm wide, and 3 mm apart.
The boats were tested under the same aluminum metallization condition similar to that of Examples 1-4 but for only 5 hours. As shown in FIG. 31( b ), deep grooves formed along the length of the prior-art boat that had longitudinal grooves. Shown in FIGS. 28( b ) and 29 ( b ), deep grooves were also formed in the prior-art boats having a ground cavity or a smooth surface at the start. FIG. 30( b ) shows that the grooves in the boat of the present invention (crisscrossed pattern and wide interval spacing) are not as deep and are more uniformly spread out over the surface of the boat, tending to follow the crisscrossed pattern. Furthermore, it was observed that the puddle shape during 5 hours of use remained more uniformly spread out over the surface of boat in FIG. 30( b ) of the present invention, as compared to the boats of the prior art ( FIGS. 28 b , 29 b , and 31 b ).
EXAMPLE 9
An evaporator boat commercially available from GE Advanced Ceramics of Strongsville, Ohio, under the trade name “VaporStar” was used. The boat was machined for an overall dimensions of 10.2 mm thickness×40 mm×132 mm with grooves having dimensions identical to the boat of Example 4, i.e., 1 mm thickness, 0.9 depth, and 5 mm spacing. The boat surface, including the evaporation surface in contact with molten metal and the grooves, was coated with a boron nitride (BN) paint. BN coating paint is commercially available from sources including General Electric Company of Strongsville, Ohio and Zyp Coatings, Inc. of Oak Ridge, Tenn. (e.g., a water based BN from GE, or BN Lubricoat® Blue from Zyp).
The boat was tested under the same aluminum metallization condition similar to that of Example 4. The boat held up quite well with minimal and more uniform grooving even compared with the boat of Example 4 after 8 hours. The test continued for a total of 17 hours, showing that the coating substantially extended the life of the grooved boat.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
All citations referred herein are expressly incorporated herein by reference.
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A refractory container for evaporating metals, having improved useful life and corrosion resistance properties, the evaporation surface of the container having a plurality of grooves formed at the bottom surface. The grooves have either a depth of at least 1.2 mm, a width of at least 1.75 mm, or an interval spacing of at least 2.2 mm between adjacent grooves (or centers of adjacent grooves), and combinations thereof.
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[0001] This application claims priority to U.S. Provisional Application Ser. No. 60/943/839, filed Jun. 13, 2007.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to collapsible crates and more particularly to a collapsible crate with support members for supporting another container thereon.
[0003] Collapsible crates are well known. Four walls each connected via a hinge to a base are selectively movable about the hinge between a use position, in which the wall is generally perpendicular to the base, and a collapsed position onto the base. Various mechanisms have been provided to connect adjacent walls at the corner to selectively lock the crate in the use position.
[0004] Some collapsible crates also include retractable supports so that another container can be supported thereon. One such crate includes end walls each having a support that is partially supported on the adjacent walls when in the support position. As the end walls are pivoted to the upright position, a biasing member on the support contacts a portion of the adjacent wall to automatically move the support to the support position. However, the biasing members are subject to breakage.
SUMMARY OF THE INVENTION
[0005] The present invention provides a collapsible container having a plurality of walls collapsible onto the base. At least one wall has a support movable between a support position where it is partially supported on an adjacent wall and a retracted position. In the retracted position, the wall can lie flat on the base.
[0006] In one embodiment, when the wall is pivoted to the upright position, a hard stop on the adjacent wall moves the support to the support position. Thus, the supports are always guaranteed to be fully in the support position, so that a container stacked thereon will not fall into the lower container and damage the goods in the lower container.
[0007] In another embodiment, the hard stop moves the support only partly from the retracted position toward the support position. This makes it easier for the user to move the support fully to the support position. The support in the partly retracted position permits some additional access to the mouth of the container.
[0008] The supports may be formed on short end walls of the container, such that the supports and end walls can be collapsed onto the base and the long side walls can be pivoted onto the end walls.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Other advantages of the present invention can be understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
[0010] FIG. 1 is a perspective view of a container according to the present invention in the assembled position.
[0011] FIG. 2 is a perspective view of the container of FIG. 1 in a collapsed position.
[0012] FIG. 3 is a perspective view of a quarter of the container of FIG. 1 . The other quadrants would be mirror images.
[0013] FIG. 4 is an enlarged view of the corner of the container of FIG. 3 .
[0014] FIG. 5 is partial section view of the container of FIG. 1 with the end wall in the collapsed position.
[0015] FIG. 6 is a view similar to that of FIG. 5 , with the end wall being pivoted toward the upright position.
[0016] FIG. 7 is a view similar to that of FIG. 5 with the end wall in the upright position and the support in the deployed position.
[0017] FIG. 8 is a view similar to that of FIG. 7 of a container according to a second embodiment of the present invention.
[0018] FIG. 9 illustrates a mold half for making the side wall of FIGS. 1-7 or FIG. 8 or a side wall without a stop.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Referring to FIG. 1 , a container 10 includes a base 12 having upstanding side walls 14 (or long walls) and upstanding end walls 18 (or short walls). The side walls 14 and end walls 18 are pivotably connected along long and short edges of the base 12 , respectively. The side walls 14 and end walls 18 are movable between the upright position shown in FIG. 1 and a collapsed position on the base 12 , as shown in FIG. 2 .
[0020] Referring to FIG. 3 , each end wall 18 has a support 20 (or flap). The support 20 is pivotably mounted at its lower edge to a position spaced below an upper edge of the end wall 18 . The support 20 is shown in FIG. 3 in a support position where it projects into the interior of the container 10 , partly narrowing the mouth of the container 10 . The support 20 includes a tab 21 projecting from each side into the side wall 14 . The end wall 18 includes a lip 36 protruding inwardly from the uppermost edge above the support 20 . The lip 36 includes at least one inwardly-open cutout 38 therethrough.
[0021] The interiors of the side walls 14 each include an upper frame portion 22 protruding into the container 10 . A curved channel 24 is formed through each upper frame portion 22 . The interior of the side walls 14 each further include a lower frame portion 26 having a pair of channels 28 formed therethrough. A recess 30 is defined between the upper frame portion 22 and the lower frame portion 26 . The base 12 includes a pair of side upstanding portions 32 to which the side walls 14 are pivotably attached. Each side upstanding portion 32 includes a pair of channels 34 formed on an interior thereof. The channels 24 , 28 and 34 are aligned with one another and with the tabs 21 on the supports 20 , so that the end walls 18 can be pivoted to the collapsed position.
[0022] Referring to FIG. 3 , the base 12 includes a pair of shallow recessed channels 45 (one shown) in alignment with the channels 34 of the side upstanding portions 32 . When the end wall 18 is collapsed onto the base 12 as shown in FIG. 5 , the lip 36 of the end wall 18 and the upper edge of the support 20 are received in the channel 45 in the base 12 . The lip 36 and the support 20 both project toward the interior of the container 10 further than the inner surface of the remainder of the end wall 18 , so the recess 45 permits the end wall 18 to lie flatter on the base 12 . This reduces the overall stacking height of the container 10 in a collapsed position.
[0023] Referring to FIG. 4 , each side wall 14 includes a stop 40 projecting inward adjacent the channel 24 . As the end wall 18 is pivoted toward the upright position, the tab 21 ( FIG. 3 ) of the support 20 passes through the channel 24 in the side wall 14 . In FIG. 6 , the end wall 18 is being pivoted toward the upright position from the position of FIG. 5 . The tab 21 passes through the channels 24 , 28 , 34 and the recess 30 in side wall 14 as the end wall 18 is pivoted toward the upright position, as shown in FIG. 6 .
[0024] As shown in FIG. 7 , the support then contacts the stops 40 (one shown—the other one is on the opposite side wall 14 ) and is forced from the retracted position below lip 36 to the support position as shown. Thus, in this embodiment, the support 20 cannot be moved to the retracted position when the end wall 18 and the side wall 14 are in the upright position. This guarantees that the supports 20 will be ready to support a container thereon. Further, there is no need for a user to manually deploy the supports 20 after erecting the walls 14 , 18 .
[0025] As another feature of the present invention, the side wall 14 is designed such that the stop 40 can easily be removed from the mold (such as by adding an insert). As can be seen in FIG. 7 , the channel 24 continues past the stop 40 , such that without the stop 40 , the support 20 could be retracted completely into the end wall 18 . Thus, containers with or without the automatic deployment of the supports 20 could be made in the same molds.
[0026] A container 110 according to another embodiment is shown in FIG. 8 . The container 110 is identical to the container 10 of FIGS. 1-7 except as shown in FIG. 8 or described below. The container 110 has a stop 140 that is closer to the end wall 18 than the stop 40 , such that the support 20 is only partially deployed by the stop 140 as the end wall 18 is moved to the upright position. FIG. 8 illustrates the support 20 moved to the partially deployed position by the stop 140 . This makes it easier for the user to move the support 20 to the fully deployed position, similar to that as shown in FIG. 7 . Gravity may then permit the support 20 to fall the rest of the way into the support position, but also permit the support 20 to be moved toward the end wall 18 to the extent shown for greater access through the opening of the container 110 . Alternatively, the container 110 can be used with the support in the partially deployed position (without supporting another container thereon), in which case, the supports 20 restrict the mouth of the container 110 less than the supports 20 of the container 10 of FIGS. 1-7 .
[0027] FIG. 9 illustrates a mold half 200 for making the side wall 14 of FIGS. 1-7 or a side wall 114 according to FIG. 8 or a side wall without a stop 40 , 140 . A side wall without a stop can be made by using the insert 202 in the mold half 200 . A side wall 14 with a full hard stop 40 according to FIGS. 1-7 can be made with the insert 202 a in the mold half 200 , the insert 202 a having a recess 204 a corresponding to the hard stop 40 . A side wall 114 with a partial hard stop 140 according to FIG. 8 can be made with the insert 202 b in the mold half 200 , the insert 202 b having a recess 204 b corresponding to the hard stop 140 . Thus, the same mold half 200 can be used to make any of the desired types of side walls 114 .
[0028] In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.
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A collapsible container includes a plurality of walls collapsible onto the base. A first wall has a support pivotable between a support position where it is partially supported on an adjacent wall and a retracted position. An adjacent wall has a stop formed thereon which forces the support into the support position when the first wall is moved to the upright position.
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This application claims the benefit of U.S. Provisional Application No. 60/394,651 filed Jul. 10, 2002, the disclosure of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is directed to a method for activating carbon and thermally reactivating activated carbon and, more particularly, a technique for enhancing the thermal reactivation of activated carbon that once served in water treatment for the removal of taste and odor causing compounds (T&Os; e.g., 2-methylisobomeol and geosmin), volatile organic compounds (VOCs; e.g., benzene, xylenes, and toluene), synthetic organic chemicals (SOCs; e.g., atrazine and lindane), and naturally occurring organic matter (NOM).
2. Description of the Related Prior Art
Activated carbon both in the powdered (PAC) form (generally defined as 90% passing the 325 mesh) and granular (GAC) form (generally defined as passing the 8 mesh, but retained on the 30 mesh or passing the 12 and retained by the 40 mesh) has been used extensively during the past several decades for the removal of unwanted compounds from drinking water. Increase in activated carbon use occurred in the late 1970's upon the U.S. EPA's recommendation of it as being the best available technology (BAT) for controlling trihalomethanes and, later, SOCs in contaminated ground water and drinking water. However, GAC has a finite adsorption capacity, and approaches a point where it cain no longer remove the organics required to purvey aesthetically pleasing water that also meets the EPA's stringent water quality standards.
After GAC has exhausted its finite adsorption capacity or when users deem it necessary, a common practice is to reactivate and return the activated carbon back to service. Typically, spent activated carbon is reactivated in a rotary kiln furnace, but also can be reactivated in fluidized bed or multiple hearth furnaces. Conventional thermal reactivation includes the following steps as discussed by Suzuki et al. “Study of thermal regeneration of spent activated carbons: Thermogravimetric measurement of various single component organics loaded on activated carbons” Chlem Eng Sci 1978;33(3):271-279. First, the wet carbon is dried at 105° C. to release water. Second, the GAC is pyrolyzed in a starved gas environment between 650 and 850° C. During pyrolysis, volatile compounds that accumulated during operation are released. This step also causes fragments of adsorbed organic compounds on the GAC surface to form a carbonaceous char. Finally, the adsorbed char is oxidized and gasified by exposing the GAC to C0 2 , steam, or a combination of both at 650 to 900° C. The inherent limitation of this oxidation step is that it gasifies a fraction of the carbon surface while it is gasifying the char. In other words, some of the carbon is burned during thermal reactivation.
Activated carbon's excellent performance in removing numerous organic compounds has been proven, but it is common to hear the words “activated carbon” and “expensive” in the same sentence. Thermal reactivation can often represent the largest expense associated with using GAC.
Therefore, a method that can reactivate activated carbon that decreases the mass and volume loss, results in a BET surface area or iodine number (as measured by ASTM D4607) near its virgin counterpart, and that lasts longer for removing compounds compared to its virgin counterpart presents an opportunity to decrease the costs associated with thermal reactivation. In other words, if mass loss and volume loss could be decreased during thermal reactivation, then less virgin carbon make-up would be required to replace the carbon lost during reactivation. If the reactivated carbon could stay in service for longer periods of time, then reactivation frequencies would decrease, which would decrease costs because reactivation cycles would be farther apart. Finally, if the reactivated carbon's iodine number and/or BET surface area are close to the virgin counterpart, then the carbon could experience more thermal reactivation cycles. Similarly, a method that improves the efficacy of activated carbon for removing unwanted compounds (such as those listed above) presents an opportunity to improve water treatment.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is a method for reactivating activated carbon which decreases the mass and volume loss yet results in a BET surface area or iodine number near its virgin counterpart: the reactivated carbon lasting longer for removing compounds compared to conventionally reactivated carbon and, in some instances, its virgin counterpart.
Another object of the present invention is a method for the development of an activated carbon superior in removing unwanted compounds to improve water treatment compared to those that are activated conventionally (i.e., pyrolysis followed by steam).
This object and other objects are achieved by a method for reactivating activated carbon, comprising the steps of steam treating the activated carbon followed by pyrolysis, both the steam treatment and pyrolysis being conducted at a temperature within the range of about 400° C. to about 900° C.
An additional aspect of the invention includes a method for reactivating activated carbon, comprising the steps of pyrolysis followed by steam treating the activated carbon, both the steam treatment and pyrolysis being conducted at a temperature within the range of about 400° C. to about 900° C., wherein the steam treatment comprises treating the activated carbon with steam prepared from water having a dissolved oxygen (DO) content of less than about 9 mg of oxygen per liter of water.
Another aspect of the invention includes a method for activating a carbonaceous material, comprising the steps of steam treating the carbonaceous material followed by pyrolysis.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a breakthrough curve comparing conventionally reactivated carbons reactivated with water containing varying dissolved oxygen concentrations in accordance with the present invention.
FIG. 2 represents a traditional breakthrough curve comparing conventionally reactivated, virgin, and steam-pyrolysis reactivated carbons prepared in the experiments conducted in accordance with the present invention.
FIG. 3 represents a MIB breakthrough curve for spent GAC reactivated using the present invention at various temperatures (dissolved oxygen=4.5 mg/L) in accordance with the present invention.
FIG. 4 represents a breakthrough curve comparing spent carbon reactivated at 750° C. for 15 minutes in steam and 15 minutes in an inert/starved gas environment at 2 different dissolved oxygen levels (i.e., 4.5 and 8.3 mgfL) in accordance with the present invention.
FIG. 5 represents a comparison of a wood-based material activated with two levels of dissolved oxygen (4.5 and 9.8 mg/L) for the removal of T&Os (i.e. MIB and geosmin) in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention includes subjecting activated carbon to a two-step process (herein referred to as steam-pyrolysis) at temperatures equal to or greater than about 400° C. wherein the steam was produced preferably by heating deoxygenated water. As used herein the term pyrolysis refers to heating in an inert/starved gas environment where further deoxygenation/devolatilization can occur. The activated carbon reactivated via this method results in a BET surface area or iodine number near its virgin counterpart, and is capable of processing more bed volumes compared to conventionally reactivated (pyrolysis followed by oxidation) activated carbon. In some cases, this deoxygenated steam-pyrolysis reactivated carbon can outperform its virgin (new) counterpart. In addition, the steam-pyrolysis reactivated carbon results in a lower mass and volume loss compared to conventional reactivation.
The first noticeable difference between the reactivation protocol of the present invention and the conventional reactivation is the reversal of the pyrolysis and oxidation steps. The steam-pyrolysis technique of the present invention employs steam followed by pyrolysis, and this technique is opposite compared to conventional reactivation. While not wishing to be bound by theory, it is believed that by applying steam first, the organics that sorbed during treatment can be oxidized easier through steam gasification rather than first charring the organics through pyrolysis. In addition, completing the reactivation in the pyrolysis step will further remove oxygen functional groups that are deleterious to the removal of the aforementioned organics.
The water gas shift reaction (equation 1 below) is an important reaction that occurs during the thermal reactivation process. This is because it controls the quantity of H 2 produced, which anneals carbon reactive sites created from functional decomposition, and thereby prevents subsequent oxidation, which would improve carbon performance.
CO+H 2 O⇄H 2 +CO 2 (1)
It is further believed that by deoxygenating the water heated for steam that the water gas shift reaction rate would progress to the right more quickly. In addition, by removing the oxygen from water, the only oxidant present in the furnace would be H 2 O versus H 2 O and liberated oxygen gas. Water can be deoxygenated by any suitable conventional technique in the art including, for example, by bubbling with N 2 or by adding chemicals (e.g., sodiumsulfite) to achieve the desired dissolved oxygen level. On the contrary, under some circumstances it may be desirable to supersaturate the steam with oxygen in which case bubbling with pure O 2 can increase the water's oxygen content.
In accordance with the general principles of the invention, activated carbon is thermally reactivated in a two-step process of steam treatment followed by pyrolysis in an inert/starved gas atmosphere. The steam treatment and the pyrolysis are both conducted at a temperature of about 400° C. to about 900° C., preferably about 450° C. to about 850° C., most preferably about 650° C. to about 850° C. Preferably, the steam treatment and the pyrolysis are both conducted at the same temperature, but if desired they may be conducted at different temperatures. The steam treatment and the pyrolysis steps may be conducted for as long as desired. Preferably, both steps are conducted for a combined total of about 5 minutes to about 2 hours, more preferably, about 10 to about 60 minutes, most preferably, about 15 minutes to about 30 minutes. The time is preferably split evenly between the steam treatment and pyrolysis steps. Of course, one of ordinary skill in the art will recognize that the time may be apportioned as desired. In one aspect of the invention, at least about half of the time is apportioned to the steam treatment. Further, for the reasons discussed above, the steam used in the steam treatment in accordance with the invention is preferably deoxygenated steam. As used herein, the term “deoxygenated steam” refers to steam prepared by heating water to a temperature of, for example, 105° C. the water having an oxygen content of less than about 9 mg of oxygen per liter of water, preferably less than about 6 mg of oxygen per liter of water, more preferably less than about 5 mg of oxygen per liter of water, and most preferably substantially free of oxygen, i.e., an oxygen content of less than 1 mg of oxygen per liter of water.
In accordance with the present invention, the steam treatment includes subjecting the activated carbon to a flow of steam of at least about 0.01 pounds of steam per pound of carbon, more preferably about 0.05 to about 0.50 pounds of steam per pound of carbon. Further, the pyrolysis may be conducted in any suitable inert (e.g., nitrogen, argon or helium) or starved gas environment (e.g., an environment devoid of oxygen). Other suitable inert, or starved gas, atmospheres will be apparent to one of ordinary skill in the art. Similarly, as one of ordinary skill in the art will recognize, the present invention may be carried out in any suitable conventional apparatus with appropriate accommodation for the reversal of the order of the steam treatment and pyrolysis steps.
It is within the scope of this invention to conventionally reactivate spent carbon using water containing low DO (i.e., water having an oxygen content of less than about 9 mg of oxygen per liter of water, preferably less than about 6 mg of oxygen per liter of water, more preferably less than about 5 mg of oxygen per liter of water, and most preferably substantially free of oxygen, i.e., an oxygen content of less than 1 mg of oxygen per liter of water). In this aspect of the invention, the process conditions including reactivation temperatures and time, as well as the flow rate of steam, would be the same as discussed above in connection with reactivation in which steam treatment is conducted prior to pyrolysis.
Further, it will be recognized that while the present invention has been described in connection with reactivating activated carbon, it is within the scope of the present invention to prepare activated carbon, either powdered or granular, by treating a carbonaceous material in accordance with the method described herein, including the above discussed temperatures, times, flow rates, etc. Examples of carbonaceous material suitable for this aspect of the invention include those that have already experienced pyrolysis/charring (e.g., carbon recovered from coal fired power plant's fly ash and bark char from paper mills, and the like). Other suitable materials would be apparent to one skilled in the art. As mentioned above, under some circumstances it may be desirable to supersaturate the steam with oxygen, for example, as in the context of activating carbon in accordance with the invention, in which case bubbling the water with oxygen can increase the DO concentration to greater than about 10 mg of oxygen per liter of water, more preferably to greater than about 12 mg of oxygen per liter of water. Suitably, the DO concentration may be up to about 30 mg of oxygen per liter of water, or even up to about 100 mg of oxygen per liter of water under some conditions. It will be recognized by one skilled in the art that higher DOs are within the scope of the invention.
The invention will now be described in connection with certain experiments conducted in accordance with the present invention. The experiments are described in the following general discussion as well as in summary form in the following tables and figures.
EXAMPLE 1
Preferably, the pyrolysis and oxidation steps are reversed whereby the spent GAC experiences steam prior to the inert/starved gas environment. However, performance gains are achievable if one uses water that contains low dissolved oxygen water for the steam in the conventional reactivation process. As an example, 10 g of spent GAC was reactivated conventionally at 750° C. for 5 minutes (pyrolysis) followed by 10 minutes of steam (0.2 lb steam/lb carbon), at the same temperature, in a one inch diameter quartz fluidized bed furnace, using water that contained DO of 4.6, 9.8, and 13.7 mg/L. The spent GAC reactivated with the lower DO water processed approximately 2000 more bed volumes to the odor threshold concentration (OTC) compared to that reactivated with water containing higher DO (FIG. 1 ). The OTC represents the concentration whereby customers can detect (taste or smell) MIB in their water. FIG. 1 also shows that the conventionally reactivated carbon with 9.8 mg/L DO performed similarly to that reactivated with the low DO to about 3200 bed volumes. After 3200 BV, the reactivation with the low DO water performed better.
EXAMPLE 2
In general, in accordance with the present invention, spent GAC was reactivated at 750° C. for 15 minutes in steam (0.2 lbs of steam/lb of carbon) followed by 15 minutes in N 2 . Its BET surface area was 950 m 2 /g, which was identical to its virgin counterpart, and considerably greater than the conventionally reactivated activated carbon (750 m 2 /g). In addition, its mass loss (12.1%) and volume loss (2.3%) were less than the conventionally reactivated carbon (17.3% and 4.1%, respectively). Other temperatures (e.g., 650 and 850° C.) and times (e.g., 5 to 120 minutes) were likewise investigated, and were suitable. The carbons reactivated at 650 and 850° C. had high surface areas (820 and 830 m 2 /g) compared to the conventional reactivation, but the 850° C. reactivated carbon experienced almost 22% mass loss which under some circumstances might be acceptable. In any event, the process in accordance with the present invention at 750° C. for 15 minutes in deoxygenated steam and 15 minutes of an inert/starved gas environment provided optimal results.
The following table represents a summary of experiments conducted in accordance with the present invention whereby the temperatures for both steps were identical. More specifically, 6 activated carbon samples (“Utilized F300”) were collected from 6 water treatment plants, and each sample was reactivated with the present invention in triplicate. The data shown in Table 1 represents an average of these reactivations. In the table, “Virgin F300” is virgin activated carbon available from Calgon Carbon Corporation of Pittsburgh, Pa. The experimental protocol identified as “Conventional Reactivation” included pyrolysis at 850° C. for 5 minutes and oxidation in steam (0.2 lb steam/lb carbon) at 850° C. for 10 minutes. The experimental protocol identified as “Steam Plus Ramped Temperature” included steam treatment at 375° C. (45.8 lb steam/lb carbon) for 1-hr followed by a step in which the temperature was ramped up to 850° C. in an inert/gas starved environment (which took 20 minutes). The remaining experiments were conducted using a protocol in accordance with the present invention, including steam treatment (0.2 lb steam/lb carbon) with deoxygenated steam having an oxygen content of 4-5 mg of oxygen per liter of water followed by pyrolysis in an inert/starved gas environment for a total of 30 minutes (the time being split evenly between the steam treatment and pyrolysis steps), with the temperature being as indicated.
TABLE 1
Comparison of Thermal Reactivation Process Parameters
Percent
BET
Mass
Percent Volume
Surface Area
Protocol
Loss
Loss
(m 2 /g)
Virgin F300
NA
NA
950
Utilized F300
NA
NA
720
Conventional Reactivation
17.3
4.1
750
Steam Plus Ramped
15.9
3.9
830
Temperature
Steam-Pyrolysis (450° C.,
5.4
0.6
780
30 minutes)
Steam-Pyrolysis (550° C.,
5.4
0.6
750
30 minutes)
Steam-Pyrolysis (650° C.,
10.3
2.3
820
30 minutes)
Steam-Pyrolysis (750° C.,
12.1
2.3
950
30 minutes)
Steam-Pyrolysis (850° C.,
21.9
2.9
830
30 minutes)
Of importance to the thermal reactivation industry is the performance of the reactivated carbon compared to its virgin counterpart. Therefore, the conventionally reactivated, virgin, and steam-pyrolysis reactivated carbons of Table 1 were compared for their performance in removing the common odorant 2-methylisoborneol (MIB). As illustrated in FIG. 2, the conventionally reactivated carbon experienced breakthrough at approximately 1000 bed volumes, and crossed the odor threshold concentration (OTC) at approximately 2300 bed volumes. The OTC represents the concentration whereby customers can detect (taste or smell) MIB in their water. The virgin carbon likewise broke through at ca. 1000 bed volumes, but did not reach the OTC until ca. 3200 bed volumes. Therefore, the conventionally reactivated carbon had less capacity for MIB than the virgin carbon, and performed worse. The concern that arises is that it is likely that every time this carbon experiences conventional reactivation, its performance is likely to progressively worsen. The steam-pyrolysis reactivated carbon (750° C.) out performed both the conventionally reactivated carbon and its virgin counterpart because the steam-pyrolysis reactivated carbon did not break through until ca. 3500 bed volumes, and did not cross the OTC until 5200 bed volumes.
In FIG. 3, the greatest volume of water processed before reaching breakthrough and the odor threshold concentration was the steam-pyrolysis reactivated carbon at 750° C. However, this temperature is dependent upon the nature of the adsorbed organics. For example, the reactivated carbons in FIG. 4 were capable of processing more water before breakthrough and surpassing the OTC than those in FIG. 3 . For example, the steam-pyrolysis reactivation with the lower DO water did not experience breakthrough until 5000 bed volumes, more than 1000 bed volumes more than the steam-pyrolysis reactivation with the higher DO.
EXAMPLE 3
In accordance with the invention, 3 g of a wood-based material was activated at 850° C. with steam having a DO concentration of 4.5 and 9.8 mg/L followed by pyrolysis at 850° C. for 15 minutes each step. Subsequently, the activated carbons were powdered and tested in batch tests for their ability to either remove MIB or geosmin from two different raw water sources. FIG. 5 demonstrates that the activated carbon, which was activated with steam having been prepared with the water from the lower DO performed better, on a comparison basis, than that which was activated with steam having the higher DO (i.e., 9.8 mg/L), both results (i.e., 4.5 and 9.8 mg/L) being favorable/acceptable.
There are no other known inventions whereby activated carbons are thermally reactivated such that the reactivated carbon resembles its virgin counterpart with respect to physical properties and performance. There are no other known inventions where the steam is deoxygenated for either activation or reactivation.
Water utilities that employ activated carbon must routinely face the costs and operational challenges associated with removing and replacing carbon that has lost its capacity for removing contaminants. The invention described herein would facilitate the water utilities to reactivate their carbon less frequently.
Although the present application has been described in connection with the preferred embodiments thereof, many other variations and modifications will become apparent to those skilled in the art without departure from the scope of the invention.
|
The present invention generally relates to a method of thermally reactivating activated carbon via a two-step process: steam followed by pyrolysis; whereby the steam is preferably deoxygenated. Activated carbons reactivated by this method resemble their virgin counterpart's physical characteristics (e.g., BET surface area) and often perform better in water treatment. The present invention also includes a method of reactivating activated carbon via conventional processes (i.e. pyrolysis followed by steam) at low dissolved oxygen (DO) concentrations. The third aspect of the present invention is the activation of carbonaceous material comprising of steam treating the carbonaceous material followed by pyrolysis.
| 2
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of PCR methods, and specific primers therefore, as well as their use in the identification of any type of bacteria, and in particular RNA forms of bacteria.
BACKGROUND OF THE INVENTION
[0002] The use of biological fluids for therapeutic human application such as plasmas, albumin, live vaccines, stem cells requires that they are absolutely devoid of bacterial contamination. It has been found that filtering, and possibly other traditional methods, may fail to eliminate all forms of organisms, leading to possible contamination or experimental artifacts.
[0003] It is believed that certain pathologies are associated with bacteria or bacterial forms which are difficult to detect, and which may pass through nano-porous barriers. This leads to possible errors in diagnosis or causation, and which may lead to erroneous treatment and impede prevention.
[0004] See, Hopert, Anne, Uphoff, Cord C., Wirth, Manfred, Hauser, Hansjorg, and Drexler, Hans G., “Specificity and sensitivity of Polymerase Chain Reaction (PCR) in comparison with other methods for the detection of mycoplasma contamination in cell lines”, J. Immunological Methods, 164(1993):91-100, expressly incorporated herein by reference.
[0005] Kajander, E. O., et al., “Comparison of Staphylococci and novel Bacteria-Like Particles from blood”, Zbl. Bakt. Suppl. 26, 1994, expressly incorporated herein by reference.
[0006] Akerman, Kari K., “Scanning Electron Microscopy of Nanobacteria—Novel Biofilm Producing Organisms in Blood”, Scanning Vol. 15, Suppl. III (1993), expressly incorporated herein by reference. www.newcastle.edu.au/discipline/biology/projects/hons_cpru.html, expressly incorporated herein by reference.
[0007] Cifticioglu, Neva, et al., “Apoptotic effect of nanobacteria on cultured mammalian cells”, Mol. Biol. Cell. Suppl., Vol. 7 (1996):517a
[0008] Cifticioglu, Neva, et al., “A new potential threat in antigen and antibody products: Nanobacteria”, Vaccines 97, Brown et al. Ed., Cold Spring Harbor Laboratory Press, New York, 1997, expressly incorporated herein by reference.
[0009] Baseman, Joel B., et al., “ Mycoplasmas: Sophisticated, Reemerging, and Burdened by their Notoriety”, EID Vol. 3, N o 1 www.cdc.gov/ncidod/EID/vol3no1/baseman.htm, expressly incorporated herein by reference.
[0010] Relman, David A., “Detection and Identification of Previously Unrecognized Microbial Pathogens”, EID Vol. 4, N o 3 www.cdc.gov/ncidod/EID/vol4no3/relman.htm, expressly incorporated herein by reference.
[0011] Mattman, Lida H., Cell Wall Deficient Forms-Stealth Pathogens, 2nd Ed., CRC Press (1993), expressly incorporated herein by reference.
[0012] U.S. Pat. No. 5,688,646, expressly incorporated herein by reference, describes novel mycoplasmas which are prominent in patients who are thought to be suffering from AIDS. Devices are also provided for the in vitro detection of mycoplasmas in biological fluid by means of a reagent which is specific for the mycoplasma group without being specific for particular species within said group. Devices for testing mycoplasma sensitivity to antibiotics are also described.
[0013] See the following, each of which and cited references is expressly incorporated herein by reference in their entirety:
Pat. 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polynucleotides polypeptides and their uses 6,348,328 Compounds 6,348,314 Invasive cleavage of nucleic acids 6,346,397 GyrA 6,340,564 yhxB 6,331,411 TopA 6,326,172 ytgP 6,312,932 Yfil pseudouridine synthase 6,309,866 6-phosphogluconate dehydrogenase 6,303,771 Pth 6,294,652 Response regulator 6,294,357 FabF from Staphylococcus aureus 6,287,807 MurF 6,287,804 nrdG 6,277,595 FabZ 6,274,719 Gcp 6,274,361 pth 6,270,762 tdk 6,268,177 Isolated nucleic acid encoding nucleotide pyrophosphorylase 6,261,802 Ups (ugc) 6,261,769 Intergenic spacer target sequence for detecting and distinguishing Chlamydial species or strains 6,255,075 Bira 6,251,631 nadE from Streptococcus pneumoniae 6,251,629 ABC transporter 6,248,721 Method of using mouse model for evaluation of HIV vaccines 6,245,891 nusB polypeptides and polynucleotides and methods thereof 6,245,542 tRNA methyltransferase from Streptococcus pneumoniae 6,238,900 Polynucleotides encoding glutamyltrna synthetase from staphylococcus aureus 6,238,887 Ribosome recycling factor (FRR) of Staphylococcus aureus 6,238,882 GidA1 6,228,625 metK from Streptococcus pneumoniae 6,228,584 DexB 6,210,880 Polymorphism analysis by nucleic acid structure probing with structure-bridging oligonucleotides 6,204,014 DnaB 6,197,549 Ama 6,197,300 ftsZ 6,194,170 MurF of Streptococcus pneumoniae 6,190,881 Ribonucleotide diphosphate reductase, nrdF, of streptococcus pneumoniae 6,168,797 FabF 6,165,992 Histidine kinase 6,165,991 Sensor histidine kinase of Streptococcus pneumoniae 6,165,764 Polynucleotides encoding tRNA methyl transferases from Streptococcus pneumoniae 6,162,619 Sensor histidine kinase of streptococcus pneumoniae 6,162,618 6-phosphogluconate dehydrogenase of Streptococcus pneumoniae 6,156,537 Phospho-N-acetylmuramoyl-pentapeptide transferase of Streptococcus pneumoniae 6,146,863 Staphylococcus aureus 3-hydroxyacyl-CoA dehydrogenase 6,146,846 Primosome protein a of streptococcus pneumoniae 6,140,079 GidB 6,140,061 Response regulator 6,111,074 PyrH of Streptococcus pneumoniae 6,110,723 Yfii pseudouridine synthase 6,110,685 infB 6,090,543 Cleavage of nucleic acids 6,060,294 Alanyl tRNA synthetase from Staphylococcus aureus 6,001,567 Detection of nucleic acid sequences by invader-directed cleavage 5,994,111 Leucyl tRNA synthetase from staphylococcus aureus 5,985,557 Invasive cleavage of nucleic acids 5,882,643 Lep 5,851,764 Human prostate tumor inducing gene-1 and uses thereof 5,843,669 Cleavage of nucleic acid acid using thermostable methoanococcus jannaschii FEN-1 endonucleases 5,843,654 Rapid detection of mutations in the p53 gene 5,795,976 Detection of nucleic acid heteroduplex molecules by denaturing high-performance liquid chromatography and methods for comparative sequencing 5,789,217 DNA encoding asparaginyl tRNA synthetase from staphylococcus aureus 5,786,197 Lep 5,776,750 Alanyl tRNA synthetase polynucleoyides of staphylococcus 5,763,246 DNA encoding arginyl tRNA synthetase from staphylococcus aureus 5,750,387 DNA encoing leucyl TRNA synthetase from staphylococcus aureus 5,688,646 Mycoplasmas -agents for detecting and characterizing mycoplasmas in vitro (See above) 6,562,957 Genomic sequence encoding endoglin and fragments thereof 6,545,140 DNA encoding an avian beta-defensin and uses thereof 6,531,148 Therapeutic agents 6,495,661 DNA encoding the outer membrane protein of Pasteurella multocida 6,475,990 Drugs, foods or drinks with the use of algae-derived physiologically active substances 6,451,601 Transiently immortalized cells for use in gene therapy 6,403,564 Ribavirin-interferon alfa combination therapy for eradicating detectable HCV-RNA in patients having chronic hepatitis C infection 6,399,373 Nucleic acid encoding a retinoblastoma binding protein (RBP-7) and polymorphic markers associated with said nucleic acid 6,368,600 Parasitic helminth cuticlin nucleic acid molecules and uses thereof 6,339,151 Enzyme catalyzed therapeutic agents 6,277,830 5′-amino acid esters of ribavirin and the use of same to treat hepatitis C with interferon 6,258,778 Methods for accelerating bone and cartilage growth and repair 6,248,329 Parasitic helminth cuticlin nucleic acid molecules and uses thereof 6,245,750 Enzyme catalyzed therapeutic agents 6,022,687 Diagnosis of and therapy for hereditary haemorrhagic telangiectasia 6,593,086 Nucleic acid amplification methods 6,583,266 Nucleic acid and amino acid sequences relating to mycobacterium tuberculosis and leprae for diagnostics and therapeutics 6,573,068 Claudin-50 protein 6,569,647 Nucleic acid amplification method: ramification-extension amplification method (RAM) 6,562,611 FEN-1 endonucleases, mixtures and cleavage methods 6,558,953 Grapevine leafroll virus proteins and their uses 6,558,909 Haemobartonella PCR methods and materials 6,558,905 Diagnostics and therapeutics for osteoporosis 6,558,902 Infrared matrix-assisted laser desorption/ionization mass spectrometric analysis of macromolecules 6,555,357 FEN-1 endonuclease, mixtures and cleavage methods 6,548,633 Complementary DNA's encoding proteins with signal peptides 6,531,648 Grain processing method and transgenic plants useful therein 6,524,795 Diagnostics for cardiovascular disorders 6,521,426 Preparation of recombinant adenovirus carrying a rep gene of adeno-associated virus 6,518,020 Haemobartonella PCR methods and materials 6,503,747 Serotype-specific probes for Listeria monocytogenes 6,495,325 Detection and quantification of micro-organisms using amplification and restriction enzyme analysis 6,458,584 Customized oligonucleotide microchips that convert multiple genetic information to simple patterns, are portable and reusable 6,458,535 Detection of nucleic acids by multiple sequential invasive cleavages 02 6,444,876 Acyl CoA: cholesterol acyltransferase related nucleic acid sequences 6,436,399 Nucleic acid encoding the major outer membrane protein of the causative agent of human granulocytic ehrlichiosis and peptides encoded thereby 6,432,649 Methods for detecting Ehrlichia canis and Ehrlichia chaffeensis in vertebrate and invertebrate hosts 6,423,499 PCR primers for detection and identification of plant pathogenic species, subspecies, and strains of acidovorax 6,403,093 Methods to detect granulocytic ehrlichiosis 6,399,307 Methods of quantifying viral load in an animal with a ribonuclease resistant RNA preparation 6,387,617 Catalytic nucleic acid and methods of use 6,372,424 Rapid detection and identification of pathogens 6,348,314 Invasive cleavage of nucleic acids 6,329,138 Method for detection of the antibiotic resistance spectrum of mycobacterium species 6,312,922 Complementary DNAs 6,312,903 Simulataneous detection, identification and differentiation of eubacterial taxa using a hybridization assay 6,306,653 Detection and treatment of breast disease 6,300,091 Herbicide target genes and methods 6,300,072 PCR methods and materials for detecting bartonella species 6,287,779 Detection of fermentation-related microorganisms 6,268,142 Diagnostics and therapeutics for diseases associated with an IL-1 inflammatory haplotype 6,261,773 Reagent for nucleic acid amplification and process for nucleic acid amplification 6,252,130 Production of somatic mosaicism in mammals using a recombinatorial substrate 6,251,607 PCR primers for the rapid and specific detection of Salmonella typhimurium 6,248,519 Detection of fermentation-related microorganisms 6,221,582 Polynucleic acid sequences for use in the detection and differentiation of prokaryotic organisms 6,214,982 Ribonuclease resistant RNA preparation and utilization 6,214,548 Diagnostic methods for Cyclospora 6,194,145 Genus and species-specific identification of Legionella 6,180,339 Nucleic acid probes for the detection and identification of fungi 6,103,468 Rapid two-stage polymerase chain reaction method for detection of lactic acid bacteria in beer 6,090,543 Cleavage of nucleic acids 6,033,858 Detection of transmissible spongiform encephalopathies 6,025,132 Probes targeted to rRNA spacer regions, methods and kits for using said probes, for the detection of respiratory tract pathogens 6,001,567 Detection of nucleic acid sequences by invader-directed cleavage 6,001,564 Species specific and universal DNA probes and amplification primers to rapidly detect and identify common bacterial pathogens and associated antibiotic resistance genes from clinical specimens for routine diagnosis in microbiology laboratories 5,994,066 Species-specific and universal DNA probes and amplification primers to rapidly detect and identify common bacterial pathogens and associated antibiotic resistance genes from clinical specimens for routine diagnosis in microbiology laboratories 5,985,557 Invasive cleavage of nucleic acids 5,976,805 Neisseria gonorrhoeae specific DNA fragment-GC3 5,958,693 Extraction of DNA by boiling cells in an alkaline phenol/guanidine thiocyanate solution 5,948,888 Neural thread protein gene expression and detection of Alzheimer's disease 5,948,634 Neural thread protein gene expression and detection of Alzheimer's disease 5,942,391 Nucleic acid amplification method: ramification-extension amplification method (RAM) 5,939,262 Ribonuclease resistant RNA preparation and utilization 5,922,538 Genetic markers and methods for the detection of Listeria monocytogenes and Listeria spp 5,919,625 Ribonuclease resistant viral RNA standards 5,912,117 Method for diagnosis of lyme disease 5,907,085 Grapevine leafroll virus proteins and their uses 5,876,924 Nucleic acid amplification method hybridization signal amplification method (HSAM) 5,843,669 Cleavage of nucleic acid acid using thermostable methoanococcus jannaschii FEN-1 endonucleases 5,830,670 Neural thread protein gene expression and detection of Alzheimer's disease 5,795,976 Detection of nucleic acid heteroduplex molecules by denaturing high-performance liquid chromatography and methods for comparative sequencing 5,763,169 Nucleic acid probes for the detection and identification of 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SUMMARY OF THE INVENTION
[0014] The present invention allows improved detection of such bacterial contaminants, including unconventional forms such as filtering forms (nanoforms), nanobacteria, and L-forms.
[0015] Its principal applications are the:
Detection of very low levels of mycoplasma contamination of cell lines and biological fluids Identification of latent bacterial infections in various pathologies Detection of live forms passing through filters having a pore size of between 100 and 20 nm Direct detection of RNA-containing subunits of bacteria.
[0020] Different primers have been designed:
[0021] MOLL primers have been designed initially to detect mollicutes ( mycoplasma ) species based on the conserved regions of the 16s ribosomal RNA gene. In fact they can also detect gram positive bacteria
1) Moll Outer Primer (sense) (AAYGGGTGAGTAACACGT), 2) Moll Outer Primer (antisense) (CCCGAGAACGTATTCACCG) 3) Moll Inner Primer (sense) (CTACGGGAGGCAGCAGTA) 4) Moll Inner Primer (antisense) (GTATCTAATCCTRTTTGCTCCCCA)
[0022] BACT primers will detect gram positive and gram negative bacteria. The sequence of MOLL primers is included in the degenerated sequence of the BACT primers.
1) Bact Outer Primer (antisense) (CCCGRGAACGTATTCACSG), 2) Bact Inner Primer (sense) (CTACGGGAGGCWGCAGTRRGGAAT), 3) Bact Inner Primer (antisense) (WGGGTATCTAATCCTRTTTGMTCCCCW)
[0023] The GNEG set of primers is specific of gram negative bacteria. It differs from the Moll 16 out S by a single nucleotide
1) Gneg Outer Primer (sense) (RAYGGGTGAGTAAYGYMT),
[0025] The present invention therefore provides a method for identifying an RNA form of a bacteria, comprising reverse transcribing RNA material; conducting PCR using primers for a first highly conserved genetic sequence generic of the bacteria; conducting nested PCR using primers for a second highly conserved genetic sequence within the first amplified genetic sequence of the bacteria; and identifying the bacteria based on unconserved amplified sequences linked to the conserved sequences.
[0026] It is believed that the Nanoforms are a stable, low metabolic rate form of bacteria, which may be related to pathology, which have characteristic DNA which is generally undetectable by PCR or nested PCR. However, these organisms do have characteristic RNA, and therefore these can be detected by nested RT-PCR. Likewise, because these are now detectable according to the present invention, it is therefore possible to monitor and optimize treatments directed toward clearing these from infected subjects.
[0027] It is believed that Nanoforms are involved in human pathology, and further that these low metabolic organisms are involved in a constellation of chronic human diseases. Further, it is believed that some of these Nanoforms may be subcellular, that is, incomplete, and therefore may require association with other Nanoform, or other organisms or cells, for replication or reconstitution as a complete DNA bacterial form. Preliminary evidence suggests that the genetic material within a single Nanoforms is insufficient to reconstitute the entirety of a related bacterial (DNA) form, and therefore that multiple Nanoforms may be required in order to be self-replicating for the complete organism.
[0028] For example, multiple Nanofoms may infect a single cell, together constituting a complete genome for the associated DNA bacteria. Reverse transcriptase activity, for example, due to retroviruses, endogenous retroviral sequences, DNA pol I activity, etc., may be sufficiently active to generate the bacterial genome.
[0029] These Nanoforms may be biologically associated with retroviruses, such as HIV, which would therefore increase their likelihood of replication, since they would then carry their own reverse transcriptase, and potentially account for replication of sub-cellular fragments. The retroviruses may be passengers within the Nanoforms, and the Nanoforms represent an infectious particle for the virus.
[0030] The present invention reveals that the Nanoforms retain conserved sequences of 16S rRNA, and therefore may be targeted on this basis, for example by tetracycline analog antibiotics, especially administered over extended durations.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Material and Methods
[0000] Oligonucleotide Primers.
[0031] The oligonucleotide primers used were:
1) Moll Outer Primer (sense) (AAYGGGTGAGTAACACGT), 2) Gneg Outer Primer (sense) (RAYGGGTGAGTAAYGYMT), 3) Bact Outer Primer (antisense) (CCCGRGAACGTATTCACSG), 4) Bact Inner Primer (sense) (CTACGGGAGGCWGCAGTRRGGAAT), and 5) Bact Inner Primer (antisense) (WGGGTATCTAATCCTRTTTGMTCCCCW) where R = G or A, S = G or C, W = A or T, M = A or C, and Y = T or C.
[0032] Expected lengths of amplicons are ˜1,200 bp and ˜450 bp with the outer and inner primers, respectively. The primers employed were formulated as equal amounts of each primer within the class identified by the sequence.
[0000] Nucleic Acid Preparation and PCR/RT-PCR.
[0033] Cell line supernatants (400 μl), human plasma (200-400 μl) and human peripheral blood mononuclear cells (PBMC, 3-10 millions cells) were lyzed with 10 mM Tris, pH 7.4, 10 mM EDTA, 150 mM NaCl, 0.4% SDS, and 10 μg Proteinase K at 60° C. for 1 h. Nucleic samples were extracted three times with one volume of phenol/chloroform and one time with chloroform and precipitated by addition of 1/10 volume of 3M sodium acetate and two volumes of ethanol at −60° C. for 1 h. Samples were centrifuged 30 min. and the nucleic acid pellets were washed with 70% cold ethanol and solubilized in 10 mM Tris-HCI, pH 8.0. These preparations were stored at −60° C.
[0034] PCR reaction mix (50 μl) consisted of 5 mM MgCl2, 50 mM Tris, pH 8.0, 15 mM (NH4)2SO4, 10 mM B-Mercaptoethanol, 500 μM dATP, dCTP, dGTP, and DTTP, 0.025% BSA, 1 μM of each outer primer, 1 U Taq polymerase (Roche Molecular biochemicals, Laval, Canada), and 5-10 μl nucleic acid sample. For the first round PCR, the denaturation, annealing, and elongation temperatures and times used were 95° C. for 30 s, 42° C. for 30 s, and 78° C. for 2 m, respectively, for 42 cycles. After the final cycle, the products were kept at 78° C. for 10 m. One μl of the PCR product was subjected to a second round PCR with the set of inner primers. Denaturation, annealing, and elongation temperatures and times used were 95° C. for 30 s, 47° C. for 30 s, and 78° C. for 1 m, respectively, for 42 cycles, followed by a single incubation at 78° C. for 10 m. After the first and second round PCR, 10 μl of PCR product was analyzed by gel electrophoresis using 1.5% agarose, stained with ethidium bromide, visualized under ultraviolet light and photographed. Visible bands with appropriate size were cut and sequenced using the inner primers (DNA Landmarks, St-Jean sur le Richelieu, Canada). Sequence homology search was performed using the BLAST program of the NIH web site.
[0035] Samples negative for the appropriate band by PCR were subjected to a first round RT-PCR followed by a second round PCR. RT-PCR reaction mix (50 μl) consisted of 5 mM MgCl2, 50 mM Tris, pH 8.0, 15 mM (NH4)2SO4, 10 mM B-Mercaptoethanol, 500 μM dATP, dCTP, dGTP, and DTTP, 0.025% BSA, 1 μM of each outer primer, and Titan enzyme mix (Roche Molecular biochemicals, Laval, Canada), and 5 μl nucleic acid sample. The reverse transcription step was performed at 42° C. for 30 m. The first and second rounds PCR were performed as described above.
[0036] The precautions addressed elsewhere (Kwok and Higuchi, 1989) were followed to minimize the risk of false-positive results caused by the carry-over of previously amplified DNA. For example, extraction of nucleic acids and preparation of PCR/RT-PCR mix were performed under a sterile flow bench, only aliquoted reagents and filter tips were used, and negative controls were incorporated into each run.
Results
[0000] All Samples:
[0037] First round PCR/RT-PCR: no detection of expected amplicon (˜1,200 bp).
[0038] Second round PCR (nested-PCR): all amplicon (˜450 bp) sequences related to bacterial 16S ribosomal RNA gene.
[0000] Patients' Lymphocytes (18 Samples):
[0039] No 450 bp amplicon detected by nested-PCR from first round PCR.
[0040] All samples positive (450 bp) by nested-PCR from RT-PCR.
[0041] Therefore, bacteria are in an “RNA state”, and are referred to herein as “Nanoforms”.
[0000] Samples of Patients' Plasma:
[0042] 11 samples/12 positive for 450 bp amplicon by nested-PCR from first round PCR.
Discussion
[0043] Cell wall deficient pathogenic microorganisms, which may be mycoplasma, so-called L-forms, or potentially other types, are difficult to detect. Therefore, their involvement in pathology may be vastly under-reported.
[0044] It has been found, however, that these organisms have a well-conserved RNA sequences, such as the 16S rRNA, even when corresponding DNA or RNA is undetectable by a traditional polymerase chain reaction (PCR) or reverse transcriptase PCR (RT-PCR) method, which may be detected by nested RT-PCR amplification, using primers according to the present invention.
[0045] The present invention therefore provides a sensitive and specific method for detecting bacterial forms, which may be called “Nanoforms”, even when traditional methods fail. This therefore allows diagnosis of pathogens previously unrecognized, and monitoring of treatment thereof.
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A method for identifying an RNA form of a bacteria, comprising reverse transcribing RNA material; conducting PCR using primers for a first highly conserved genetic sequence generic of the bacteria; conducting nested PCR using primers for a second highly conserved genetic sequence within the first genetic sequence of the bacteria; and identifying the bacteria based on unconserved amplified sequences linked to the conserved sequences.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the National Stage of International Application No. PCT/CH02/00725, filed Dec. 27, 2002, which claimed the benefit of Switzerland Application No. 2381/01, filed Dec. 31, 2001 and PCT/CH02/00429, filed Aug. 5, 2002, the contents of which are incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to pyrrolidonecarboxamide derivatives.
BACKGROUND OF THE INVENTION
WO 01/074090 A1 relates to carbazole derivatives whose general formula partially overlaps with the below formula I but does not specifically describe a single compound covered by the below formula I and, furthermore, does not contain any sufficient concrete general pointers in the direction of compounds of the below formula I.
SUMMARY OF THE INVENTION
In particular, the invention relates to pyrrolidone-carboxamides of the formula
in which
R 1 is phenyl which is optionally monosubstituted or disubstituted in the phenyl radical by alkyl, alkoxy, dialkylamino, halogen or trifluoromethyl, benzyl, phenylethyl or α-hydroxyphenylethyl; naphthyl or naphthylmethyl; thienyl-, furyl-, pyridyl-, 1-alkylpyrrolidin-2-yl-, pyrrolidino- or morpholino-alkyl; or cycloalkyl which can optionally possess a fused-on benzene ring; R 2 is a radical of the formula
X is —CH 2 —, —CO—, —O— or —NR 3 —;
R 3 is hydrogen or alkyl;
R 4 is hydrogen or alkoxy;
R 5 is phenyl, heteroalkyl, aryloxy, alkoxy, alkanoyl or —NR 6 R 7 ;
R 6 is hydrogen, alkyl, aralkyl, cycloalkylalkyl or alkoxycarbonylalkyl; and
R 7 is aryl, heteroaryl, alkyl, hydroxyalkyl or acyl;
to pharmaceutically utilizable acid addition salts of basic compounds of the formula I, to pharmaceutically utilizable salts of acid compounds of the formula I with bases, to pharmaceutically utilizable esters of compounds of the formula I which contain hydroxyl or carboxyl groups, and to hydrates or solvates thereof.
Since the pyrrolidonecarboxamides of the formula I contain at least one asymmetric C atom, they can be present as optically pure enantiomers, as mixtures of enantiomers, such as racemates, or, where appropriate, as optically pure diastereomers, as mixtures of diastereomers, as diastereomeric racemates or as mixtures of diastereomeric racemates.
The compounds defined at the outset are novel and are distinguished by possessing valuable pharmacodynamic properties. They inhibit the interaction of the neuro-peptide Y (NPY) with one of the neuropeptide receptor subtypes (NPY-Y5) and are suitable, in particular, for preventing and treating arthritis, diabetes and, especially, eating disturbances and obesity.
The present invention relates to the above compounds as such and as therapeutic active compounds; to processes and intermediates for preparing them; to pharmaceuticals which comprise one of the above compounds; and to the use of the above compounds for preventing and treating arthritis, diabetes and, especially, eating disturbances and obesity or for producing corresponding pharmaceuticals.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the present description, the term “alkyl” denotes, on its own or in combination, a branched or unbranched saturated hydrocarbon radical having from 1 to 8 carbon atoms, preferably having from 1 to 6 carbon atoms and, particularly preferably, having from 1 to 4 carbon atoms. Examples of these radicals are methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, the isomeric pentyls, the isomeric hexyls and the isomeric octyls; methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl and the like are preferred.
The term “cycloalkyl” denotes, on its own or in combination, a saturated cyclic hydrocarbon radical having 3–8 carbon atoms, preferably having from 3 to 6 carbon atoms, which can be substituted, for example by alkyl groups, such as methyl, and which can possess a fused-on benzene ring. Examples of cycloalkyl groups which are optionally substituted by alkyl are cyclopropyl, methylcyclopropyl, dimethylcyclopropyl, cyclobutyl, methylcyclobutyl, cyclopentyl, methylcyclopentyl, cyclohexyl, methylcyclohexyl, dimethylcyclohexyl, cycloheptyl and cyclooctyl; examples of cycloalkyl radicals having a fused-on benzene ring are 1-indanyl, 2-indanyl and the like.
The term “hydroxyalkyl” denotes, on its own or in combination, an alkyl group, as described above, with one or two H atoms, preferably one H atom, being replaced with a hydroxyl group. Examples are hydroxymethyl, hydroxyethyl, hydroxypropyl and the like.
The term “alkoxy” denotes, on its own or in combination, an alkyl radical, as described above, which is linked by way of an oxygen bridge. Examples are methoxy, ethoxy and the like.
The term “alkanoyl” denotes, on its own or in combination, an alkyl group, as described above, which is linked by way of a CO bridge. Examples are acetyl, 3-methylbutyryl, 2,2-dimethylpropionyl and the like.
The term “aryl” denotes, on its own or in combination, a phenyl or naphthyl group, preferably a phenyl group, which can carry up to four, preferably from one to three and particularly preferably one or two, substituents. Examples of such substituents are alkyl, hydroxyalkyl, alkoxy, alkoxyalkyl, nitro, fluoro, bromo, chloro, hydroxy, dialkylamino and the like. Particularly preferred substituents are alkyl and alkoxy. Examples of these aryl groups are phenyl, methylphenyl, dimethylphenyl, ethylphenyl, isopropylphenyl, methoxyphenyl, methoxymethylphenyl, dimethylaminophenyl, phenylaminophenyl and the like.
The term “aralkyl” denotes, on its own or in combination, an alkyl group, as described above, in which at least one H atom is replaced with an aryl group, as described above, in particular with a phenyl or naphthyl group, which can carry one or more substituents, such as alkyl or alkoxy groups. Examples of these aralkyl radicals are benzyl, phenethyl, 2-(3,4-dimethoxyphenyl)ethyl and the like.
The term “heteroaryl” denotes, on its own or in combination, an aromatic monocyclic, bicyclic or tricyclic heterocyclic ring system having from 5 to 10, preferably from 5 to 6, ring members which contains from one to four, preferably from one to two, heteroatoms which are selected, independently of one another, from nitrogen, oxygen and sulphur. Examples of these heteroaryl groups are pyridyl, pyrimidinyl, thiazolyl, thiophenyl, furanyl, tetrazolyl, carbazolyl and the like. These heteroaryl groups can be substituted, expediently monosubstituted, disubstituted or trisubstituted, with suitable substituents primarily being alkyl, alkoxy, amino or aryl groups. Examples are 2-pyridyl, 2-thienyl, 4,6-dimethyl-2-pyrimidinyl and the like.
The term “acyl” denotes, alone or in combination, an alkanoyl group, as described above, or a cycloalkyl, aryl, aralkyl or heteroaryl group, as described above, which is linked by way of a CO bridge. Examples are, as mentioned above, acetyl, 3-methylbutyryl and 2,2-dimethylpropionyl as well as cyclopropanecarbonyl, benzoyl, phenylacetyl, 2-methoxybenzoyl, 4-methoxybenzoyl, 3-fluorobenzoyl, benzo[1,3]dioxole-5-carbonyl, furan-2-carbonyl and the like.
The term “pharmaceutically utilizable salts” relates to those salts which do not impair the biological effect and properties of the free bases or free acids and which are not undesirable biologically or in some other way. The salts are formed from the free bases using inorganic acids, such as hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid and the like, preferably hydrochloric acid, or using organic acids, such as acetic acid, propionic acid, glycolic acid, pyruvic acid, oxalic acid, maleic acid, malonic acid, succinic acid, tartaric acid, salicylic acid, citric acid, benzoic acid, mandelic acid, methanesulfonic acid, p-toluenesulfonic acid and the like. The free acids can form salts with inorganic bases or with organic bases. Preferred salts with inorganic bases are, but not exclusively, sodium salts, potassium salts, lithium salts, ammonium salts, calcium salts, magnesium salts and the like. Preferred salts with organic bases are, but not exclusively, salts with primary, secondary and tertiary amines, substituted amines, including all naturally occurring substituted amines, cyclic amines and basic ion exchange resins, such as isopropylamine, trimethylamine, diethylamine, triethylamine, tripropylamine, ethanolamine, lysine, arginine, N-ethylpiperidine, piperidine, polyamine resins and the like. Compounds of formula I can also be present as zwitterions.
The invention also includes pharmaceutically suitable esters of compounds of the formula I which contain hydroxyl or carboxyl groups. “Pharmaceutically suitable esters” means that, in compounds of the formula I, corresponding functional groups are derivatized to form ester groups such that they are once again retransformed, in vivo, into their active form. On the one hand, COOH groups can be esterified. Examples of suitable esters of this nature are the alkyl esters and aralkyl esters. Preferred esters of this nature are the methyl, ethyl, propyl, butyl and benzyl esters as well as the (R/S)-1-[(isopropoxycarbonyl)oxy]ethyl esters. The ethyl esters and the isomeric butyl esters are particularly preferred. On the other hand, OH groups can be esterified. Examples of these compounds contain physiologically acceptable and metabolically labile ester groups, such as methoxymethyl ester, methylthiomethyl ester and pivaloyloxymethyl ester, and similar ester groups.
Preferred possible meanings for R 1 are phenyl, 4-tolyl, 2,5-dimethylphenyl, 2-isopropylphenyl, 3-methoxyphenyl, 2-methyl-5-methoxyphenyl, benzyl, 2-phenylethyl, 2-(2-pyridyl)ethyl, 2-(2-thienyl)ethyl, 2-indanyl and 2-morpholinoethyl. Other preferred possible meanings for R 1 are cycloheptyl, 2-hydroxy-2-phenylethyl, 2-thienylmethyl, 2-furanylmethyl, 4-chlorobenzyl, 3-fluorophenyl, 2-chlorobenzyl and 2,4-dimethoxybenzyl as well as 2-naphthyl, naphthalen-1-ylmethyl, 4-dimethylaminophenyl, 2-pyrrolidin-1-ylethyl, 1-methylpyrrolidin-2-ylethyl, 4-isopropylphenyl and 3,5-bis-trifluoromethylphenyl.
Particularly preferred possible meanings for R 1 are 2,5-dimethylphenyl, 2-isopropylphenyl and 2-methyl-5-methoxyphenyl.
Preferred possible meanings for R 2 are biphenyl-4-yl, 4-methoxyphenyl, 4-phenoxyphenyl, 4-dimethylaminophenyl, 4-diethylaminophenyl, 4-phenylaminophenyl, 4-[N-ethyl-N-(2-hydroxyethyl)amino]phenyl, 4-(N-ethyl-N-isopropylamino)phenyl, 4-N-(4,6-dimethyl-2-pyrimidinyl)aminophenyl, 4-[N-ethyl-N-(4,6-dimethyl-2-pyrimidinyl)amino]phenyl, 4-[N-methyl-N-(4,6-dimethyl-2-pyrimidinyl)amino]phenyl, 4-acetylphenyl, 9H-fluoren-2-yl, 9-oxo-9H-fluoren-2-yl and 9-ethylcarbazol-3-yl. Other preferred possible meanings for R 2 are 4-(N-ethoxycarbonylmethyl-N-phenylamino)phenyl, 4-(N-ethyl-N-phenylamino)phenyl, 4-(N-methyl-N-phenylaminophenyl, 4-(N-cyclopropylmethyl-N-phenylamino)phenyl, 4-(N-isobutyl-N-phenylamino)phenyl, 4-(2-methoxybenzoylamino)phenyl, 4-(2,2-dimethylpropionylamino)phenyl, 4-(3-methylbutyrylamino)phenyl, 4-(cyclopropanecarbonylamino)phenyl, 4-(3-fluorobenzoylamino)phenyl and 4-[(furan-2-carbonyl)amino]phenyl as well as biphenyl-3-yl, 9H-fluoren-1-yl, 2-methoxydibenzofuran-3-yl, 4-(N-isopropyl-N-phenylamino)phenyl, 4-(N-benzyl-N-phenylamino)phenyl, 4-acetylaminophenyl, 4-benzoylaminophenyl, 4-phenylacetylaminophenyl, 4-[(benzo[1,3]dioxole-5-carbonyl)amino]phenyl and 4-(4-methoxybenzoylamino)phenyl.
Particularly preferred possible meanings of R 2 are 9-ethyl-9H-carbazol-3-yl, 4-[N-ethyl-N-(4,6-dimethyl-2-pyrimidinyl)amino]phenyl, 4-[N-methyl-N-(4,6-dimethyl-2-pyrimidinyl)amino]phenyl, 4-(4,6-dimethyl-2-pyrimidinyl)amino]phenyl, 4-phenylaminophenyl, 4-diethylaminophenyl, 4-(N-ethyl-N-isopropylamino)phenyl, 4-(N-ethoxycarbonylmethyl-N-phenylamino)phenyl, 4-(N-ethyl-N-phenylamino)phenyl, 4-(N-methyl-N-phenylamino)phenyl and 2,4-dimethoxybenzyl.
Representative examples of preferred compounds of formula I are:
rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2-hydroxy-2-phenylethyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(4-Diethylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-(2-thiophen-2-ylethyl)pyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(4-chlorobenzyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-thiophen-2-ylmethylpyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-furan-2-ylmethyl-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Ethylisopropylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-phenethylpyrrolidine-3-carboxamide; rac. Ethyl [(4-{[1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carbonyl]amino}phenyl)phenylamino]acetate; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-cycloheptyl-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[Ethyl-(2-hydroxyethyl)amino]phenyl}-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Ethylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2-chlorobenzyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-phenylpyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]phenyl}-5-oxo-1-p-tolylpyrrolidine-3-carboxamide; rac. N-[4-(Isopropylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Ethylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]phenyl}-5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxamide; rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Methylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Methylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(4-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(3-fluorophenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(4-Phenylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Ethylphenylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-benzyl-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-5-oxo-1-p-tolylpyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-indan-2-yl-5oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]-phenyl}-1-(2-hydroxy-2-phenylethyl)-5-oxo-pyrrolidine-3-carboxamide; rac. N-(Biphenyl-4-yl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Cyclopropylmethylphenylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Isopropylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(4-Phenylaminophenyl)-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]phenyl)-1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]phenyl}-5-oxo-1-m-tolylpyrrolidine-3-carboxamide; rac. N-[4-(Cyclopropylmethylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. Ethyl [(4-([1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carbonyl]amino}phenyl)phenylamino]acetate; rac. N-[4-(Cyclopropylmethylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Ethylphenylamino)phenyl]-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide; and rac. N-[4-(Isobutylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide.
Other representative examples of preferred compounds of formula I are:
rac. N-[4-(2-Methoxybenzoylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(2,2-Dimethylpropionylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2-morpholin-4-ylethyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-p-tolylpyrrolidine-3-carboxamide; and rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2,4-dimethoxybenzyl)-5-oxopyrrolidine-3-carboxamide; as well as rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-1-(4-dimethylaminophenyl)-5-oxopyrrolidine-3-carboxamide; and rac. N-[4-(4,6-Dimethylpyrimidin-2-yl)methylamino-phenyl]-1-(4-dimethylaminophenyl)-5-oxopyrrolidine-3-carboxamide.
Compounds of the formula I can be prepared, according to the invention, by reacting a pyrrolidonecarboxylic acid of the formula III (see scheme below), in which R 1 has the meaning mentioned at the outset, or a reactive derivative thereof, with an amine of the formula IV, in which R 2 has the meaning mentioned at the outset, or a reactive derivative thereof. Any stereoisomeric mixtures, such as racemates, which are obtained can, if desired, be resolved using generally customary methods.
In order to prepare the corresponding pyrrolidone carboxylic acid of the formula III, it is possible, for example, to take the following route, with the substituents and indices given in the following scheme having the meanings mentioned at the outset unless otherwise indicated; this route consists in reacting an amine of the formula II, such as aniline or the like, in a solvent, such as water, dioxane, ethanol or the like, at elevated temperature, with itaconic acid (Buzas et al., Chim Ther 7, 398–403, 1972).
The compounds of the formula I can be prepared by reacting a pyrrolidonecarboxylic acid of the formula III with an amine of the formula IV. For this, the pyrrolidonecarboxylic acid of the formula III is expediently converted, where appropriate in a suitable solvent, such as toluene, into the corresponding acid chloride using a halogenating agent such as SOCl 2 or POCl 3 . This reactive derivative of the pyrrolidonecarboxylic acid of the formula III is then reacted with an amine of the formula IV in a suitable solvent, such as methylene chloride, in the presence of a base, such as triethylamine.
In a process variant, the pyrrolidonecarboxylic acid of the formula III is reacted with an amine of the formula IV in the added presence of a coupling reagent, such as EDC, DCC or BOP, in a solvent, such as DMF, and, where appropriate, in the presence of a base, such as triethylamine.
Compounds of the formula I in which R 2 is a radical of the formula (b), R 5 is —NR 6 R 7 and R 7 is acyl can also be prepared by acylating a corresponding compound in which R 7 is hydrogen, such as rac. N-(4-aminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, for example using acetyl chloride, isovaleryl chloride, cyclopropylcarbonyl chloride, benzoyl chloride, phenylacetyl chloride, 2-methoxybenzoyl chloride, piperonyloyl chloride, pivaloyl chloride, 4-methoxybenzoyl chloride, 3-fluorobenzoyl chloride and the like.
While only some of the pyrrolidonecarboxylic acids of the formula III are known, they can be prepared by methods which are known per se and with which every skilled person is familiar, for example using the abovementioned method (Buzas et al., Chim Ther 7, 398–403, 1972); furthermore, some of the examples which follow contain information regarding the preparation of particular pyrrolidonecarboxylic acids of the formula III.
Some of the amines of the formula IV are also known or can be prepared by methods which are known per se; some of the examples which follow also contain information regarding the preparation of particular amines of the formula IV.
Insofar as the starting compounds of the formulae III and IV, and also the nitro precursors of the compounds of the formula IV, are novel, they also form part of the subject matter of the present invention. Thus, the following compounds of the formula IV and their nitroprecursors, in particular:
ethyl [(4-nitrophenyl)phenylamino]acetate; ethyl [(4-aminophenyl)phenylamino]acetate; cyclopropylmethyl(4-nitrophenyl)phenylamine; N-cyclopropylmethyl-N-phenylphenylene-1,4-diamine; isobutyl(4-nitrophenyl)phenylamine; N-isobutyl-N-phenylphenylene-1,4-diamine; ethyl [(4-nitrophenyl)phenylamino]pentanoate; ethyl [(4-aminophenyl)phenylamino]pentanoate; benzyl(4-nitrophenyl)phenylamine; and N-benzyl-N-phenylphenylene-1,4-diamine;
as well as the following compounds of the formula III:
rac. 1-indan-2-yl-5-oxopyrrolidine-3-carboxylic acid; rac. 1-naphthalen-2-yl-5-oxopyrrolidine-3-carboxylic acid; rac. 1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxylic acid; rac. 5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxylic acid; rac. 1-cycloheptyl-5-oxopyrrolidine-3-carboxylic acid; rac. 1-(2-hydroxy-2-phenylethyl)-5-oxopyrrolidine-3-carboxylic acid; rac. 5-oxo-1-(2-pyrrolidin-1-ylethyl)pyrrolidine-3-carboxylic acid; rac. 1-[2-(1-methylpyrrolidin-2-yl)ethyl]-5-oxopyrrolidine-3-carboxylic acid; and rac. 1-(3-fluorophenyl)-5-oxopyrrolidine-3-carboxylic acid;
are part of the subject matter of the present invention.
As mentioned at the outset, the compounds of the formula I and their pharmaceutically utilizable salts and esters are novel and possess valuable pharmacological properties. In particular, they inhibit the interaction of the neuropeptide Y (NPY) with one of the neuropeptide receptor subtypes (NPY-Y5). NPY is a regulatory, 36-amino acid peptide belonging to the pancreatic polypeptide family. NPY is the most widespread neuropeptide in the central and peripheral nervous systems and has prominent and complex effects on nutrient uptake, anxiety, depression, circadian rhythm, sexual function, reproduction, memory function, migraine, pain, epileptic seizures, blood pressure, cerebral hemorrhages, shock, sleep disturbance, diarrhea, etc.
NPY interacts with a heterogeneous population of at least five NPY receptor subtypes, i.e. Y1–Y5, which activate adenylate cyclase using a G protein. One of the most prominent effects is the induction of nutrient uptake in vertebrates. Recent investigations involving the selective activation and blocking of the individual NPY receptors have shown that it is principally the NPY-Y5 receptor which is responsible for appetite-inducing signals.
Obesity is an important and increasing problem in the industrialized world. Obesity is associated with a variety of diseases such as non-insulin-dependent diabetes (type II diabetes), high blood pressure, coronary diseases of the heart, dyslipidemia etc., and has an influence on the life expectancy and quality of life of the population affected. For this reason, there is a need for pharmaceutical substances which exert an influence on eating habits. The NPY-Y5 receptor is a possible target for a corresponding pharmacological intervention. Using a low molecular weight compound to inhibit this receptor represents an attractive possibility for preventing or treating the above diseases.
Because of their property of inhibiting the interaction of neuropeptide Y with the neuropeptide Y5 receptor subtype, the compounds of the formula I, and their pharmaceutically utilizable salts and esters, are suitable for preventing and treating arthritis, diabetes and, in particular, eating disturbances and obesity.
The valuable pharmacodynamic properties of the novel compounds according to the invention can be demonstrated using the methods which are described below.
Cloning the Mouse NPY-Y5 Receptor cDNAs
The full-length cDNA which contains the mouse NPY-Y5 (mNPY-Y5) receptor coding was amplified from mouse brain cDNA using specific primers, which were custom-made on the basis of published sequences, and employing Pfu DNA polymerase (Stratagene). The amplification product was subcloned into a mammalian expression vector pcDNA3 using EcoRI and XhoI restriction sites. Positive clones were sequenced; one clone, which contained the published sequence, was selected for preparing stable cell clones.
Stable Transfection
Human embryonic kidney 293 (HEK293) cells were transfected with 10 μg of mNPY5 DNA using Lipofectamine reagent (Gibco BRL) in accordance with the manufacturer's instructions. Two days after the transfection, the geneticin selection (1 mg/ml) was initiated and several stable clones were isolated. One of the clones was used for further pharmacological characterization.
Radioligand Competition Binding
Human embryonic kidney cells (HEK293) which express recombinant mouse NPY-Y5 receptors (mNPY-Y5) were disrupted by being frozen/thawed three times in hypotonic Tris buffer (5 mM, pH 7.4, 1 mM MgCl 2 ), after which they were homogenized and centrifuged at 72 000 G for 15 minutes. The precipitate was washed twice with Tris buffer (pH 7.4) containing 25 mM MgCl 2 , 250 mM sucrose, 0.1 mM phenylmethylsulfonyl fluoride and 0.1 mM 1,10-phenanthroline, then resuspended in the same buffer and stored in aliquots at −80° C. The protein was determined by the Lowry method using bovine serum albumin (BSA) as the standard.
The competition binding analysis was carried out in 250 μl of 25 mM Hepes buffer (pH 7.4, 2.5 mM CaCl 2 , 1 mM MgCl 2 , 1% bovine serum albumin and 0.01% sodium azide) which 5 μg of protein, 100 pM 125 I-labeled peptide YY (PYY) and 10 μl of a DMSO solution containing increasing quantities of DMSO solution containing unlabeled test compound. After a one-hour incubation at 22° C., the bound ligand was separated from the unbound ligand by means of filtration through a glass fiber filter. Nonspecific binding was determined in the presence of 1 μM unlabeled PYY. Specific binding is defined as the difference between total binding and nonspecific binding. An IC 50 value is defined as the concentration of the antagonist which displaces 50% of the 125 I-labeled neuropeptide Y. This concentration is determined by linear regression analysis following logit/log transformation of the binding values.
In the above-described test, preferred compounds according to the invention exhibit IC 50 values of less than 1000 nM, while particularly preferred compounds exhibit IC 50 values of less than 100 nM and very particularly preferred compounds exhibit IC 50 values of less than 50 nM.
The results which were obtained in the above-described test using representative compounds of the formula I as test compounds are compiled in the following table.
NPY5
IC 50
Substance
(μM)
rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-
0.003
(2-pyridin-2-ylethyl)pyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2-hydroxy-
0.008
2-phenylethyl)-5-oxopyrrolidine-3-carboxamide
rac. N-(4-Diethylaminophenyl)-1-(2,5-dimethylphenyl)-
0.009
5-oxopyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-(2-thiophen-
0.010
2-ylethyl)pyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(4-chloro-
0.010
benzyl)-5-oxopyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-thiophen-
0.010
2-ylmethylpyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-furan-2-yl-
0.010
methyl-5-oxopyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2-isopropylphenyl)-
0.010
5-oxopyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(5-methoxy-
0.010
2-methylphenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-[4-(Ethylisopropylamino)phenyl]-1-(2,5-dimethylphenyl)-
0.010
5-oxopyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-phenethyl-
0.012
pyrrolidine-3-carboxamide
rac. Ethyl [(4-{[1-(2,5-dimethylphenyl)-5-oxopyrrolidine-
0.013
3-carbonyl]amino}phenyl)phenylamino]acetate
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-cycloheptyl-5-
0.015
oxopyrrolidine-3-carboxamide
rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]-
0.015
phenyl}-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-
3-carboxamide
rac. N-{4-[Ethyl-(2-hydroxyethyl)amino]phenyl}-
0.016
1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-[4-(Ethylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-
0.017
5-oxopyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(3-methoxy-
0.020
phenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2-chloro-
0.020
benzyl)-5-oxopyrrolidine-3-carboxamide
rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-
0.020
1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]-
0.020
phenyl}-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-
3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-phenyl-
0.021
pyrrolidine-3-carboxamide
rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]-
0.022
phenyl}-5-oxo-1-p-tolylpyrrolidine-3-carboxamide
rac. N-[4-(Isopropylphenylamino)phenyl]-1-(2,5-
0.022
dimethylphenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-[4-(Ethylphenylamino)phenyl]-1-(2-isopropylphenyl)-
0.023
5-oxopyrrolidine-3-carboxamide
rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]-
0.024
phenyl}-5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-
3-carboxamide
rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-
0.025
1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-
0.026
1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-
3-carboxamide
rac. N-[4-(Methylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-
0.026
5-oxopyrrolidine-3-carboxamide
rac. N-[4-(Methylphenylamino)phenyl]-1-(2-isopropylphenyl)-
0.020
5-oxopyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(4-isopropylphenyl)-
0.030
5-oxopyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(3-fluoro-
0.030
phenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-(4-Phenylaminophenyl)-1-(2,5-dimethylphenyl)-
0.030
5-oxopyrrolidine-3-carboxamide
rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-
0.030
1-indan-2-yl-5-oxopyrrolidine-3-carboxamide
rac. N-[4-(Ethylphenylamino)phenyl]-1-(5-methoxy-
0.030
2-methylphenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]-
0.031
phenyl}-1-(2-isopropylphenyl)-5-oxopyrrolidine-
3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-benzyl-5-oxopyrrolidine-
0.032
3-carboxamide
rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-
0.032
5-oxo-1-p-tolylpyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-indan-2-yl-
0.032
5-oxopyrrolidine-3-carboxamide
rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]-
0.033
phenyl}-1-(2-hydroxy-2-phenylethyl)-5-oxo-pyrrolidine-
3-carboxamide
rac. N-(Biphenyl-4-yl)-1-(2,5-dimethylphenyl)-5-oxo-
0.034
pyrrolidine-3-carboxamide
rac. N-[4-(Cyclopropylmethylphenylamino)phenyl]-
0.034
1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-[4-(Isopropylphenylamino)phenyl]-1-(2-
0.034
isopropylphenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-(4-Phenylaminophenyl)-1-(2-isopropylphenyl)-
0.041
5-oxopyrrolidine-3-carboxamide
rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]-
0.041
phenyl}-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-
3-carboxamide
rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]-
0.044
phenyl}-1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-(4-Isopropylphenyl)-1-(2,5-dimethylphenyl)-5-
0.045
oxopyrrolidine-3-carboxamide
rac. N-[4-(Cyclopropylmethylphenylamino)phenyl]-1-
0.045
(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]-
0.046
phenyl}-1-(2-isopropylphenyl)-5-oxopyrrolidine-
3-carboxamide
rac. Ethyl [(4-{[1-(5-methoxy-2-methylphenyl)-5-oxo-
0.046
pyrrolidine-3-carbonyl]amino}phenyl)phenylamino]-
acetate
rac. N-[4-(Cyclopropylmethylphenylamino)phenyl]-
0.047
1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide
rac. N-[4-(Ethylphenylamino)phenyl]-1-indan-2-yl-
0.049
5-oxopyrrolidine-3-carboxamide;
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2-morpholin-4-
0.01
ylethyl)-5-oxopyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-p-tolyl-
0.03
pyrrolidine-3-carboxamide
rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2,4-dimethoxybenzyl)-
0.02
5-oxopyrrolidine-3-carboxamide
Methods which are well known and familiar to every skilled person can be used to bring the compounds according to the invention into suitable pharmaceutical forms for administration. Examples of these administration forms are tablets, lacquered tablets, sugar-coated tablets, capsules, solutions for injection, etc. Excipients and auxiliary substances which are suitable for producing these pharmaceutical administration forms are likewise well known and familiar to every skilled person. In addition to one or more compounds according to the invention, these administration forms can also comprise additional pharmacological active compounds.
The attending physician has to adjust the dosage of the compounds according to the invention, or of the administration forms which comprise them, in dependence on the particular requirements of the patient. In general, a daily dose of 0.1–20 mg, preferably 0.5–5 mg, of a compound according to the invention per kg of the patient's body weight ought to be appropriate.
The following examples are intended to clarify the invention without, however, restricting its scope in any way.
EXAMPLE 1
R 1 is Phenyl
20.5 mg (0.1 mmol) of rac. 5-oxo-1-phenylpyrrolidine-3-carboxylic acid (Buzas et al., Chim Ther 7, 398–403, 1972), dissolved in 0.5 ml of methylene chloride/DMF (9:1), were added to solid phase coupling reagents (DCC, loading 1.7 mmol/g). The mixture was shaken for 5 minutes after which 13.6 mg (0.1 mmol) of N,N-dimethyl-p-phenylenediamine, dissolved in 0.5 ml of methylene chloride/DMF (9:1), were added and the mixture was shaken at room temperature overnight. The solid was then filtered off and the filtrate was evaporated; the residue was dissolved in 1 ml of methylene chloride and methylisocyanate polystyrene (1.8 mmol/g) (solid phase scavenger) was then added to the solution, which was shaken at room temperature for 12 hours and then filtered; Tris(2-aminoethyl)amine polystyrene (3.4 mmol/g) was then added to the filtrate, which was shaken at room temperature for 12 hours and then filtered; the filtrate was evaporated. This resulted in 18 mg of colorless rac. N-(4-dimethylaminophenyl)-5-oxo-1-phenylpyrrolidine-3-carboxamide, MS (M+H) 324.3, MS (M−H) 322.5.
EXAMPLE 2
R 1 is Phenyl
The following products were prepared in analogy with example 1 and using the amines which are listed below:
a) from 4-phenoxyaniline, rac. N-(4-phenoxyphenyl)-5-oxo-1-phenylpyrrolidine-3-carboxamide, MS(M+H) 373.3, MS(M−H) 371.4. b) from 2-(3,4-dimethoxyphenyl)ethylamine, rac. N-[2-(3,4-dimethoxyphenyl)ethyl]-5-oxo-1-phenylpyrrolidine-3-carboxamide, MS(M+H) 369.3. c) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-5-oxo-1-phenylpyrrolidine-3-carboxamide, MS(M+H) 430.3, MS(M−H) 428.5. d) from 2-aminofluorene, rac. N-(9H-fluoren-2-yl)-5-oxo-1-phenylpyrrolidine-3-carboxamide, MS(M+H9) 369.3, MS(M−H) 367.4. e) from 3-aminobiphenyl, rac. N-(biphenyl-3-yl)-5-oxo-1-phenylpyrrolidine-3-carboxamide, MS(M+H) 357.2, MS(M−H) 355.4. f) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-5-oxo-1-phenylpyrrolidine-3-carboxamide, MS(M+H) 402.3, MS(M−H) 400.5. g) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-5-oxo-1-phenylpyrrolidine-3-carboxamide, MS(M+H) 416.3, MS(M−H) 414.5. h) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-5-oxo-1-phenylpyrrolidine-3-carboxamide, MS(M+H) 372.2, MS(M−H) 370.5. i) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-5-oxo-1-phenylpyrrolidine-3-carboxamide, MS(M+H) 398.2, MS(M−H) 396.3.
EXAMPLE 3
R 1 is Benzyl
a) The following products were prepared from rac. 1-benzyl-5-oxo-1-pyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-benzyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 444.3, MS(M−H) 442.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-1-benzyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 430.4, MS(M−H) 428.5.
a3) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-benzyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 412.1, MS(M−H) 410.3.
b) The rac. 1-benzyl-5-oxo-1-pyrrolidine-3-carboxylic acid which was required for example 3a was prepared from benzylamine and itaconic acid in analogy with a protocol published by Buzas et al. (Chim Ther 7, 398–403 (1972)).
EXAMPLE 4
R 1 is 2,5-dimethylphenyl
a) The following products were prepared from rac. 1-(2,5-dimethylphenyl)-5-oxo-1-pyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from 4′-aminoacetophenone, rac. N-(4-acetylphenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 351.3, MS(M−H) 349.5.
a2) from 3-aminobiphenyl, rac. N-(biphenyl-3-yl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 385.3, MS(M−H) 383.4.
a3) from 3-amino-2-methoxydibenzofuran, rac. N-(2-methoxydibenzofuran-3-yl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 429.2, MS(M−H) 427.4.
a4) from 2-amino-9-fluorenone, rac. N-(9-oxo-9H-fluoren-2-yl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 411.2, MS(M−H) 409.4.
a5) from 2-aminofluorene, rac. N-(9H-fluoren-2-yl)-1-(2,5-dimethylphenyl)-5-oxopyrrlidine-3-carboxamide, MS(M+H) 397.3, MS(M−H) 395.5.
a6) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 458.4, MS(M−H) 456.5.
a7) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 430.4, MS(M−H) 428.5.
a8) from N-(4-aminophenyl-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 444.4, MS(M−H) 442.5.
a9) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 400.3, MS(M−H) 398.5.
a10) from N,N-dimethyl-p-phenylenediamine, rac. N-(4-dimethylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 352.3, MS(M−H) 350.5.
a11) from p-methoxyaniline, rac. N-(4-methoxyphenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 339.2, MS(M−H) 337.4.
a12) from N-ethyl-N-(2-hydroxyethyl)-p-phenylenediamine, rac. N-{4-[ethyl-(2-hydroxyethyl)amino]phenyl}-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 396.4, MS(M−H) 394.5.
a13) from 4-amino-N-ethyl-N-isopropylaniline, rac. N-[4-(ethylisopropylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 394.4, MS(M−H) 392.5.
a14) from 4-amino-N,N-diethylaniline, rac. N-(4-diethylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 380.4, MS(M−H) 378.5.
a15) from 1-amino-9-fluorene, rac. N-(9H-fluoren-1-yl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 397.3, MS(M−H) 395.5.
a16) from 4-aminobiphenyl, rac. N-(biphenyl-4-yl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 385.3, MS(M−H) 383.4.
a17) from ethyl [(4-aminophenyl)phenylamino]acetate (example 4b2), rac. ethyl [(4-{[1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carbonyl]amino}phenyl)phenylamino]acetate, MS(M+H) 486.4, MS(M−H) 484.5.
a18) from N-cyclopropylmethyl-N-phenylphenylene-1,4-diamine(example 4c2), rac. N-[4-(cyclopropylmethylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 454.15, MS(M−H) 454.5.
a19) from N-isobutyl-N-phenylphenylene-1,4-diamine (example 4d2), rac. N-[4-(isobutylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 456.4, MS(M−H) 454.5.
a20) from N-methyl-N-phenylphenylene-1,4-diamine (example 4e2), rac. N-[4-(methylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 414.3, MS(M−H) 412.5.
a21) from ethyl [(4-aminophenyl)phenylamino]pentanoate (example 4f2), rac. ethyl 5-[(4-{[1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carbonyl]amino}phenyl)phenylamino]pentanoate, MS(M+H) 528.5.
a22) from N-benzyl-N-phenyl-1,4-diamine(example 4g2), rac. N-[4-(benzylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 490.3, MS(M−H) 488.5.
a23) from N-isopropyl-N-phenyl-1,4-diamine(example 4h2), rac. N-[4-(isopropylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 442.4, MS(M−H) 440.5.
a24) from N-ethyl-N-phenyl-1,4-diamine(example 4i2), rac. N-[4-(ethylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 428.4, MS(M−H) 426.5.
b) The rac. 2,5-dimethylphenyl-5-oxo-1-pyrrolidine-3-carboxylic acid which was required for example 4a was prepared in analogy with example 3b) but using 2,5-dimethylaniline in place of benzylamine.
b1) The ethyl [(4-aminophenyl)phenylamino]acetate required in example 4a17) was prepared as follows: 62 mg of sodium hydride dispersion (60%), and then 178 μl of ethyl bromoacetate, were added to a solution of 300 mg of 4-nitrodiphenylamine in 3 ml of DMF. The reaction mixture was stirred at room temperature for 16 hours and then at 50° C. for 4 hours, after which it was cooled down and diluted with 3 ml of toluene; the solution was then filtered. The filtrate was evaporated and the residue was purified by chromatography on silica gel (pentane/toluene). This resulted in 197 mg of pure ethyl [(4-nitrophenyl)phenylamino]acetate.
b2) The 197 mg of ethyl [(4-nitrophenyl)phenylamino]acetate which were obtained as described in example 4b1 were dissolved in 2 ml of methanol after which 20 mg of palladium/charcoal catalyst were added and the mixture was hydrogenated at room temperature for 3 hours. After the reaction mixture had been filtered and the filtrate evaporated, 173 mg of ethyl [(4-aminophenyl)phenylamino]acetate, MS(M+H) 271.1, were obtained.
c1) The cyclopropylmethyl(4-nitrophenyl)phenylamine was prepared in analogy with example 4b1 but using (bromomethyl)cyclopropane in place of ethyl bromoacetate.
c2) The N-cyclopropylmethyl-N-phenylphenylene-1,4-diamine, MS(M+H) 239.3, was prepared in analogy with example 4b2 but using the product from example 4c1.
d1) The isobutyl(4-nitrophenyl)phenylamine was prepared in analogy with example 4b1 but using 3-bromo-2-methylpropane in place of ethyl bromoacetate.
d2) The N-isobutyl-N-phenylphenylene-1,4-diamine, MS(M+H) 241.3, was prepared in analogy with example 4b2 but using the product from example 4d1.
e1) The methyl(4-nitrophenyl)phenylamine was prepared in analogy with example 4b1 but using methyl iodide in place of ethyl bromoacetate.
e2) The N-methyl-N-phenylphenylene-1,4-diamine, MS(M+H) 199.3, was prepared in analogy with example 4b2 but using the product from example 4e1.
f1) The ethyl [(4-nitrophenyl)phenylamino]pentanoate was prepared in analogy with example 4b1 but using ethyl bromopentanoate in place of ethyl bromoacetate.
f2) The ethyl [(4-aminophenyl)phenylamino]pentanoate, MS(M+H) 313.2, was prepared in analogy with example 4b2 but using the product from example 4f1.
g1) The benzyl(4-nitrophenyl)phenylamine was prepared in analogy with example 4b1 but using benzyl bromide in place of ethyl bromoacetate.
g2) The N-benzyl-N-phenylphenylene-1,4-diamine, MS(M+H) 275.3, was prepared in analogy with example 4b2 but using the product from example 4g1.
h1) The isopropyl(4-nitrophenyl)phenylamine was prepared in analogy with example 4b1 but using 2-bromopropane in place of ethyl bromoacetate.
h2) The N-isopropyl-N-phenylphenylene-1,4-diamine, MS(M+H) 227.3, was prepared in analogy with example 4b2 but using the product from example 4h1.
i1) The ethyl(4-nitrophenyl)phenylamine was prepared in analogy with example 4b1 but using bromoethane in place of ethyl bromoacetate.
i2) The N-ethyl-N-phenylphenylene-1,4-diamine, MS(M+H) 213.3, was prepared in analogy with example 4b2 but using the product from example 4i1.
EXAMPLE 5
R 1 is Indan-2-yl
a) The following products were prepared from rac. 1-indan-2-yl-5-oxopyrrolidine-3-carboxylic cid, in analogy with example 1, using the amines which are listed below:
a1) from 3-aminobiphenyl, rac. N-(biphenyl-3-yl)-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 397.3, MS(M−H) 395.5.
a2) from 3-amino-2-methoxydibenzofuran, rac. N-(2-methoxydibenzofuran-3-yl)-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 441.2, MS(M−H) 439.5.
a3) from 2-amino-9-fluorenone, rac. N-(9-oxo-9H-fluoren-2-yl)-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 423.2, MS(M−H) 421.4.
a4) from 2-aminofluorene, rac. N-(9H-fluoren-2-yl)-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 409.3, MS(M−H) 407.5.
a5) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 470.4, MS(M−H) 468.5.
a6) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 442.4, MS(M−H) 440.5.
a7) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 456.3, MS(M−H) 454.5.
a8) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 412.3, MS(M−H) 410.5.
a9) from 1-amino-9-fluorene, rac. N-(9H-fluoren-1-yl)-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 409.3, MS(M−H) 407.5.
a10) from 4-aminobiphenyl, rac. N-(biphenyl-4-yl)-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 397.3, MS(M−H) 395.5.
a11) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 438.4, MS(M−H) 436.3.
a12) from N,N-dimethyl-p-phenylenediamine, rac. N-(4-dimethylaminophenyl)-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 364.3, MS(M−H) 362.1.
a13) from ethyl [(4-aminophenyl)phenylamino]acetate (see example 3a22), rac. ethyl({4-[(1-indan-2-yl-5-oxopyrrolidine-3-carbonyl)amino]phenyl}phenylamino)acetate, MS(M+H) 498.3, MS(M−H) 496.5.
a14) from N-cyclopropylmethyl-N-phenylphenylene-1,4-diamine (see example 3a23), rac. N-[4-(cyclopropylmethylphenylamino)phenyl]-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 466.4, MS(M−H) 464.5.
a15) from N-isobutyl-N-phenylphenylene-1,4-diamine (example 4d2), rac. N-[4-(isobutylphenylamino)phenyl]-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 468.3, MS(M−H) 466.5.
a16) from N-methyl-N-phenylphenylene-1,4-diamine (example 4e2), rac. N-[4-(methylphenylamino)phenyl]-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 426.3, MS(M−H) 424.5.
a17) from ethyl [(4-aminophenyl)phenylamino]pentanoate (example 4f2), rac. ethyl 5-({4-[(1-indan-2-yl-5-oxopyrrolidine-3-carbonyl)amino]phenyl}phenylamino)pentanoate, MS(M+H) 540.4, MS(M−H) 538.5.
a18) from N-benzyl-N-phenylphenylene-1,4-diamine (example 4g2), rac. N-[4-(benzylphenylamino)phenyl]-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 502.3, MS(M−H) 500.5.
a19) from N-isopropyl-N-phenylphenylene-1,4-diamine (example 4h2), rac. N-[4-(isopropylphenylamino)phenyl]-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 454.4, MS(M−H) 452.5.
a20) from N-ethyl-N-phenylphenylene-1,4-diamine (example 4i2), rac. N-[4-(ethylphenylamino)phenyl]-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 440.3, MS(M−H) 438.5.
b) The rac. 1-indan-2-yl-5-oxopyrrolidine-3-carboxylic acid required for example 5a was prepared in analogy with example 3b) but using indan-2-amine in place of benzylamine.
EXAMPLE 6
R 1 is 2-naphthyl
a) The following products were prepared from rac. 1-naphthalen-2-yl-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from 4-phenoxyaniline, rac. N-(4-phenoxyphenyl)-1-naphthalen-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 423.4, MS(M−H) 421.3.
a2) from N,N-dimethyl-p-phenylenediamine, rac. N-(4-dimethylaminophenyl)-1-naphthalen-2-yl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 374.3, MS(M−H) 372.5.
b) The rac. 1-naphthalen-2-yl-5-oxopyrrolidine-3-carboxylic acid required for example 6a was prepared in analogy with example 3b) but using 2-naphthylamine in place of benzylamine.
EXAMPLE 7
R 1 is 2-isopropylphenyl
a) The following products were prepared from rac. 1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 444.4, MS(M−H) 442.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 458.4, MS(M−H) 456.5.
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 472.2, MS(M−H) 470.5.
a4) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 414.3, MS(M−H) 412.5.
a5) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 440′.4, MS(M−H) 438.3.
a6) from ethyl [(4-aminophenyl)phenylamino]acetate (see example 3a22), rac. ethyl [(4-{[1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carbonyl]amino}phenyl)phenylamino]-acetate, MS(M+H) 500.3, MS(M−H) 498.5.
a7) from N-cyclopropylmethyl-N-phenylphenylene-1,4-diamine (see example 3a23), rac. N-[4-(cyclopropylmethylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 468.4, MS(M−H) 466.5.
a8) from N-isobutyl-N-phenylphenylene-1,4-diamine (example 4d2), rac. N-[4-(isobutylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 470.4, MS(M−H) 468.5.
a9) from N-methyl-N-phenylphenylene-1,4-diamine (example 4e2), rac. N-[4-(methylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 428.4, MS(M−H) 426.5.
a10) from ethyl [(4-aminophenyl)phenylamino]pentanoate (example 4f2), rac. ethyl 5-[(4-{([1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carbonyl]amino}phenyl)phenylamino]pentanoate, MS(M+H) 542.4, MS(M−H) 540.6.
a11) from N-benzyl-N-phenylphenylene-1,4-diamine (example 4g2), rac. N-[4-(benzylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 504.3, MS(M−H) 502.5.
a12) from N-isopropyl-N-phenylphenylene-1,4-diamine (example 4h2), rac. N-[4-(isopropylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 456.4, MS(M−H) 454.5.
a13) from N-ethyl-N-phenylphenylene-1,4-diamine (example 4i2), rac. N-[4-(ethylphenylamino)phenyl]1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 442.4, MS(M−H) 440.5.
b) The rac. 1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxylic acid required for example 7a was prepared in analogy with example 3b) but using isopropylamine in place of benzylamine.
EXAMPLE 8
R 1 is 2-phenylethyl
a) The following products were prepared from rac. 5-oxo-1-phenethylpyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from 4-phenoxyaniline, rac. N-(4-phenoxyphenyl)-5-oxo-1-phenethylpyrrolidine-3-carboxamide, MS(M+H) 401.3, MS(M−H) 399.5.
a2) from N,N-dimethyl-p-phenylenediamine, rac. N-(4-dimethylaminophenyl)-5-oxo-1-phenethylpyrrolidine-3-carboxamide, MS(M+H) 352.3, MS(M−H) 350.5.
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-5-oxo-1-phenethylpyrrolidine-3-carboxamide, MS(M+H) 458.4, MS(M−H) 456.5.
a4) from 3-aminobiphenyl, rac. N-(biphenyl-3-yl)-5-oxo-1-phenethylpyrrolidine-3-carboxamide, MS(M+H) 385.2, MS(M−H) 383.4.
a5) from 2-amino-9-fluorenone, rac. N-(9-oxo-9H-fluoren-2-yl)-5-oxo-1-phenethylpyrrolidine-3-carboxamide, MS(M+H) 411.3, MS(M−H) 409.4.
a6) from 2-aminofluorene, rac. N-(9H-fluoren-2-yl)-5-oxo-1-phenethylpyrrolidine-3-carboxamide, MS(M+H) 397.3, MS(M−H) 395.5.
a7) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-5-oxo-1-phenethylpyrrolidine-3-carboxamide, MS(M+H) 430.3, MS(M−H) 428.5.
a8) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-5-oxo-1-phenethylpyrrolidine-3-carboxamide, MS(M+H) 444.3, MS(M−H) 442.5.
a9) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-5-oxo-1-phenethylpyrrolidine-3-carboxamide, MS(M+H) 400.3, MS(M−H) 398.5.
a10) from 4-aminobiphenyl, rac. N-(biphenyl-4-yl)-5-oxo-1-phenethylpyrrolidine-3-carboxamide, MS(M+) 385.4, MS(M−H) 383.4.
a11) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-5-oxo-1-phenethylpyrrolidine-3-carboxamide, MS(M+H) 426.3, MS(M−H) 424.4.
b) The rac. 5-oxo-1-phenethylpyrrolidine-3-carboxylic acid required for example 8a was prepared in analogy with example 3b) but using phenethylamine in place of benzylamine.
EXAMPLE 9
R 1 is 5-methoxy-2-methylphenyl
a) The following compounds were prepared from rac. 1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 446.4, MS(M−H) 444.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 460.4, MS(M−H) 458.5.
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 474.0, MS(M−H) 472.5.
a4) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 416.3, MS(M−H) 414.5.
a5) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 442.6, MS(M−H) 440.3.
a6) from ethyl [(4-aminophenyl)phenylamino]acetate (see example 3a22), rac. ethyl [(4-{[1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carbonyl]amino}phenyl)phenylamino]acetate, MS(M+H) 502.3, MS(M−H) 500.5.
a7) from N-cyclopropylmethyl-N-phenylphenylene-1,4-diamine (see example 3a23), rac. N-[4-(cyclopropylmethylphenylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 470.4, MS(M−H) 468.5.
a8) from N-isobutyl-N-phenylphenylene-1,4-diamine (example 4d2), rac. N-[4-(isobutylphenylamino)phenyl]-1-(5-methoxy-2-methylphenyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 472.3, MS(M−H) 470.5.
a9) from N-methyl-N-phenylphenylene-1,4-diamine (example 4e2), rac. N-[4-(methylphenylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 430.3, MS(M−H) 428.5.
a10) from ethyl [(4-aminophenyl)phenylamino]pentanoate (example 4f2), rac. ethyl 5-[(4-{[1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carbonyl]amino}phenyl)phenylamino]pentanoate, MS(M+H) 544.5, MS(M−H) 542.6.
a11) from N-benzyl-N-phenylphenylene-1,4-diamine (example 4g2), rac. N-[4-(benzylphenylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 506.3, MS(M−H) 504.5.
a12) from N-isopropyl-N-phenylphenylene-1,4-diamine (example 4h2), rac. N-[4-(isopropylphenylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 458.4, MS(M−H) 456.5.
a13) from N-ethyl-N-phenylphenylene-1,4-diamine (example 4i2); rac. N-[4-(ethylphenylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 444.4, MS(M−H) 442.5.
b) The rac. 1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxylic acid required for example 9a was prepared in analogy with example 3b) but using 5-methoxy-2-methylaniline in place of benzylamine.
EXAMPLE 10
R 1 is Morpholinoethyl
a) The following products were prepared from rac. 1-(2-morpholin-4-ylethyl)-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from 2-aminofluorene, rac. N-(9H-fluoren-2-yl)-1-(2-morpholin-4-ylethyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 406.4, MS(M−H) 404.5.
a2) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(2-morpholin-4-ylethyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 467.3, MS(M−H) 4465.5.
a3) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-(2-morpholin-4-ylethyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 435.5, MS(M−H) 433.3.
b) The rac. 1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxylic acid required for example 10a was prepared in analogy with example 3b) but using 4-(2-aminoethyl)morpholine in place of benzylamine.
EXAMPLE 11
R 1 is thien-2-ylethyl
a) The following products were prepared from rac. 5-oxo-1-(2-thiophen-2-ylethyl)pyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-5-oxo-1-(2-thiophen-2-ylethyl)pyrrolidine-3-carboxamide, MS(M+H) 436.3, MS(M−H) 434.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-5-oxo-1-(2-thiophen-2-ylethyl)pyrrolidine-3-carboxamide, MS(M+H) 450.3, MS(M−H) 448.4.
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-5-oxo-1-(2-thiophen-2-ylethyl)pyrrolidine-3-carboxamide, MS(M+H) 464.5, MS(M−H) 462.5.
a4) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-5-oxo-1-(2-thiophen-2-ylethyl)pyrrolidine-3-carboxamide, MS(M+H) 406.2, MS(M−H) 404.4.
a5) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-5-oxo-1-(2-thiophen-2-ylethyl)pyrrolidine-3-carboxamide, MS(M+H) 432.2, MS(M−H) 430.2.
b) The rac. 5-oxo-1-(2-thiophen-2-ylethyl)pyrrolidine-3-carboxylic acid required for example 11a was prepared in analogy with example 3b) but using 2-thiophene-ethylamine in place of benzylamine.
EXAMPLE 12
R 1 is 2-pyridin-2-ylethyl
a) The following products were prepared from rac. 5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxamide, MS(M+H) 431.3, MS(M−H) 429.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxamide, MS(M+H) 445.3, MS(M−H) 443.5.
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxamide, MS(M+H) 459.3, MS(M−H) 457.5.
a4) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxamide, MS(M+H) 401.3, MS(M−H) 399.5.
a5) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxamide, MS(M+H) 427.5, MS(M−H) 425.4.
b) The rac. 5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxylic acid required for example 12a was prepared in analogy with example 3b) but using 2-(2-aminoethyl)pyridine in place of benzylamine.
EXAMPLE 13
R 1 is p-tolyl
a) The following products were prepared from rac. 5-oxo-1-p-tolylpyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-5-oxo-1-p-tolylpyrrolidine-3-carboxamide, MS(M+H) 416.4, MS(M−H) 414.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-5-oxo-1-p-tolylpyrrolidine-3-carboxamide, MS(M+H) 430.4, MS(M−H) 428.4.
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-5-oxo-1-p-tolylpyrrolidine-3-carboxamide, MS(M+H) 444.3, MS(M−H) 442.5.
a4) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-5-oxo-1-p-tolylpyrrolidine-3-carboxamide, MS(M+H) 386.3, MS(M−H) 384.4.
a5) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-5-oxo-1-p-tolylpyrrolidine-3-carboxamide, MS(M+H) 412.1, MS(M−H) 410.3.
b) The rac. 5-oxo-1-p-tolylpyrrolidine-3-carboxylic acid required for example 13a was prepared in analogy with example 3b) but using p-toluidine in place of benzylamine.
EXAMPLE 14
R 1 is m-methoxyphenyl
a) The following products were prepared from rac. 1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 432.2, MS(M−H) 430.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 446.4, MS(M−H) 444.5.
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 460.3, MS(M−H) 458.5.
a4) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 402.2, MS(M−H) 400.4.
a5) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 428.2, MS(M−H) 426.3.
b) The rac. 1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxylic acid required for example 14a was prepared in analogy with example 3b) but using m-anisidine in place of benzylamine.
EXAMPLE 15
R 1 is Cycloheptyl
a) The following products were prepared from rac. 1-cycloheptyl-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-1-cycloheptyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 422.5, MS(M−H) 420.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-1-cycloheptyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 436.6, MS(M−H) 434.0.
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-cycloheptyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 450.6, MS(M−H) 448.6.
a4) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-1-cycloheptyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 392.4, MS(M−H) 390.5.
a5) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-cycloheptyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 418.5, MS(M−H) 426.3.
b) The rac. 1-cycloheptyl-5-oxopyrrolidine-3-carboxylic acid required for example 15a was prepared in analogy with example 3b) but using cycloheptylamine in place of benzylamine; MS(M+H) 226.1, MS(M−H) 224.1.
EXAMPLE 16
R 1 is naphthalen-1-ylmethyl
a) The following products were prepared from rac. 1-naphthalen-1-ylmethyl-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-1-naphthalen-1-ylmethyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 466.3, MS(M−H) 464.3.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-1-naphthalen-1-ylmethyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 480.4, MS(M−H) 478.5
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-naphthalen-1-ylmethyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 494.4, MS(M−H) 492.5.
b) The rac. 1-naphthalen-1-ylmethyl-5-oxopyrrolidine-3-carboxylic acid required for example 16a was prepared in analogy with example 3b) but using 1-naphlyl-methylamine in place of benzylamine; MS(M+H) 270.1, MS(M−H) 268.1.
EXAMPLE 18
R 1 is 2-hydroxy-2-phenylethyl
a) The following products were prepared from rac. 1-(2-hydroxy-2-phenylethyl)-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-1-(2-hydroxy-2-phenylethyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 446.4, MS(M−H) 444.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(2-hydroxy-2-phenylethyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 460.6, MS(M−H) 458.5.
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(2-hydroxy-2-phenylethyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 475.6, MS(M−H) 472.5.
a4) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-1-(2-hydroxy-2-phenylethyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 416.3, MS(M−H) 414.5.
a5) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-(2-hydroxy-2-phenylethyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 442.6, MS(M−H) 440.3.
b) The rac. 1-(2-hydroxy-2-phenylethyl)-5-oxopyrrolidine-3-carboxylic acid required for example 18a was prepared in analogy with example 3b) but using 2-hydroxy-2-phenylethylamine in place of benzylamine; MS(M+H) 250.1, MS(M−H) 248.1.
EXAMPLE 18
R 1 is m-tolyl
a) The following products were prepared from rac. 5-oxo-1-m-tolylpyrrolidine-3-carboxylic acid, in analogy with example 1, using the amines which are listed below:
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-5-oxo-1-m-tolylpyrrolidine-3-carboxamide, MS(M+H) 416.3, MS(M−H) 414.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-5-oxo-1-m-tolylpyrrolidine-3-carboxamide, MS(M+H) 430, MS(M−H) 428.5.
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-5-oxo-1-m-tolylpyrrolidine-3-carboxamide, MS(M+H) 444.6, MS(M−H) 442.5.
a4) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-5-oxo-1-N-tolylpyrrolidine-3-carboxamide, MS(M+H) 386.3, MS(M−H) 384.5.
b) The rac. 5-oxo-1-m-tolylpyrrolidine-3-carboxylic acid required for example 18a was prepared in analogy with example 3b) but using m-toluidine in place of benzylamine; MS(M+H) 220.1, MS(M−H) 218.1.
EXAMPLE 19
R 1 is 2-thienylmethyl
a) The following product was prepared from rac. 5-oxo-1-(2-thienylmethyl)pyrrolidine-3-carboxylic acid (Maybridge), in analogy with example 1, using the amine which is listed below:
a1) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-5-oxo-1-thiophen-2-ylmethylpyrrolidine-3-carboxamide, MS(M+H) 418.1, MS(M−H) 416.2.
EXAMPLE 20
R 1 is 2-furylmethyl
a) The following products were prepared from rac. 1-(2-furylmethyl)-5-oxopyrrolidine-3-carboxylic acid (Maybridge), in analogy with example 1 using the amines which are listed below:
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-1-furan-2-ylmethyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 406.3, MS(M−H) 404.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-1-furan-2-ylmethyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 420.5, MS(M−H) 418.5.
a3) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-furan-2-ylmethyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 434.6, MS(M−H) 432.5.
a4) from N-phenyl-1,4-phenylenediamine, rac. N-(4-phenylaminophenyl)-1-furan-2-ylmethyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 376.3, MS(M−H) 474.5.
a5) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-furan-2-ylmethyl-5-oxopyrrolidine-3-carboxamide, MS(M+H) 401.9, MS(M−H) 400.1.
EXAMPLE 21
R 1 is p-chlorobenzyl
a) The following product was prepared from rac. 1-(4-chlorobenzyl)-5-oxopyrrolidine-3-carboxylic acid (Maybridge), in analogy with example 1, using the amine which is listed below:
a1) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-(4-chlorobenzyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 446.1, MS(M−H) 444.1.
EXAMPLE 22
R 1 is p-dimethylaminophenyl
a) In analogy with example 1, and using suitable amines, rac. 1-(4-dimethylaminophenyl)-5-oxopyrrolidine-3-carboxylic acid can be converted into products of the formula I.
a1) from N-(4-aminophenyl)-4,6-dimethyl-2-pyrimidineamine, rac. N-[4-(4,6-dimethylpyrimidin-2-ylamino)phenyl]-1-(4-dimethylaminophenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 445.2, MS(M−H) 443.5.
a2) from N-(4-aminophenyl)-N-methyl-4,6-dimethyl-2-pyrimidineamine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(4-dimethylaminophenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 459.4, MS(M−H) 457.5.
b) The rac. 1-(4-dimethylaminophenyl)-5-oxopyrrolidine-3-carboxylic acid required for example 22a was prepared in analogy with example 3b but using N,N-dimethyl-p-phenylenediamine in place of benzylamine; MS(M+H) 249.1, MS(M−H) 247.1.
EXAMPLE 23
R 1 is 2-pyrrolidin-1-ylethyl
a) The following product was prepared from rac. 5-oxo-1-(2-pyrrolidin-1-ylethyl)pyrrolidine-3-carboxylic acid, in analogy with example 1, using the amine which is listed below:
a1) from N-(4-aminophenyl)-N-ethyl-4,6-dimethyl-2-pyrimidine, rac. N-{4-[(4,6-dimethylpyrimidin-2-yl)ethylamino]phenyl}-5-oxo-1-(2-pyrrolidin-1-ylethyl)pyrrolidine-3-carboxamide, MS(M+H) 451.2, MS(M−H) 449.3.
b) The rac. 5-oxo-1-(2-pyrrolidin-1-ylethyl)pyrrolidine-3-carboxylic acid required for example 23a was prepared in analogy with example 3b) but using 1-(2-aminoethyl)pyrrolidine in place of benzylamine; MS(M+H) 227.1, MS(M−H) 225.1.
EXAMPLE 24
R 1 is 1-methylpyrrolidin-2-ylethyl
a) The following product was prepared from rac. 1-[2-(1-methylpyrrolidin-2-yl)ethyl]-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amine which is listed below:
a1) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-[2-(1-methylpyrrolidin-2-yl)ethyl]-5-oxopyrrolidine-3-carboxamide, MS(M+H) 433.4, MS(M−H) 431.3.
b) The rac. 1-[2-(1-methylpyrrolidin-2-yl)ethyl]-5-oxopyrrolidine-3-carboxylic acid required for example 24a was prepared in analogy with example 3b) but using 2-(2-aminoethyl)-1-methylpyrrolidine in place of benzylamine; MS(M+H) 241.2, MS(M−H) 239.1.
EXAMPLE 25
R 1 is 4-isopropylphenyl
a) The following product was prepared from rac. 1-(4-isopropylphenyl)-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amine which is listed below:
a1) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-(4-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 440.4, MS(M−H) 438.3.
b) The rac. 1-(4-isopropylphenyl)-5-oxopyrrolidine-3-carboxylic acid required for example 25a was prepared in analogy with example 3b) but using 4-isopropylaniline in place of benzylamine; MS(M+H) 248.1, MS(M−H) 246.1.
EXAMPLE 26
R 1 is 3,5-bis-(trifluoromethyl)-phenyl
a) The following product was prepared from rac. 1-(3,5-bis-(trifluoromethyl)-phenyl)-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amine which is listed below:
a1) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-(3,5-bistrifluoromethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 534.4.
§
b) The rac. 1-(3,5-bistrifluoromethylphenyl)-5-oxopyrrolidine-3-carboxylic acid required for example 26a was prepared in analogy with example 3b) but using 3,5-bis(trifluoromethyl)aniline in place of benzylamine.
EXAMPLE 27
R 1 is 3-fluorophenyl
a) The following product was prepared from rac. 1-(3-fluorophenyl)-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amine which is listed below:
a1) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-(3-fluorophenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 416.1, MS(M−H) 414.2.
b) The rac. 1-(3-fluorophenyl)-5-oxopyrrolidine-3-carboxylic acid required for example 27a was prepared in analogy with example 3b) but using 3-fluoroaniline in place of benzylamine; MS(M+H) 224.2, MS(M−H) 222.1.
EXAMPLE 28
R 1 is 2-chlorobenzyl
a) The following product was prepared from rac. 1-(2-chlorobenzyl)-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using the amine which is listed below:
a1) from 3-amino-9-ethylcarbazole, rac. N-(9-ethyl-9H-carbazol-3-yl)-1-(2-chlorobenzyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 446.2, MS(M−H) 444.2.
b) The rac. 1-(2-chlorobenzyl)-5-oxopyrrolidine-3-carboxylic acid required for example 28a was prepared in analogy with example 3b) but using 2-chlorobenzylamine in place of benzylamine; MS(M+H) 254.1, MS(M−H) 252.1.
EXAMPLE 29
Enantiomerically Pure Compounds
The rac. N-(9-ethyl-9H-carbazol-3-yl)-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide prepared as described in example 7a5) can be resolved into the two enantiomers
(a) (R)-N-(9-ethyl-9H-carbazol-3-yl)-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; and (b) (S)-N-(9-ethyl-9H-carbazol-3-yl)-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide
by means of HPLC on a LichroCART (R,R) Whelk-01 column using a solvent gradient (n-hexane+0.5% acetic acid/isopropanol+0.5% acetic acid).
EXAMPLE 30
Enantiomerically Pure Compounds
The following racemic compounds can be resolved into the corresponding enantiomers in analogy with example 29:
rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2-hydroxy-2-phenylethyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(4-Diethylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-(2-thiophen-2-ylethyl)pyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(4-chlorobenzyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-thiophen-2-ylmethylpyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-furan-2-ylmethyl-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Ethylisopropylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-phenethylpyrrolidine-3-carboxamide; rac. Ethyl [(4-{[1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carbonyl]amino}phenyl)phenylamino]acetate; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-cycloheptyl-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[Ethyl-(2-hydroxyethyl)amino]phenyl}-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Ethylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2-chlorobenzyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-phenyl-pyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]phenyl}-5-oxo-1-p-tolylpyrrolidine-3-carboxamide; rac. N-[4-(Isopropylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Ethylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]phenyl}-5-oxo-1-(2-pyridin-2-ylethyl)pyrrolidine-3-carboxamide; rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Methylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Methylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(4-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(3-fluorophenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(4-Phenylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Ethylphenylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-benzyl-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-5-oxo-1-p-tolylpyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(2-hydroxy-2-phenylethyl)-5-oxo-pyrrolidine-3-carboxamide; rac. N-(Biphenyl-4-yl)-1-(2,5-dimethylphenyl)-5-oxo-pyrrolidine-3-carboxamide; rac. N-[4-(Cyclopropylmethylphenylamino)phenyl]-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Isopropylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(4-Phenylaminophenyl)-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]phenyl}-1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(3-methoxyphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)methylamino]phenyl}-5-oxo-1-m-tolylpyrrolidine-3-carboxamide; rac. N-[4-(Cyclopropylmethylphenylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(4,6-Dimethylpyrimidin-2-yl)ethylamino]phenyl}-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. Ethyl [(4-{[1-(5-methoxy-2-methylphenyl)-5-oxopyrrolidine-3-carbonyl]amino}phenyl)phenylamino]acetate; rac. N-[4-(Cyclopropylmethylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; and rac. N-[4-(Ethylphenylamino)phenyl]-1-indan-2-yl-5-oxopyrrolidine-3-carboxamide.
EXAMPLE 31
R 1 is 2,5-dimethylphenyl
a) 29 μl of Hünig's base and 1 equivalent of the acid chloride listed below were added to a solution of 50 mg of rac. N-(4-aminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide in 0.5 ml of methylene chloride. The reaction mixture was stirred overnight at room temperature and then evaporated and the residue was chromatographed on silica gel using ethyl acetate/ethanol (8:2). The evaporated product fractions in each case yielded approx. 30 mg of product. This method was used to prepare the following compounds:
a1) with acetyl chloride, rac. N-(4-acetylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 366.3, MS(M−H) 364.4.
a2) with isovaleryl chloride, rac. N-[4-(3-methylbutyrylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 408.3, MS(M−H) 406.4.
a3) with cyclopropylcarbonyl chloride, rac. N-[4-(cyclopropanecarbonylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 392.3, MS(M−H) 390.4.
a4) with benzoyl chloride, rac. N-(4-benzoylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 428.3, MS(M−H) 426.4.
a5) with phenylacetyl chloride, rac. N-(4-phenylacetylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 442.4, MS(M−H) 440.5.
a6) with 2-methoxybenzoyl chloride, rac. N-[4-(2-methoxybenzoylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 458.2, MS(M−H)-456.5.
a7) with piperonyloyl chloride, rac. N-{4-[(benzo-[1,3]dioxole-5-carbonyl)amino]phenyl}-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 472.3, MS(M−H) 470.5.
a8) with pivaloyl chloride, rac. N-[4-(2,2-dimethylpropionylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 408.3, MS(M−H) 406.4.
a9) with 4-methoxybenzoyl chloride, rac. N-[4-(4-methoxybenzoylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 458.2, MS(M−H) 456.4.
a10) with 3-fluorobenzoyl chloride, rac. N-[4-(3-fluorobenzoylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 446.3, MS(M−H) 444.4.
a11) with 2-furoyl chloride, rac. N-{4-[(furan-2-carbonyl)amino]phenyl}-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 418.4, MS(M−H) 416.4.
b) The rac. N-(4-aminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide required in example 31a) was prepared as follows:
b1) 1.18 g of p-nitroaniline, 1.95 g of N-(3-dimethylaminopropyl)-N′-ethylcarbodiimide hydrochloride (EDC HCl), 2.22 ml of Hünig's base and 1.04 g of 4-(N,N-dimethylamino)pyridine were added consecutively to a solution of 2 g of 1-(2,5-dimethylphenyl)-5-oxo-1-pyrrolidine-3-carboxylic acid (example 4b) in 28 ml of methylene chloride. The reaction mixture was stirred at 40° C. for 3 hours and then taken up in ethyl acetate and washed with water until neutral. The organic phase was evaporated and this resulted in 2.5 g of rac. N-(4-nitrophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 354.1, MS(M−H) 352.3.
b2) The 2.5 g of rac. N-(4-nitrophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide which were obtained as described in example 31b1) were dissolved in 70 ml of methanol and 70 ml of methylene chloride after which 0.5 g of palladium/charcoal catalyst was added and the mixture was hydrogenated overnight at room temperature. After the reaction mixture had been filtered and the filtrate evaporated, 2.3 g of rac. N-(4-aminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide, MS(M+H) 324.3, MS(M−H) 322.4, were obtained.
EXAMPLE 32
Enantiomerically Pure Compounds
The following racemic compounds can be resolved into the corresponding enantiomers in analogy with example 29:
rac. N-(4-Acetylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(3-Methylbutyrylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(Cyclopropanecarbonylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(4-Benzoylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(4-Phenylacetylaminophenyl)-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(2-Methoxybenzoylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(Benzo[1,3]dioxole-5-carbonyl)amino]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(2,2-Dimethylpropionylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(4-Methoxybenzoylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(3-Fluorobenzoylamino)phenyl]-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-{4-[(Furan-2-carbonyl)amino]phenyl}-1-(2,5-dimethylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2-morpholin-4-ylethyl)-5-oxopyrrolidine-3-carboxamide; rac. N-(9-Ethyl-9H-carbazol-3-yl)-5-oxo-1-p-tolylpyrrolidine-3-carboxamide; and rac. N-(9-Ethyl-9H-carbazol-3-yl)-1-(2,4-dimethoxybenzyl)-5-oxopyrrolidine-3-carboxamide.
EXAMPLE 33
Enantiomerically Pure Compounds
The following racemic compounds can be resolved into the corresponding enantiomers in analogy with example 29:
rac. N-[4-(Isobutylphenylamino)phenyl]-1-(2-isopropylphenyl)-5-oxopyrrolidine-3-carboxamide; rac. N-[4-(4,6-Dimethylpyrimidin-2-ylamino)phenyl]-1-(4-dimethylaminophenyl)-5-oxopyrrolidine-3-carboxamide; and rac. N-[4-(4,6-Dimethylpyrimidin-2-yl)methylaminophenyl]-1-(4-dimethylaminophenyl)-5-oxopyrrolidine-3-carboxamide.
EXAMPLE 34
R 1 is 2,4-dimethoxybenzyl
a) rac. N-(9-Ethyl-9H-carbazole-3-yl)-1-(2,4-dimethoxybenzyl)-5-oxopyrrolidine-3-carboxamide was prepared from rac. 1-(2,4-dimethoxybenzyl)-5-oxopyrrolidine-3-carboxylic acid, in analogy with example 1, using 3-amino-9-ethylcarbazole; MS(M+H) 472.4, MS(M−H) 470.2.
b) The 1-(2,4-dimethoxybenzyl)-5-oxopyrrolidine-3-carboxylic acid required for example 34a was prepared in analogy with example 3b) but using 2,4-dimethoxybenzylamine; MS(M+H) 280.1, MS(M−H) 278.1.
EXAMPLE A
A compound of the formula I can be used, in a manner known per se, as the active compound for producing tablets of the following composition:
Per tablet
Active compound
200 mg
Microcrystalline cellulose
155 mg
Corn starch
25 mg
Talc
25 mg
Hydroxypropylmethyl cellulose
20 mg
425 mg
EXAMPLE B
A compound of the formula I can be used, in a manner known per se, as the active compound for producing capsules of the following composition:
Per capsule
Active compound
100 mg
Corn starch
20 mg
Lactose
95 mg
Talc
4.5 mg
Magnesium stearate
0.5 mg
220.0 mg
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Pyrrolidone carboxamides of formula (I) where R 2 =a group of formula (a) or (b), R 5 =phenyl, heteroalkyl, aryloxy, alkoxy, alkanoyl or —NR 6 R 7 and R 1 , X, R 3 , R 4 , R 6 and R 7 have the meanings given in the description and the claims, pharmaceutically applicable acid addition salts with basic compounds of formula (I), pharmaceutically applicable salts of acid compounds of formula (I) with bases, pharmaceutically applicable esters of hydroxy- or carboxy-group containing compounds of formula (I) and hydrates and solvates thereof, inhibit the interaction of neuropeptide Y (NPY) with one of the neuropeptide receptor subtypes (NPY-Y5) and are particularly suitable for the prevention and treatment of arthritis, diabetes and especially eating disorders and obesity. The above can be produced by known methods and converted into a galenic dosage form.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a powertrain for a hybrid electric vehicle (HEV), and in particular to controlling torque transmitted by the output of the powertrain to the vehicle wheels while executing a gear shift.
2. Description of the Prior Art
In a conventional vehicle with a fixed-ratio transmission, the driver can experience driveline disturbances during a transmission shift event, i.e., an upshift or a downshift. The driveline disturbances occur due to the acceleration and deceleration of engine and transmission components, which acceleration and deceleration produce an inertial torque during the shift event. In the case of an upshift, the transmission output torque increases during the ratio change phase, i.e., inertia phase, of the shift as a result of the engine speed changing, as shown in FIG. 1 at point 12 . This output torque disturbance is felt by the vehicle's occupants and severely degrades shift quality.
The magnitude of the output shaft torque disturbance increases the faster the upshift is performed, since the magnitude of engine deceleration is greater. By reducing engine torque produced during the upshift, as shown at point 14 , the inertial torque can be offset and the output shaft torque increase can be minimized, as shown at point 16 , thereby improving the quality of the shift. This method described with reference to FIG. 1 is referred to as “input torque modulation” control.
In the case of a downshift, the transmission output torque decreases during the ratio change phase as the engine and transmission components accelerate to the synchronous speed for the lower gear, as shown in FIG. 2 at point 18 . Moreover, as shown at point 20 during the torque transfer phase, the transmission output torque can spike near the completion of the downshift as the engine accelerates. The drop in output torque during the ratio change phase is felt by vehicle's occupants and can give the sense of an acceleration discontinuity as the downshift is performed. The output torque spike at the end of the downshift can degrade shift quality and give the occupants a feeling of a harsh or rough shift. Furthermore, the magnitude of output shaft torque drop and spike near the end of the downshift increases in proportion to speed of the downshift. By using input torque modulation, the engine combustion torque is reduced near the end of the downshift, as shown at point 22 , in order to reduce the engine's acceleration as the shift ends. As a result, the transmission output torque spike can be minimized and avoided, as shown at point 24 , thereby reducing the shift disturbance.
In conventional vehicle applications, the problems that can occur with input torque modulation during shifts include limited engine torque reduction authority due to other constraints such as emissions, delayed or poor engine torque response to torque modulation requests, further degrading shift quality; and wasted fuel energy and efficiency since spark retardation is commonly used for achieving torque modulation requests.
SUMMARY OF THE INVENTION
In a powertrain for motor vehicle that includes an engine, an electric machine, a transmission having an input driveably connected to the engine and a transmission output driveably connected to the electric machine, and a powertrain output driveably connected to the electric machine and wheels of the vehicle, a method for controlling torque during a shift includes transmitting engine torque through the transmission to the powertrain output; during a shift, operating the electric machine to modify the torque transmitted to the powertrain output; and storing energy generated by the electric machine during the shift.
Excess transmission output torque is converted into electrical energy that is stored by a battery while achieving the requested torque modulation and providing optimum shift quality.
Delays in crankshaft torque reduction are avoided by taking advantage of the electric machine's responsiveness, which produces an accurate magnitude of torque modulation.
In some cases, the electric machine and engine both reduce the total driveline output torque shift disturbance to meet the requested torque modulation level. This is useful in the case where the electric machine may not be fully available or the battery state of charge is near the maximum limit.
The scope of applicability of the preferred embodiment will become apparent from the following detailed description, claims and drawings. It should be understood, that the description and specific examples, although indicating preferred embodiments of the invention, are given by way of illustration only. Various changes and modifications to the described embodiments and examples will become apparent to those skilled in the art.
DESCRIPTION OF THE DRAWINGS
The invention will be more readily understood by reference to the following description, taken with the accompanying drawings, in which:
FIG. 1 is a graph that illustrates the variation of transmission output shaft torque, gear ratio and engine torque during an upshift with input torque modulation in a conventional vehicle driveline;
FIG. 2 is a graph that illustrates the variation of transmission output shaft torque, gear ratio and engine torque during an downshift with input torque modulation in a conventional vehicle driveline;
FIG. 3 is a schematic diagram of a powertrain for a RWD HEV;
FIG. 4 is a schematic diagram showing propulsion and power flow in the HEV powertrain of FIG. 3 ;
FIG. 5 is a schematic diagram showing vectors representing torque transmission among components of the powertrain operating in mode A;
FIG. 6 is a schematic diagram showing vectors representing torque transmission among components of the powertrain operating in mode B;
FIG. 7 is a schematic diagram showing vectors representing torque transmission among components of the powertrain operating in mode D;
FIGS. 8A-8D illustrate the change of powertrain variables during a transmission upshift performed with output torque modulation;
FIGS. 9A-9D illustrate the change of powertrain variables during a transmission downshift performed with output torque modulation;
FIG. 10 is a logic flow diagram of an algorithm for selecting the operating mode of the powertrain of FIG. 3 during output torque modulation control; and
FIG. 11 is a logic flow diagram of an algorithm for providing output torque modulation transmission control in the HEV powertrain of FIG. 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 3 illustrates a powertrain 26 for a hybrid electric vehicle that includes an internal combustion engine (ICE) 28 , preferably an Atkinson cycle ICE; a first electric machine 30 , preferably a crank integrated starter generator (CISG) driveably connected to the engine crankshaft 32 and able to function alternately as a motor and a generator; a fixed-ratio automatic transmission 34 , a second electric machine 38 such as an electric rear axle drive (ERAD) or electric front axle drive (EFAD) driveably connected to transmission output shaft 36 and able to function alternately as a motor and a generator; adriveline output shaft 40 , driveably connected to the second electric machine 38 ; a differential mechanism 42 ; and wheels 44 , 45 , driveably connected to the differential 42 .
During a transmission shift event, the electric machine 38 that is coupled to the transmission output can be controlled to achieve accurately the transmission torque modulation request and reduce the driveline output torque shift disturbance at 40 . By using the electric machines 30 , 38 and the powertrain 26 , torque disturbances on transmission output shaft 36 can be reduced and optimum shift quality can be achieved. Other configurations including RWD, FWD, or AWD full or mild HEV with at least one electric machine at the transmission output are also applicable. Furthermore, this concept is not limited to any particular transmission technology and includes conventional automatic, dual clutch (i.e. powershift), and converterless automatic transmissions.
FIG. 4 illustrates the power and energy flow in the powertrain 26 . Power produced by engine 28 and power produced by CISG 30 are combined at 50 and transmitted to the transmission input 52 . Electric power produced by both electric machines 30 , 38 is combinable at 54 for charging the battery 56 , or is transmitted from the battery to the electric machines 30 , 38 . Mechanical power produced by ERAD 38 is transmitted through ERAD gearing 58 to the load at the wheels 44 , 45 through the rear final drive 42 .
The RWD-HEV CISG/ERAD platform shown in FIG. 3 preferably incorporates an Atkinson cycle (4.6 L, 3V) internal combustion engine, a fixed ratio, six-speed automatic transmission and two electric machines. The first electric machine 30 (CISG) is integrated at the output 32 of the engine 28 and is connected to the impeller 60 of a torque converter transmission, thus providing starter/generator capability. The second electric machine 38 (ERAD) is coupled to the output 36 of the transmission 34 through a planetary gear set 58 , which is connected to the final drive, thus providing additional propulsion capability in either an electric drive or hybrid drive mode.
Major operating modes for this powertrain configuration include (1) electric drive with ERAD motoring/generating); series hybrid drive with engine running, CISG generating and ERAD motoring/generating); engine drive with CISG & ERAD shutdown and conventional drive; parallel hybrid drive with engine running and CISG and ERAD motoring; engine starting with CISG motoring to start engine and the engine cranking; and engine stopped with the engine cranking or shutting down.
As shown in FIGS. 5-7 , operating modes of the powertrain 10 are used to provide transmission output torque modulation during transmission shift events. Depending on the type of shift event, i.e., an upshift or downshift, level of torque modulation request, ERAD operating conditions, battery conditions, and other factors, the appropriate powertrain operating mode will be used to provide the desired output torque modulation request.
FIG. 5 is a schematic diagram of the powertrain 26 showing vectors representing torque transmission among components during operating mode A, in which output torque modulation occurs with ERAD 38 reducing driveline output torque during a gear shift.
FIG. 6 is a schematic diagram of the powertrain 26 showing vectors representing torque transmission among components during operating mode B, in which output torque modulation occurs with ERAD 38 increasing driveline output torque during a gear shift.
FIG. 7 is a schematic diagram of the powertrain 26 showing vectors representing torque transmission among components during operating mode D, in which torque modulation occurs with only the engine 28 reducing driveline output torque during a gear shift.
FIGS. 8A-8D illustrate an example of a transmission upshift, in which output torque modulation is provided by the ERAD 38 using the power path of operating mode A, shown in FIG. 5 . In operating mode A, ERAD 38 provides output torque modulation by operating as a generator and provide negative torque as shown at 70 , reducing the transmission output torque disturbance 72 during the shift to provide a smooth total driveline output torque 74 , provided the ERAD is available for this purpose. The ERAD 38 is available if its current temperature is lower than its thermal limit, its speed is lower than its operational speed limit, and the state of charge (SOC) of battery 56 is below the maximum allowable SOC limit.
By using operating mode A, excess transmission output torque 76 is converted into electrical energy that is stored by battery 56 while achieving the requested torque modulation and providing optimum shift quality. Furthermore, delays in crankshaft torque reduction are avoided by taking advantage of the ERAD's responsiveness, which produces an accurate magnitude of torque modulation. In operating mode A, both the ERAD 38 and engine 28 can also be used to reduce the total driveline output torque shift disturbance 72 in order to meet the requested torque modulation level. This combination of engine 28 and ERAD 38 is useful in the case where the ERAD may not be fully available or the battery SOC is near its maximum limit.
FIGS. 9D-9D illustrate an example of a transmission downshift in which output torque modulation is provided by the ERAD 38 using both operating modes A and B. During the ratio change phase of the downshift, operating mode B can be used with the ERAD 38 in a motoring mode to produce ERAD output torque 80 so that the net total driveline output torque 82 is increased in order to offset or compensate for the decrease 84 in transmission output torque that normally occurs during the ratio change phase of a downshift. Operating mode B can only be used if ERAD 38 is available for this purpose. The ERAD 38 is available if its current temperature is lower than its thermal limit, its speed is lower than its operational speed limit, and the state of charge (SOC) of battery 56 is above the minimum allowable SOC limit.
The powertrain 26 changes to operating mode A in the torque transfer phase near completion of the downshift so that ERAD operates as generator to produce negative torque 86 , which reduces the net total driveline output torque in order to soften or eliminate the output torque spike 88 , which would normally occur without torque modulation. Unlike that of the conventional case, with an HEV this excess torque 89 is converted into electrical energy to be stored by battery 56 while achieving the requested torque modulation and providing optimum shift quality.
FIG. 10 shows the steps of an algorithm for providing output torque modulation transmission control of the HEV powertrain 26 of FIG. 3 . After execution of the algorithm is started and the operating conditions of powertrain 10 are assessed at step 90 , a test is performed at step 92 to determine whether a gear ratio change of the transmission 34 has been requested by a transmission controller acting in response to vehicle parameters that include without limitation engine throttle position, accelerator pedal position, vehicle speed, engine speed, the position of a manually operated gear selector, and a schedule of the preferred gear ratios related to the vehicle parameters.
If the result of test 92 is logically positive, control advances to step 94 where a test is performed to determine whether shift output torque modulation is requested by the controller. If the result of either test 92 or 94 is logically negative, control returns to step 90 . But if the result of test 94 is positive, the magnitude of desired output torque modulation is determined at step 96 . The desired magnitude of output torque modulation is determined based on the progress of the shift event. For example, at the beginning of the ratio change phase of an upshift, the desired magnitude will ramp from zero to a negative steady-state level as the ratio change phase continues, and will ramp back to zero as the ratio change phase is completed.
At step 98 , the operating mode of powertrain 26 is selected in accordance with the algorithm of FIG. 11 upon reference to current operating parameters and the desired magnitude of output torque modulation.
At step 100 , powertrain 26 is placed in the desired operating mode selected by the algorithm of FIG. 11 in order to provide the desired output torque modulation during the shift event.
Referring now to the algorithm for selecting the desired operating mode shown in FIG. 11 , a test is performed at step 102 to determine whether the ERAD 38 temperature is less than a reference temperature representing the maximum allowable operating temperature of the ERAD.
If the result of test 102 is positive, a test is performed at step 104 to determine whether the speed of ERAD 38 is less than a reference speed representing the maximum allowable operating speed of the ERAD.
If the result of test 104 is positive, a test is performed at step 106 to determine whether the magnitude of a request for transmission output torque modulation is less than a reference torque limit representing the current maximum torque capability of ERAD 38 .
If the result of any of tests 102 , 104 and 106 is negative, control advances to step 108 , where powertrain 10 is placed in operating mode D, in which torque produced by engine 28 alone is transmitted to transmission output 36 without CISG 30 torque affecting any change in torque carried on crankshaft 52 to the transmission input 52 , i.e., CISG 30 neither produces nor draws power. Operating mode D, shown in FIG. 7 , is that of a conventional vehicle and the engine torque will be reduced to provide the desired level of output torque modulation since CISG 30 and ERAD 38 cannot be used.
If the result of test 106 is positive, a test is performed at step 110 to determine whether the desired magnitude of transmission output torque modulation is negative. If the result of test 110 is positive indicating that the desired output torque modulation level is negative, a test is performed at step 112 to determine whether the battery SOC is less than a maximum allowable SOC reference.
If the result of test 112 is positive indicating that the battery SOC can be further increased while ERAD 38 is operated as an electric generator, at step 114 operating mode A is selected as the operating mode for powertrain 26 and ERAD 38 performs output torque modulation by converting power produced by engine 12 into electrical energy to be stored by battery 56 during an upshift while achieving the desired output torque modulation level.
If the result of test 112 is negative indicating that the battery SOC cannot be further increased, control advances to step 116 , where powertrain 26 is placed in operating mode D, in which torque produced by engine 12 alone is transmitted to output shaft 40 without ERAD participating in the torque modulation.
If the result of test 110 is negative indicating that the desired output torque modulation level is positive and the output shaft 40 torque is to be increased, a test is performed at step 118 to determine whether the battery SOC is greater than a minimum SOC.
If the result of test 118 is positive, indicating that the battery SOC can be further decreased, control advances to step 120 , At step 120 operating mode B is selected, indicating that ERAD 38 is available to function as a motor and to participate in output torque modulation by supplementing power produced by engine 28 during a downshift.
If the result of test 118 is negative, indicating that the minimum battery SOC limit has been reached, control advances to step 108 , where powertrain 26 is placed in operating mode D, in which torque produced by engine 28 alone is transmitted to output 40 without ERAD 38 torque affecting any change in torque carried on output shaft 40 .
The output torque modulation control can be applied to RWD, FWD, AWD full or mild HEV powertrain configurations that include at least one electric machine driveably connected to the transmission output 36 . Furthermore, the control strategy is not limited to any particular transmission technology, but can be applied to a conventional automatic transmission, a dual clutch powershift transmission, and a converterless automatic transmission.
In accordance with the provisions of the patent statutes, the preferred embodiment has been described. However, it should be noted that the alternate embodiments can be practiced otherwise than as specifically illustrated and described.
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In a powertrain for motor vehicle that includes an engine, an electric machine, a transmission having an input driveably connected to the engine and a transmission output driveably connected to the electric machine, and a powertrain output driveably connected to the electric machine and wheels of the vehicle, a method for controlling torque during a shift includes transmitting engine torque through the transmission to the powertrain output; during a shift, operating the electric machine to modify the torque transmitted to the powertrain output; and storing energy generated by the electric machine during the shift.
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FIELD OF THE INVENTION
The invention relates to fluid treatment systems and fluid filters, particularly disposable fluid filters adapted for use in removing contaminants and the like from fluids prior to consumption.
BACKGROUND OF THE INVENTION
In the past, various devices have been used to filter liquids prior to consumption. Liquor and wine contain fusel oils, contaminants and polymers that cause headaches. Water supplies often contain contaminants which results in water having offensive tastes and odors. Brewing coffee in coffee makers using such contaminated water commonly produces coffee having a disagreeable flavor and generally distasteful.
Water purification devices are known. Water to be purified flows through a filter having a purification agent, such as an ion exchanger, activated carbon or the like, and is collected in purified forms in a collecting container. It is common place that these filters may become partially blocked considerably slowing down and disturbing water flow.
SUMMARY OF THE INVENTION
The invention is directed to a liquid filter for filtering liquid prior to consumption. The filter functions to remove contaminants, offensive tastes and odors from the liquid to provide a better, smoother tasting liquid.
The filter has a generally annular sleeve having a passage with an open top and an open bottom. A shoulder projects inwardly from the inner surface of the sleeve in engagement with a resin member located in the passage of the sleeve with a tight fit relation. The resin member has a top cover located in the passage of the sleeve and a second bottom cover located in the passage spaced from the first cover. The resin member includes a resin medium of filter grade granulated activated charcoal particles operable to filter and purify liquid flowing through the sleeve thereby removing contaminants, offensive tastes and odors from the liquid before consumption. A sheet member encloses the resin medium within the passage of the sleeve between the first and second covers. The first and second covers each have a generally convex shape with a plurality of openings to allow passage of liquid through the resin member.
A modification of the filter has a resin member located in the passage of an annular sleeve with a tight fit relation. The resin member has a top cover located in the passage of the sleeve, a second bottom cover located in the passage spaced from the first cover, and a third middle plate located between the top and bottom covers. The resin member includes a first layer of resin medium horizontally separated from a second layer of resin medium with the middle plate. The first layer of resin medium contains large filter grade activated charcoal particles whereas the second layer of resin medium contains small filter grade activated charcoal particles. The first layer of resin medium removes larger sized contaminants and the like to avoid partial blockage of the resin member. A sheet member encloses the first and second layers of the resin medium within the passage of the sleeve between the first and second covers.
The filter is adapted for use with conventional coffee makers. The lower end of the annular sleeve has a plurality of upwardly directed slots therein. The slots are circumferentially spaced on the lower end of the sleeve. This enables hot water and steam moving out of the lower end of the sleeve to move laterally along the surface of the coffee grounds located in the coffee maker basket. The sleeve has a height and circumference that are less than the height and circumference of the basket of the coffee maker so as to not interfere with the pivotal movements of the basket. The resin medium contains high temperature resistant activated charcoal to filter and purify heated water flowing from the coffee maker.
DESCRIPTION OF THE DRAWING
FIG. 1 is a coffee maker equipped with the water filter of the invention;
FIG. 2 is a top plan view of the water filter of FIG. 1;
FIG. 3 is a front elevational view thereof;
FIG. 4 is bottom plan view thereof;
FIG. 5 is an enlarged sectional view taken along the line 5--5 of FIG. 2;
FIG. 6 is a top plan view of a modification of the water filter;
FIG. 7 is a bottom plan view thereof;
FIG. 8 is a front elevational view thereof; and
FIG. 9 is an enlarged sectional view taken along the line 9--9 of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown a coffee maker indicated generally at 10 used for brewing coffee. Coffee maker 10 has a coffee pot 11 for accommodating coffee. A receptacle or basket 12 is pivotally mounted on coffee maker 10 above pot 11. Basket 12 holds a filter paper 13 containing coffee grounds 14. A filter of the invention, indicated generally at 20, is shown located on top of coffee grounds 14 contained within filter paper 13. Filter 20 is used to filter heated water prior to brewing of coffee. Hot water flows out of coffee maker 10 through filter 20 before passing through coffee grounds 14. Filter 20 removes contaminants present in the water thereby purifying the water. Filter 20 also functions to minimize bacterial growth known to be found in local tap drinking water supplies. Moreover, beneficial minerals, such as sodium and magnesium as well as the pH value of the water, are largely unaffected by filter 20. Filter 20 can also be used to remove contaminants and residuals from other consumed liquids, such as alcoholic beverages.
Referring to FIGS. 2 to 5, filter 20 has a generally annular outer shell or sleeve 21. Sleeve 21 has a top portion 23 that diverges outwardly from the middle of sleeve 21 to an outwardly turned top edge. A generally circular or ring-like side wall 22 extends below top portion 23. The top of side wall 22 is connected to top portion 23 of sleeve 21 with an outwardly inclined rib 28. The bottom end 26 of side wall 22 has a plurality of notches or slots 27. Filtered water flows through slots 27 to surrounding coffee grounds 14.
The inside surface of sleeve 21 has an inwardly directed annular shoulder 24 located above bottom end 26 of the sleeve. Shoulder 24 supports a filter disc 31 thereby preventing filter disc 31 from passing through sleeve 21. As seen in FIG. 5, filter disc 31 has a top cover 32 and a bottom cover 34. Top filter cover 32 is a concave curve shaped circular plastic member having a plurality of openings 33. Bottom filter cover 34 is a circular plastic member having a concave curve shape similar to top cover 32. Bottom cover 34 has a plurality of openings 36 to facilitate water flow out of filter 20. An inner ring 37 is located between filter covers 34 and 36. Ring 37 has a tight fit relation with the inside surface of side wall 22. Circular screens or filter sheets 39 and 41 are located below top cover 32 and above bottom cover 34 of filter disc 31. Each filter sheet 39, 41 is a porous plastic or fabric disc that prevents fine particles of activated charcoal from escaping filter bed 38 of charcoal. The outer edges of filter sheet 39 are clamped between top cover 32 and ring 37. The outer edges of filter sheet 41 are clamped between bottom cover 34 and ring 37.
Filtration with filter 20 is based on an ion exchange process without the use of additional chemical activators. A filter bed or resin 38 contained between filter sheets 39 and 41 exchanges contaminants, such as chlorine, organic pollutants and suspended solids, and hard water ions present in the water for hydrogen ions in order to purify the water. Resin 38 is a silver loaded activated ion exchange resin having high-temperature resistant granulated charcoal particles. The charcoal particles of resin 38 have a filter grade that can be subjected to hot water with temperature of approximately 170 degrees. Resin 38 removes chlorine, trihalomethanes, PCB's, odors and offensive tastes commonly found in water. Other types of resins can be incorporated in filter 20.
In operation, basket 12 is moved to an open position and fitted with a filter paper 13. A measured amount of ground coffee 14 is poured into filter paper 13. Filter 20 is placed on top of the coffee grounds 14 in a middle portion of basket 12. Coffee maker 10 is filled with water and basket 12 is pivoted to a closed brewing position by swinging basket 12 into the housing of coffee maker 10. The height of sleeve 21 is less than the distance between the top of coffee grounds 14 and the top edge of basket 12. Also, the circumference of sleeve 21 is less than the circumference of basket 12 whereby filter 20 is contained within the interior of basket 12. This enables basket 12 to be pivoted between a closed brewing position and an open position without interference from filter 20 when filter 20 is located on top of coffee grounds within basket 12. When basket 12 is located in the closed position, filter 20 is aligned with the water exit opening of coffee maker 10 whereby hot water flows downwardly out of the exit opening into filter 20, as indicated by arrow 18 in FIG. 1. When water is introduced into the top of filter 20 it passes through openings 33 in cover 32, through screen 39 and filter bed 38 and leaves through openings 36 in bottom cover 34 in a purified condition and then flows through coffee grounds 14 to be collected in container 11 as coffee having an improved aroma and smooth taste. Slots 27 in the bottom end 26 of sleeve side wall 22 allow the filtered water to flow transversely from filter 20 and cover the entire top surface area of coffee grounds 14. The brewed coffee flows out of the bottom of basket 12 through opening 17 in coffee pot cover 16 into coffee pot 11, as indicated by arrow 19 in FIG. 1.
After the brewing procedure has been completed, basket 12 is moved to the open position so that filter 20 can be removed and rinsed off. Filter paper 13 and coffee grounds 14 are replaced with a new filter paper and fresh coffee grounds. Filter 20 is then replaced on top of the fresh grounds so that another brewing cycle may be commenced. Filter 20 is used to filter water for approximately 100 pots of coffee before being discarded and replaced by another filter. An indicator (not shown) can be incorporated with filter 20 to indicate when the filter should be changed. Filter 20 fits most home and commercial coffee makers. Filter 20 is easily and conveniently removed from coffee maker basket 12 for rinsing or replacement.
Referring to FIGS. 6 to 9, there is shown a modification of the filter of the invention, indicated generally at 120, used to filter heated water flowing from a coffee maker prior to brewing of coffee. Filter 120 has a generally annular outer sleeve 121. Sleeve 121 has an outwardly diverging top portion 123 that terminates in an outwardly turned top edge. A generally circular side wall 122 extends downwardly below top portion 123. The top of side wall 122 is connected to top portion 123 of sleeve 121 with annular rib 128. The bottom end 126 of side wall 122 has a plurality of notches or slots 127 that allow filtered water to flow through slots 127 to coffee grounds that surround side wall 122.
Sleeve 121 has an inwardly directed annular shoulder 124 located on the inside surface thereof above bottom end 126. Shoulder 124 supports a filter disc 131 and prevents filter disc 131 from passing through sleeve 121. As seen in FIG. 9, filter disc 131 has a top cover 132, a bottom cover 134 and a middle partition 139. Top cover 132 is a concave curved circular member having openings 133. Bottom cover 134 is a circular member having a concave curved shape with a plurality of openings 136. Partition 139 has a concave curved shape similar to covers 132 and 134. Openings 141 in partition 139 allow water to pass from upper filter medium 138 to lower filter medium 142. An inner ring 137 joined to filter covers 134 and 136 and partition 139 has a tight fit relation with the inside surface of side wall 122. Circular screens or sheets 143 and 144 are located below top cover 132 and above bottom cover 134, respectively. Each filter sheet 143, 144 is a porous plastic or fabric disc that prevents particles of activated charcoal from escaping filter beds 138 and 142. The outer edges of filter sheet 143 are clamped between top cover 132 and ring 137. The outer edges of filter sheet 144 are clamped between bottom cover 134 and ring 137.
As shown in FIG. 9, filter bed 138 is contained between filter sheet 143 and partition 139. Filter medium 142 is located between filter sheet 144 and partition 139. Filter beds 138 and 142 have granular activated carbon that removes contaminants such as chlorine, odors and offensive tastes present in the water. Upper filter medium 138 contains large-sized or coarse activated charcoal particles. Lower filter medium 142 contains small-sized or fine activated charcoal particles. Water flows through upper filter medium 138 first to remove a substantial portion of the contaminants present in the water and then through lower filter medium 142. This reduces the potential of blockage and ineffective filtration of filter 120. The granulated charcoal particles of resins 138 and 142 are filter grade particles having a high temperature tolerance. Other types of resins can be incorporated in filter 120.
While there has been shown and described embodiments of the water filter, it is understood that changes in the structure and arrangement of structure, materials and parts may be made by one skilled in the art without departing from the invention. The invention is defined in the following claims.
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A water purification device used in connection with the brewing of coffee in an automatic drip coffee maker has an annular sleeve contained within the moveable basket of the coffee maker. The water purification device has an activated charcoal resin operable to filter and purify hot water flowing from the coffee maker through the annular sleeve. The lower end of the sleeve has a plurality of circumferentially spaced openings to allow lateral movement of the water and steam away from the annular sleeve.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of U.S. application Ser. No. 13/608,854, filed Sep. 10, 2012, and claims priority to U.S. application Ser. No. 13/608,854, filed Sep. 10, 2012 and U.S. Provisional Application Ser. No. 61/677,207 filed Jul. 30, 2012. Each of the above referenced applications are is incorporated herein by reference as if restated in full.
BACKGROUND
[0002] The present invention is directed to a data processing system for implementing an enhanced retail purchase of select financial assets. In particular, the present invention provides a data management process to facilitate the purchase of sophisticated financial products in a retail environment.
[0003] While the retail shopping experience has found expression in a wide range of distinct forms, there are many attributes common to this style of shopping. “Big box” stores such as Costco™ and Sam's Club™ offer large, wide aisles with heavily discounted but limited selections. Department stores such as Lord & Taylor™ present sophisticated islands with warm and posh fixtures, while Walmart™ and Target™ promote super low prices in comfortably large and selectively styled stores. Notwithstanding these distinct forms, browsing through merchandise in each instance is very similar—and familiar to millions.
[0004] In each instance, a browsing experience permits individualized and unmolested shopping through check-out, with assistance only if needed. It is, by far, the most commonly enjoyed shopping experience throughout most Western economies and is widely used to distribute nearly all forms of products and services. Its advantages, while well known, have not been successfully adapted for use in selling insurance products or services, or other similar financial instruments.
[0005] For example, past efforts to sell insurance products at retail outlets have been largely unsuccessful. Purchasing insurance is a complex process that often involves a dialogue with the buyer, collection of information to assist in pricing the policy, and often, intrusive private inquiries and medical examinations. In addition to the time requirement and intrusive questions, the choice of insurance is often a private matter and one that nearly always requires a trusted individual to assist in the process. In many ways, the process of purchasing insurance is the antithesis of the vastly more enjoyable retail shopping experience discussed above.
[0006] Much of these additional characteristics of financial product purchases stem from the product attributes. For example, insurance providers base their premiums on actuarial science and calculations that weigh the likelihood of the insured event occurring against a variety of factors, including the number of similarly insured individuals, i.e., the size and risk of the pool. It has been difficult to competitively price policies that are both profitable for the insurer and desirable for the insured on an individual basis without an investigation into the insured's various risk factors. In many instances, a questionnaire is provided to the insured to determine this level of risk and to appropriately price a policy. Often times, several different agents of the insurer will contact the potential insured or be involved in the approval and pricing of a policy for the potential insured. Additionally, the time from application to coverage may take upwards of six to eight weeks. This process is frequently perceived by the insured as a particularly burdensome and unfavorable experience and often leads to potential insurance customers opting to not purchase insurance products in order to avoid these drawbacks.
[0007] Finally, the benefits of insurance are far more subtle than most retail purchases. Insurance products provide peace-of-mind for a perceived risk, but in most human experiences such comfort is hard to measure, particularly in comparison to most impulse purchases. For example, the purchase of an LCD flat screen television is linked to immediate pleasurable relaxation; a $500,000 term life insurance policy—less so.
[0008] Of course insurance is still a critical aspect of any family financial picture and a must-have item. Accordingly, there remains a need for a system and method of procuring risk-based insurance policies which is convenient, private, quick, and comforting. Many individuals continue to risk being uninsured due to the undue hassles, inaccessibility, and apparent unaffordability of insurance products to the middle-class and lower-class markets.
ILLUSTRATIVE INVENTIVE CONCEPTS
[0009] It is an aspect of the patent invention to provide a computer implemented system to support retail-based financial products distribution.
[0010] It is another aspect of the present invention to provide a data processing method for tracking and coordinating insurance acquisition based on retail purchases of insurance products.
[0011] It is yet another aspect of the present invention to provide a computer system that selectively authorizes the purchase of discrete insurance products previously funded through the retail sale of pre-paid cards.
[0012] In still another aspect of the present invention, an insurance product package comprises a credit storage device such as a pre-paid card or similar, one or more insurance purchase process instructions, one or more disclosure documents, and pre-printed forms to implement an insurance purchase all contained in a single retail package.
[0013] The foregoing features of the present invention can be realized in a financial instrument purchase system that, in certain aspects, involves a two-stage operation. In an exemplary first stage, a retail/banking outlet distributes and sells a packaged financial product of select characteristics and corresponding to a specific discrete asset value, but not active, at the time of purchase. In an exemplary second stage, at retail, the package is simply added to the shopping cart and purchased at checkout. The package can include instructions, processing forms and an activation device, such as a pre-paid card, with select/unique codes to permit computer-assisted activation of the financial instrument.
[0014] In accordance with the varying aspects of the present invention, the packaged retail product is directed to financial products and services such as term life insurance, auto and home insurance, individual retirement account investment, mutual fund asset purchase and/or select equity and debt instruments for various financial purposes, including education, retirement and health care planning
[0015] In addition to the retail purchase, the second stage can utilize a computer implemented activation process where select account information is collected, risk profiles addressed, regulatory requirements tracked and confirmed, and the underlying product purchase is fulfilled, confirmed and documented.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 depicts a functional relationship diagram for the operating working environment;
[0017] FIG. 2 provides a generalized flow chart of the overall activation process for insurance;
[0018] FIG. 3 provides a “day one” diagram describing initial processing blocks for the retail insurance product/system;
[0019] FIG. 4 depicts the in-store display with pre-packaged products for retail sale;
[0020] FIGS. 5-31 are screen displays for operation of the insurance “stage two” process steps;
[0021] FIGS. 32A-B is a flow diagram and architecture of the activation process provided in the screen display;
[0022] FIGS. 33A-B provides the overview of the on-line processes;
[0023] FIGS. 34A-B provides the data fields for the on-line processes; and
[0024] FIG. 35 summarizes the Rules and Requirements for the on-line operations.
DETAILED DESCRIPTION
[0025] To better understand the features and attributes of the present invention, the following written description is provided of an illustrative embodiment, discussed in conjunction with the referenced figures.
[0026] Turning now to the illustrative arrangement depicted in the Figures, a packaged financial product for retail sale and supporting system are described. In particular, a store such as Walmart™ or Target™ will include a product display promoting packaged financial product (or “retail product”) that includes everything needed to purchase a term life insurance product with a one year fixed premium policy—all in one box. A suitably sized box with attractive graphics and informative text is displayed and a stack of similar boxes is positioned for easy review and selection. A purchase of the package is recorded at check-out and the customer can initiate the activation process through an agent with the retail product at home over the telephone or on his/her computer via internet connection. In one embodiment, a threshold level of insurance attaches after the initial purchase; in a second embodiment, no insurance is active until an activation session is completed by the purchaser.
[0027] In another embodiment, the customer searches or browses through and selects from available financial products using a preprogrammed tablet computer, smart phone or similar kiosk-type computer device presented at a retail store. The customer may complete a computer administrated questionnaire through the device to prequalify the customer for the selected products before purchase. Other products may be displayed on the tablet based on the customer's search queries, browsing selections, product selections and prequalification responses, including recommended additional purchases based on customer responses. In this illustration, the customer initiates the purchase of the computer displayed product directly through the tablet interface. Payment for the purchase is received through the tablet or check-out register.
[0028] FIG. 1 illustrates an embodiment of the system of the present disclosure for in-store insurance policy purchases. System 100 includes Client Computer 102 A and Client Computer 102 B, each containing client software (not shown) for accessing a remote system, such as a web browser accessing a webpage, such as Activation Server 104 via Internet 101 . Client Computer 102 A is one of many multiple client devices, only two of which are illustrated for purposes of simplicity of explanation, useable by Customer.
[0029] The retail financial product may consist of physical media purchased at a retail outlet as more fully described below. The product may use an electronic code, data, or communication, such as a text message or information displayed on a smartphone application. The retail financial product may be redeemed for an insurance policy by communication with Activation Server 104 by Customer through Client Computer 102 A. Activation Server 104 contains an Activation Database 103 A which includes information about each retail financial product, however and wherever purchased, such that Customer may redeem the retail financial product by inputting, scanning, or otherwise transmitting an identification code or data to Activation Server 104 . Upon receipt of the identification code or data at Activation Server 104 , the identification code or data is compared with data in Activation Database 104 A to determine the value or policy associated with the retail financial product.
[0030] Activation Server 104 will then confirm policy or value associated with the retail financial product for Customer. Upon confirmation, Activation Server 104 may activate, as more fully described in FIG. 2 , an insurance policy for Customer and transmit such insurance policy information to Insurance Policy Server 103 for storage into Insurance Policy Database 103 A. The Insurance Policy Server 103 may be used to administer the insurance policy purchased by Customer.
[0031] FIG. 2 describes the process flow in one embodiment of the invention. The process starts at step 200 where the Customer purchases the retail financial product from retail or other form of establishment. The process continues to step 210 where the Customer begins activation of the retail financial product by contacting an activation service. Customer then enters a redemption code or otherwise causes a redemption event at step 220 and is given an option or questionnaire in order to determine which policy will be redeemed by Customer. In some aspects of the invention, Customer may answer a questionnaire in order to determine for which insurance products or plans the Customer is eligible; for example, Plan A 222 or Plan B 224 . In other aspects and embodiments, Customer may be presented with the option to select from multiple plans such as Plan A 222 and Plan B 224 , which may be valued at the same or similar costs but may have different objectives, terms, or conditions. While this exemplary FIG. 2 depicts only two plans for redemption, those of skill in the art will appreciate that any number of plans may be available at the redemption process depending on various aspects and variables related to Customer, Policy Plan, etc.
[0032] Upon selection of the appropriate plan by Customer, Customer will advance to step 230 wherein Customer is optionally presented with an opportunity to increase her level of insurance beyond the level previously purchased in the retail financial product. This opportunity may come electronically or by the activation and alert of a call center which may cause a manual communication to take place. The up-sell opportunity may be provided at a reduced cost than traditionally offered at this stage as may be appreciated by those of ordinary skill in the art. The up-sell opportunity may also provide access to traditional insurance policies beyond Plan A 222 or Plan B 224 . If Customer selects to upgrade her policy, she will be issued an upgraded policy at step 245 . If Customer does not select to upgrade her policy, she will be issued her pre-purchased or pre-selected policy at step 240 . Following the activation of the Customer's policy, in some instances, the Customer is authorized to make monthly payments toward the purchased policy.
[0033] During the life of the issued policy, or upon termination of the issued policy, Customer may be prompted with the opportunity to convert or migrate her policy into a traditional, new term, or longer-term insurance policy at step 250 . According to other embodiments of the invention, Customer may have the opportunity to self-convert or migrate her policy at any time through the use of a computer, such as through a website, through a telephone, through the mail, or through any other form of communication as will be appreciated by those of skill in the art. If Customer elects to convert or migrate her policy, she will be issued a converted policy at terminating step 260 . If she elects not to convert or migrate her policy, she proceeds to step 270 wherein her original policy is managed to term.
[0034] The invention described above can be operational with general purpose or special purpose computing system environments or configurations. Examples of well-known computing systems, environments, and/or configurations that may be suitable for use with the invention include, but are not limited to: personal computers, server computers, hand-held or laptop devices, tablet devices, smartphones, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, household and commercial appliances, vehicles and other networked transportation systems, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
[0035] Components of the inventive computer system may include, but are not limited to, an input device or devices, an output device or display, a processing unit, a system memory, and a system bus that couples various system components including the system memory, processing unit, and input and output devices. The system bus may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures.
[0036] The computer system typically includes a connection or access to a variety of non-transitory computer-readable media. Computer-readable media can be any available media that can be accessed by the computer and includes both volatile and nonvolatile media, and removable and non-removable media. By way of example, and not limitation, computer-readable media may comprise computer storage media and communication media. Computer storage media may store information such as computer-readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, networked or “cloud” storage, or any other medium which can be used to store the desired information and which can accessed by the computer. Communication media typically embodies computer-readable instructions, data structures, program modules or other data in a modulated data signal and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of the any of the above should also be included within the scope of computer-readable media.
[0037] The computer system may operate in a networked environment using logical connections to one or more remote computers. The remote computer may be a personal computer, a server, a router, a network PC, hand-held or laptop devices, tablet devices, smartphones, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, household and commercial appliances, vehicles and other networked transportation systems, a peer device or other common network node, and typically includes many or all of the elements described above relative to the computer. The logical connections depicted in include one or more local area networks (LAN) and one or more wide area networks (WAN), but may also include other networks such as cellular and digital wireless networks. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets, and the Internet.
[0038] After the in-store purchase, the activation process can proceed along two potential paths on-line. First, for a simple life insurance product for a narrow group of applicants, the system permits a direct, on-line application where the applicant, assisted by a system supplied “eConsultant” (embodied intelligence for insurance questions). Second, for many other types of products, a second conversion is provided, when the applicant speaks directly to a real agent, and the agent prepares the electronic application.
[0039] For the first, unassisted process, six exemplary steps are provided via browser based internet communication link (as discussed in FIG. 2 ). The exemplary steps are:
[0000]
TABLE I
1
Learn about the Life Insurance eConsultant
2
Needs assessment
3
Provide coverage recommendations (confirm eUnderwriting
eligibility)
4
Complete the on-line application
5
Provide payment
6
Confirm consent/Electronic signature
[0040] The second, exemplary agent-assisted process is described and discussed in FIGS. 5-35 . This second exemplary procedure offers many advantages but is of course more labor intensive.
Other Insurance Applications
[0041] In addition to the products described above, a variety of insurance products can be offered and sold through the retail system described above or test marketed in select stores. These include: Accidental Death (AD) insurance; Simplified Issue Term (SIT) insurance; Hybrid AD/SIT insurance; Hybrid Life insurance; and Final Expense/Guaranteed Issue Whole Life insurance. In some arrangements, more unusual insurance products, such as pet insurance or travel insurance, are promoted.
[0042] In one arrangement, an alternative premium arrangement is presented using a deviated premium structure whereby the first month's premium is offered at a discounted rate.
Non-Insurance Applications
[0043] The above discussion has focused on insurance products, and in particular using a term life product as an illustration. The system can support direct retail sale of other financial products with characteristics that parallel those regarding insurance. In the insurance field, auto and home policies may be pre-packaged with terms for new cars, luxury cars, compact cars, or similar divisions. In home insurance, tiering can be done by location, house size, household size, house type or house value.
[0044] Outside of insurance, various investment options may be offered using the system provided herein. For example, retirement investments for 401(k) or IRA's can be pre-packaged at monetary increments, or investment type (mutual funds for equity, fixed income, inflation protection and others). Home equity loans and refinancing, home improvements and similar lending products can be pre-packaged to support subsequent “activation” in accordance with system parameters depicted herein. In the field of health care, pre-paid packages may include routine physicals, dental cleanings, hospital cash, or health insurance alone or coupled to one or more health treatments.
[0045] The insurance and other financial products offered through the retail system described herein are often purchased as gifts for others. In this embodiment, it is appreciated that insurance and financial products are purchased by a customer for the benefit of others. For example, a parent may wish to fund their child's retirement fund. By presenting these products through retail outlets as described herein, in one arrangement the process of purchasing insurance and other financial products as gifts is customized and streamlined.
Pre-Paid Card
[0046] One exemplary component of the retail package is the pre-paid card. Similar to a debit or phone card, the pre-paid insurance card can be set to a particular value (e.g., $50, $100 or $500 cards) or adjustable based on packaging or code as assigned. In a preferred embodiment, and to comply with regulatory requirements, this card will be used as a prepaid funding device for purchasing insurance. To comply with regulatory and disclosure requirements, activation can be contingent on one or more check operations necessary for use of the card. This process can be modified so that the card becomes the same as cash if the purchaser declines to use it for insurance—and authorized for use in any purchase universally, or at select retail/on-line stores. In one embodiment, the card will be an “open loop” card and may be used similarly to a debit card at many locations. In another embodiment the card will be a “closed loop” card and the customer will only be able to use the card at select locations, similar to a gift card for a particular store. In certain embodiments, the closed loop card may be converted to an open loop card. The card may also include a full-refund mechanism—in essence, a product return, but without the hassle of going back to the store.
[0047] Turning now to FIG. 3 , back-office processing features of the activation process are depicted in the function/flow chart of FIG. 3 . In this diagram, logic flows from left to right and begins with the acquisition of data from the pre-paid card (InComm) block 300 , with passage of fields to strata, block 310 , Activation, block 320 , Dell Lifesys, block 330 , and Epsilon DDDB (replacing database), block 340 .
[0048] Continuing with FIG. 3 , a data pass is made to the up-sell module, blocks 350 and 360 . Two paths are provided for the data. The first pass involves a traditional GLT product, through OMS block 350 and CAS, block 370 . Once completed, this is passed back to the database, block 340 for tracking records. For a rapid up-sell process, logic is governed by iApp block 360 , channeled through SSP, block 370 , middleware block 380 , second CAS block 390 and PMAC block 400 ; and ultimately back to database DDDB block 340 .
[0049] Payment processing operations are linked to the Activation Hub, block 320 including pre-paid cards, block 325 , OFAC service-block 335 and KBA service, block 345 .
[0050] Following the Activation Hub, policy issues with updates, Dell TPA block 330 , and records and accordingly triggered via connections to Peoplesoft Ledger block 355 , FAMIS block 375 and IBNA block 385 . Records reconciliation is completed at block 365 .
[0051] Turning now to FIG. 4 , an in-store display is depicted for the retail promotion of a term life insurance product. In this arrangement, two price levels are provided in a single one year plan at a set amount. These price levels are set by age ranges. In this arrangement, a purchaser will pick up the box that includes the desired age range—and ultimately check-out. An example of various level/arrangements that can be used is provided below.
[0000]
TABLE II
Starter Protection - Product Descriptions
One-year term with default to Accidental Death
Coverage
Age 18-44
Age 45-54
Age 55-59
Age 60-65
$10,000
$69
$99
$149
$199
$25,000
$99
$179
$279
$429
[0052] In accordance with this exemplary retail purchase arrangement, the following attributes for the pre-paid insurance are identified as part of the product as sold:
[0000]
TABLE III
Features
Simplified Issue Product
6 qualifying questions (i.e., cancers, diabetes, heart-disease, etc.)
If customer does not qualify, he/she is covered by an Accidental Death
policy at a greater coverage amount
Ability to convert starter product premium to traditional product if
converted at activation
Provides term coverage to a large number of customers with a provision to
cover every customer with some insurance product
[0053] In FIG. 5 , the connection between the retail purchase, block 500 with subsequent conversion steps is diagrammed as part of the Customer Journey. The path includes multiple touch points with the provider to permit extended services and assistance in the purchase process.
[0054] FIGS. 6-31 are screen displays for navigating an exemplary activation process, after the actual purchase is completed. In this illustration, a licensed insurance agent accomplishes the activation of select policy attributes. A licensed agent may be required to issue disclosures and proper guidance for any purchases and/or upgrades of certain policies. The operation is somewhat self-evident for the context of each screen and will not be discussed further here, but the written descriptions in each screen display are incorporated by reference as if restated here in full and in association with each display.
[0055] The first pass includes card look-up operations with assistance under “Helpful Hints”; see FIG. 10 . At FIG. 11 , customer information is collected, including information taken from the card, shown under “Case Information.” Missing data, e.g., SS Number, is flagged, FIG. 12 .
[0056] Similarly, in FIG. 13 , selection of the “state” triggers a check of current regulatory conditions in that state for the product identified. All insurance is subject to approval at the state level and confirmation of this is important in assessing candidate policies. In FIG. 14 , the creation of a virtual card is triggered if a customer lost or never purchased the retail card. Absent a card number, coverage must be entered as indicated.
[0057] Further checks are reflected at FIG. 15 where the new request is matched against various policies. If the total exceeds the current limits, a message is displayed to the agent. Similarly, in FIG. 16 , when the system needs more data, this is required.
[0058] Turning now to FIG. 18 , an illustration underwriting questionnaire is depicted. Per the product characteristics, the depth of questioning is contingent on the type of product and the amount of coverage. Once completed, the Policy Info screen, FIG. 20 , provides details regarding the policy parameters. The final aspect of this process involves the up-sell opportunity—a GLT policy in this case, FIG. 21 . At FIG. 22 , the policy type shifts to non-renewable Accidental Death, with key aspects of this policy credential as depicted in FIG. 23 . This includes various choices such as funding mechanisms, FIG. 24 (EFT) or FIG. 25 (debit/credit card).
[0059] Continuing with FIGS. 26 and 27 , additional policy data is collected (beneficiaries); at FIG. 28 , confirmation and agreements are entered, with the process conclusion at FIG. 30 . A simple summary page is depicted in FIG. 31 .
[0060] The foregoing on-line activation process is supported by server-based programming as depicted in the next series of diagrams. First turning to FIGS. 32A and 32B , a “USER FLOW” schematic extends horizontally, reflecting the processing that underlies the screen displays from the Landing page, through Basic Info, the “Questions,” the Policy, and ending with confirmation. In this depiction, both “issue” and “success” paths are presented running in parallel.
[0061] Turning now to FIGS. 33A-33B , an overview of the logic within the screen display architecture is provided for each of the significant passages within the system, including the Landing, Basic Info, Questions, and Policy. The specific text recitations under each section are herein incorporated by reference into this portion of the specification for association with each identified passage.
[0062] The data field structure for this architecture is provided in FIGS. 34A-B and the Rules for application to the four passages are illustrated in FIG. 35 .
[0063] For ease of exposition, not every step or element of the present invention is described herein as part of software or computer system, but those skilled in the art will recognize that each step or element may have a corresponding computer system or software component. Such computer systems and/or software components are therefore enabled by describing their corresponding steps or elements (that is, their functionality), and are within the scope of the present invention. In addition, various steps and/or elements of the present invention may be stored in a non-transitory storage medium, and selectively executed by a processor.
[0064] The foregoing components of the present invention described as making up the various elements of the invention are intended to be illustrative and not restrictive. Many suitable components that would perform the same or similar functions as the components described are intended to be embraced within the scope of the invention. Such other components can include, for example, components developed after the development of the present invention.
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Exemplary data processing implemented sales and activation systems and methods are used to distribute insurance products and services. Aspects provide a two stage operation facilitated by selectively arranged retail packaging used in conjunction with an on-line activation process to permit enhanced marketing of insurance and other insured products and services.
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RELATED APPLICATION
[0001] This patent application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/016,190 filed on Jun. 24, 2014, incorporated herein in its entirely by reference.
FIELD
[0002] The present disclosure primarily relates to a pharmacy contribution management system and method.
BACKGROUND
[0003] In the United States, drugs account for 10 percent of the country's $2.7 trillion annual health bill. The U.S. spends almost $1,000 per person per year on pharmaceuticals, which is around 40% more than the next highest spender, Canada, and more than twice as much as than countries like France and Germany spend, even though the average American takes fewer prescription medicines than people in France or Canada.
[0004] Many people in the U.S. obtain medical insurance through their employers. The typical insurance policy has predefined a copay amount that the employees pay for a given prescription. Because the amount that the employee is responsible for is fixed, the prescription is often filled by the employee at retailers selected without regard to the total cost of the medicine. The cost of the medicine minus the copay is then the responsibility of the employer. As a result, employees have no incentive to shop for pharmacies where the medication is offered at lower prices, and the employer assumes all the risk for the balance of the transaction. The employer also has limited control over the amount that it ultimately becomes responsible for the prescriptions filled out by its employees.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a simplified block diagram of a networked computing environment in which the pharmacy contribution management system operates;
[0006] FIG. 2 is a simplified message flow diagram of an embodiment of the pharmacy contribution management system according to the teachings of the present disclosure;
[0007] FIG. 3 is a block diagram of an embodiment of an exemplary architecture of the pharmacy contribution management system and method according to the teachings of the present disclosure;
[0008] FIG. 4 is a simplified block diagram that illustrates various exemplary functions that are provided to members, via mobile app as well as web app according to the teachings of the present disclosure;
[0009] FIG. 5 is a simplified block diagram that illustrates various exemplary functions that are provided to employers, via mobile app as well as web app according to the teachings of the present disclosure;
[0010] FIG. 6 is a simplified block diagram that illustrates various exemplary functions that are provided to pharmacy partners, via mobile app as well as web app according to the teachings of the present disclosure;
[0011] FIG. 7 is a simplified block diagram that illustrates various exemplary functions that are provided to prescribers (e.g., physicians) according to the teachings of the present disclosure;
[0012] FIG. 8 is a simplified flowchart of an exemplary embodiment of the pharmacy contribution management process according to the teachings of the present disclosure;
[0013] FIG. 9 is a simplified illustration of an exemplary employer tiered contribution model in the pharmacy contribution management process according to the teachings of the present disclosure;
[0014] FIG. 10 is a simplified block diagram of an exemplary embodiment of the basic function blocks of the pharmacy contribution management process according to the teachings of the present disclosure;
[0015] FIG. 11 is a simplified illustration of an exemplary embodiment of the claims processing Rx dispensing process in the pharmacy contribution management process according to the teachings of the present disclosure;
[0016] FIG. 12 is a simplified illustration of an exemplary embodiment of the claims adjudication process in the pharmacy contribution management process according to the teachings of the present disclosure;
[0017] FIG. 13 is a simplified illustration of an exemplary embodiment of prior authorizations in the claim approval process in the pharmacy contribution management process according to the teachings of the present disclosure;
[0018] FIG. 14 is a simplified illustration of an exemplary embodiment of the appeals process in claim processing in the pharmacy contribution management process according to the teachings of the present disclosure;
[0019] FIG. 15 is a simplified illustration of an exemplary embodiment of the claim reversal process in claim processing in the pharmacy contribution management process according to the teachings of the present disclosure;
[0020] FIG. 16 is a simplified illustration of an exemplary embodiment of the financial processing for Rx payee reimbursement process in the pharmacy contribution management process according to the teachings of the present disclosure;
[0021] FIG. 17 is a simplified illustration of an exemplary embodiment of the financial processing for payer collections process in the pharmacy contribution management process according to the teachings of the present disclosure; and
[0022] FIG. 18 is a simplified illustration of an exemplary embodiment of the manufacturer rebate to employer process in the pharmacy contribution management process according to the teachings of the present disclosure.
DETAILED DESCRIPTION
[0023] The traditional employer sponsored health insurance specifies fixed copay amounts that the employee must pay for certain healthcare services and prescriptions, and the employer is responsible for paying the balance. In this traditional pharmacy benefits manager (PBM) model, there are at least three ways that employers are put at a disadvantage. Pharmacies are not able to disclose drug prices through PBMs to pass their best pricing onto the consumers, and they are not able to compete based on pricing. Pharmacy benefits managers markup the cost of drugs that a pharmacy is willing to accept. As a result, employers are unable to predict and budget the Rx cost of its employees due to the variability of drug prices at various pharmacies.
[0024] The innovative Pharmacy Contribution Management (PCM) model flips the traditional benefits model (pharmacy benefits manager or PBM) on its head, substituting employer contribution for employee copay. The pharmacy contribution management system and method provides pharmacies with the employer's defined contribution percentage or amount, and collects the balance from the employee at the point of sale. Therefore, the employee is responsible for the balance, while the employer's Rx cost is fixed. By leveraging the present PCM system and method, employers can estimate an Rx budget amount with little variance in fluctuation. Using statistical analysis and analytics, an employer can set its own formularies and contributions to meet its budgetary goals. Employers may use a tiered contribution model to decide how much they are willing to pay for its employees' Rx spending. A tiered contribution model is offered in lieu of a traditional complex formulary. Drugs are grouped by category of their pricing, and the employer set the amount or percentage it wants to contribute to each pricing tier. The system is configured to take into account of historical claims against pharmacy partner pricing to provide recommendations for the tiered pricing ranges, as well as recommend how much the employer might contribute to help both the employee and the employer maximize savings. A further benefit is that the employees are encouraged and motivated to shop for lower drug prices using the tools of the system and permitting the pharmacies to compete for their business via pass-through pricing. This results in true transparent pricing without spreads and hidden costs that previously went to the middlemen.
[0025] FIGS. 1 and 2 illustrate that pharmacy partners in the network, employers, members (employees) can communicate via a global computer network 10 with the pharmacy contribution manager system 12 , via desktop web applications, mobile applications, and other suitable computing means. The system may further employ a claims adjudication system 14 with which it communicates via the computer network 10 . All data are stored in databases 16 with redundancy backups, and are balanced to achieve efficient and speedy transactions and service. The employer companies 18 , members/employees 20 , and pharmacy partners 22 are able to communicate and access information via the computer network 10 .
[0026] FIG. 3 is a block diagram that illustrates an exemplary architecture of the pharmacy contribution management system and method. The financial engine 24 performs many of the accounting and accounts payable functions (payables 26 and receivables 28 ). The claims adjudication engine 30 performs many of the functions associated with adjudicating Rx claims from the members. It is configured to access databases containing Rx market pricing data 32 , claims history 34 , and financial history 36 . The pharmacy contribution management system includes user applications (web and mobile) 40 that provide access to the system by pharmacy partners, employee members, and employers. It also includes an analytics engine 42 that is configured to perform analysis on various data sets and provide reports 44 , including ACH (Automated Clearing House), analytics, claims, eligibility, and Rx pricing reports. The system also interfaces with social media 45 and external data sources 46 .
[0027] FIG. 4 is a simplified block diagram that illustrates various exemplary functions that are provided to members, via a mobile app as well as a web app, for example. A mobile application (and its web desktop equivalent) enables the employee/member to access many functions, including Pharmacy Finder 50 , Rx Finder 51 , My Rx Spend 52 , Rx Transfer 53 , Rx Price Lookup 54 , Claims History 55 , and Click to Save 56 .
[0028] Pharmacy Finder—Employees or members may use the mobile app running on a smartphone or a suitable electronic device to find the lowest cost Rx (in real-time) with a nearby pharmacy in the pharmacy partner network or other available retailers. There are options to narrow the search to find, for example, pharmacies with drive-thru options, 24 hours locations, or offer value services such as immunization clinics. This concept promotes real-time location-based shopping, enabling members to search, in real-time, for the lowest prices in their area proactively and/or for a prescription while at the doctor's office. This function may utilize third party map apps such as GOOGLE MAPS to display a map showing the searched for pharmacy.
[0029] Rx Finder—the member may search for details on any prescription drug by name, or disease/indication. Members can look for available drug generics and alternatives, Rx pricing, and drug information including description, interactions, and more. Recognizing that certain patient demographics do not have high technology adoption rates, if a member does not use the technology proactively to search for prescription savings opportunities, the system will alert the member (via their preferred method such as email or text) that the prescription savings can be achieved for refills of the prescription and provide details on how to save. This approach guides patient behavior over time to drive proactive saving behaviors that benefit both members and employers.
[0030] My Rx Spend—the member may view the Rx history for his/herself and dependents and export Rx history for tax or historical use. A spend summary and projections for budgeting and review recommendations for saving is also available.
[0031] Rx Transfer—this feature presents the member with alternative pharmacies, generic vs. brand name, and alternative medications to maximize cost savings. The member may use this feature to easily transfer a prescription to a pharmacy partner their active refill. By increasing the ease of prescription transfers, patients are more likely to move their prescriptions to lower price pharmacies, which improves the likelihood of savings for both members and employers.
[0032] Rx Price Lookup—true pass-through real-time pricing from pharmacy partners is available to employee members that doesn't include spreads, hidden costs, or markups. The pharmacy partners promote their best prices and value without any middle men. Members can shop around for the Rx based on price, specials, service options, and location, all at the click of a button.
[0033] Click to Save—Based on a member's current drug spend, the Click to Save feature of the mobile application recommends pharmacies that will increase their savings on active prescriptions. The member may enter preferred distance and maximum number of pharmacies, and this feature will project the cost savings and list the lowest cost pharmacies in the selected area, as well as generic and therapeutic alternatives. This feature includes recommendations of moving to a different retail pharmacy, mail-order options, and fill alternatives.
[0034] A member may also set up his/her own Rx profile and for dependents. The member may set the mobile app to send reminders for upcoming refill straight to the mobile device or by email.
[0035] FIG. 5 is a simplified block diagram that illustrates various exemplary functions that are available and provided to employers, via a mobile app as well as a web app, for example. These employer portal functions may include contribution management 60 , savings review 61 , budget review 62 , employee administration 63 , and alerts & alarms 64 .
[0036] FIG. 6 is a simplified block diagram that illustrates various exemplary functions that are available and provided to pharmacy partners, via a mobile app as well as a web app, for example. These pharmacy portal functions may include pricing & pharmacy administration 70 , advertising & promotions 71 , network analytics 72 , and alerts & alarms 73 .
[0037] FIG. 7 is a simplified block diagram that illustrates various exemplary functions that are available to and provided to prescribers (e.g., physicians), via a mobile app as well as a web app, for example. These prescriber portal functions may include Rx finder 80 , patient history 81 , e-prescribe 82 , and alerts & alarms 83 .
[0038] FIG. 8 is a simplified flowchart of an exemplary embodiment of the pharmacy contribution management process 90 . The pharmacy receives the Rx claim from an employee, as shown in block 91 . Based on the tiered contribution model, the pharmacy determines or is provided the employer's defined contribution either as a fixed percentage or maximum amount, as shown in blocks 92 and 93 . For example, if the price of the Rx is $25, and the employer contribution is defined as 60% for drugs that fall into this price range, then the employee is responsible for the remaining 40% of the drug cost. The employee's share of the drug cost is then provided in real-time or stored as a receivable at the pharmacy, as shown in block 94 , so that the pharmacy can collect the balance from the employee at the point of sale. Therefore, the employee member is charged and pays an amount that is based on the prescription price and the employer tiered contribution model rather than a fixed copay amount. The employee member has incentive to shop for the lowest cost pharmacy to reduce his/her contribution amount for the prescription. The pharmacies can pass on savings to the customers via pass-through pricing. The invoice is then transmitted to the employer, which pays the pharmacy a fixed amount or percentage for a prescription based on the assigned tier, as shown in blocks 95 and 96 .
[0039] The tired employer contribution model is illustrated in FIG. 9 . Historical claims analysis is used to determine the tier structure for a given employer to optimize results. In this example, medication are stratified based on price into five tiers, and the employer contribution may be defined as shown:
[0000]
Tier
Price
Employer Contribution
1
$0.01-$20
50%
2
$21-$50
60%
3
$51-$100
50%
4
$101-$300
50%
5
>$301
20%
[0040] Thus, the employer set the amount that it will contribute by percentage or maximum amount for all medication in each tier. Each tier defines the drug price range. Historical claims analysis is used to set the tier structure for optimal results. The following is an example contribution model.
[0000]
% of
NDCs
% of
Avg.
Avg.
in
Rx
E'er
Max E'er
E'ee
Tier
Low
High
Cost
Range
Written
Contribution %
Contribution
Expense
1
$0
$20
$4.25
27.25%
38.50%
50%
$10.00
$0.00
2
$21
$50
$38.24
32.48%
29.25%
60%
$30.00
$8.24
3
$51
$100
$86.58
21.73%
18.56%
50%
$50.00
$36.58
4
$101
$300
$207.20
12.56%
10.65%
50%
$150.00
$57.20
5
$301
. . .
$2,765.00
5.98%
3.04%
20%
$1,000.00
$1,765.00
[0041] In this example, tier 1 drugs range in cost from $0 to $20 at pharmacies, with the average cost of $4.25. The system suggests the employer's contribution to be 50%, or a maximum of $10 per prescription for tier 1. As a further example, tier 2 drugs range in cost from $21 to $50 at pharmacies, with the average cost of $38.24. The system suggests the employer's contribution to be 60%, or at a maximum of $30 per prescription. Further, tier 3 drugs range in cost from $51 to $100 at pharmacies, with the average cost of $86.58. The system suggests the employer's contribution to be 50%, or at a maximum of $50 per prescription. Tier 4 drugs may range in cost from $101 to $300, with the average cost of $207.20. The system suggests the employer's contribution to be 50%, or at a maximum of $150 per prescription. Finally, tier 5 drugs may range in cost from $301 and up, with the average cost of $2,765.00. The system suggests the employer's contribution to be 20%, and at a maximum of $1,000 per prescription. The employer may select to set its contribution to be in the form of percentage of the prescription cost or a fixed amount. From historical data, the employer is able to determine how many of each type of prescriptions are typically filled at pharmacies by its employees, so with the fixed contribution defined by the employer, it can easily predict and budget for its employee Rx expenses. Using the system and method described herein, employees can and are incentivized to shop for the lowest Rx prices in their area while enabling pharmacies to compete on service and price. The true cost of prescriptions will no longer be hidden but become transparent to all parties. Employees may shop at any pharmacy but by shopping with pharmacy partners, more savings can be realized.
[0042] FIG. 10 is a simplified block diagram of an exemplary embodiment of the basic function blocks of the pharmacy contribution management process according to the teachings of the present disclosure. The pharmacy contribution management system and method include claims functions 101 and operations functions 102 . Claims functions 101 include configuration 108 , Rx dispensing 109 , adjudication 110 , audit & reporting 111 , prior authorizations 112 , appeals 113 , and reversal 114 modules. Operations functions 102 include financial processing 116 , call center 117 , collections 118 , rebate pass-through 119 , and sales compensation 120 modules. Selected functions and modules are described in more detail below.
[0043] FIG. 11 is a simplified illustration of an exemplary embodiment of the claims processing Rx dispensing process in the pharmacy contribution management process according to the teachings of the present disclosure. The system first receives the Rx ID information, as shown in block 131 . The claim request 133 is then transmitted to the pharmacy, as shown in block 132 . The Rx may be transmitted via paper copy, eRx, IVR (Interactive Voice Response), or a refill request. The Rx order is then fulfilled, as shown in block 134 . The Rx orders are collated, as shown in block 135 . The Rx ID is entered into the automatic will call system, as shown in block 136 . The Rx ID is also correlated with the Host Rx or pharmacy ID, as shown in block 137 . The patient is then requested to pay the pass-through price at the point of sale (POS), which is the price of the drug minus the employer's contribution percentage or amount, as shown in block 138 . If this the first time this prescription is filled, as determined in block 139 , then the pharmacist is requested to provide Rx consultation with the employee/patient, as shown in block 140 . Otherwise, the location of the Rx order is determined or set in the will call system, as shown in block 141 . The drug is then dispensed to a verified recipient, as shown in block 142 . The patient then receives the prescription, as shown in block 143 .
[0044] FIG. 12 is a simplified illustration of an exemplary embodiment of the claims adjudication process in the pharmacy contribution management process according to the teachings of the present disclosure.
[0045] FIG. 13 is a simplified illustration of an exemplary embodiment of prior authorizations in the claim approval process in the pharmacy contribution management process according to the teachings of the present disclosure.
[0046] FIG. 14 is a simplified illustration of an exemplary embodiment of the appeals process in claim processing in the pharmacy contribution management process according to the teachings of the present disclosure.
[0047] FIG. 15 is a simplified illustration of an exemplary embodiment of the claim reversal process in claim processing in the pharmacy contribution management process according to the teachings of the present disclosure.
[0048] FIG. 16 is a simplified illustration of an exemplary embodiment of the financial processing for Rx payee reimbursement process in the pharmacy contribution management process according to the teachings of the present disclosure.
[0049] FIG. 17 is a simplified illustration of an exemplary embodiment of the financial processing for payer collections process in the pharmacy contribution management process according to the teachings of the present disclosure.
[0050] FIG. 18 is a simplified illustration of an exemplary embodiment of the financial processing for sales and channel compensation process in the pharmacy contribution management process according to the teachings of the present disclosure.
[0051] The features of the present invention which are believed to be novel are set forth below with particularity in the appended claims. However, modifications, variations, and changes to the exemplary embodiments described above will be apparent to those skilled in the art, and the novel pharmacy contribution management system and method described herein thus encompasses such modifications, variations, and changes and are not limited to the specific embodiments described herein.
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A pharmacy contribution management method comprises analyzing historical claim data, determining a tiered model for prescription contributions, the tiered model describing a plurality of prescription cost tiers and recommended prescription contribution for each of the plurality of prescription cost tier, permitting an organization to determine a prescription contribution for each of the plurality of prescription cost tier, enabling a member associated with the organization to shop of lowest price drugs via pass-through pricing from the pharmacies, receiving a prescription claim from a pharmacy arising from a prescription purchase by the member associated with the organization, and transmitting the prescription contribution for the organization to the pharmacy, so that the pharmacy may charge the member an amount equal to a price of the prescription minus the organization's prescription contribution.
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BACKGROUND OF THE INVENTION
This is a continuation-in-part of our earlier application Ser. No. 170,793, filed on Aug. 11, 1971 and now abandoned.
The present invention relates generally to the weaving of fabrics, and more particularly to a novel weaving method and to an apparatus or loom for carrying out the method.
The invention is particularly concerned with the insertion of effect threads into fabrics, that is threads which are to produce on or in the fabric a particular visual and/or textural effect. When in shuttle looms effect weft threads are to be inserted into fabrics, then this is generally carried out by means of one or more shuttles which insert the effect threads. The width over which the effect thread is visible on the fabric and anchored therein, is determined by the raising or lowering of a predetermined number of warp threads in the warp. In needle looms this is somewhat different. In this type of loom it is not only the basic weft but also the effect thread or threads which are laterally inserted into the fabric with a usually needle-shaped inserting device. In this type of loom the starting point of the elongation over which the effect thread or threads can be seen in the fabric, can be determined at the side at which the effect thread is inserted into the warp by appropriately raising or lowering some of the warp threads. At the opposite side, however, the effect thread must be anchored in different manner which heretofore has been effected either by inserting the effect thread to the selvedge and retaining it with the aid of a retaining needle by appropriate formation of loops or the like in which case that portion of the effect thread which is not to be visible at the surface of the fabric remains below the upper side of the fabric. Another possibility has been to use additional retaining needles and to provide them at certain points across the width of the fabric, using them to anchor the effect thread by means of these needles.
Both possibilities have certain disadvantages. The first-mentioned possibility will obviously result in a rather displeasing appearance of the underside of the fabric because the effect threads must always led to the selvedge and are then exposed at the underside, hanging more or less freely. In the second possibility the choice of locating the connecting positions, that is the locations where the needles would engage the effect threads, is very limited and furthermore there will be an additional raised region at these different points in the fabric, interrupting the even thickness of the fabric -- particularly disadvantageous if the fabric is a ribbon -- and providing an aesthetically displeasing appearance.
SUMMARY OF THE INVENTION
It is, accordingly, a general object of the present invention to overcome the disadvantages of the prior art.
A more particular object of the invention is to provide an improved method of inserting effect threads into woven fabrics which is not possessed of the aforementioned disadvantages.
A concomitant object of the invention is to provide such a method which makes it possible to vary the width over which the effect threads are visible, even at the side where the effect thread is to be anchored, that is the side opposite from where it is inserted without aesthetically displeasing thickening of the material or without having the underside of the material have a displeasing appearance.
An additional object of the invention is to provide an apparatus for carrying out the present invention.
In pursuance of the above objects, and of others which will become apparent hereafter, one feature of the invention resides in a method of weaving a fabric which, briefly stated, comprises the steps of opening a warp, inserting an effect thread into the open warp, retainingly engaging the inserted effect thread for preventing it from being pulled off the warp, closing the warp and releasing the inserted effect thread. It is not necessary that the effect thread be retained until the warp is closed; instead, it can be released actually before the warp is closed. This will be explained in more detail later.
Advantageously the retention of the effect thread takes place at least until the reed or beating-up means has engaged the effect thread or the next effect thread or weft thread has been inserted and beaten up. Advantageously the means for engaging the inserted effect thread will be moved in at least substantial parallelism with the beating-up edge of the fabric in such a manner that it passes through the loop formed by the effect thread on insertion of the latter, so that when the device which inserts the effect thread is withdrawn the loop will pass around and tighten against the holding element. When the latter is then withdrawn it leaves behind a loop at the exposed surface of the fabric. In the event that this is not adequately retained and anchored, by the clamping effect of the change between warp opening and closing positions, by the beating-up or by subsequently inserting weft threads, then it can be anchored to or in the fabric in additional manner, by means of hot or cold adhesive, by welding (such as heat welding) or in other ways, for instance by thickening. Such thickening of the loop can for instance be achieved in that a drop of an a immediately solidifying mass (for example a synthetic plastic) is placed onto the loop.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a somewhat diagrammatic illustration showing the warp open and the inserted effect thread being engaged by a holding element;
FIG. 2 is a view similar to FIG. 1 showing the inserting element for the effect thread withdrawn and the warp closed;
FIG. 3 shows, in a view similar to FIGS. 1 and 2, a further stage of the operation;
FIG. 3a is a fragmentary plan view, showing how the loops of the effect thread can be vised;
FIG. 4 is a view similar to FIG. 3, showing the inserting element ready for withdrawal from the closed warp;
FIG. 5 is a diagrammatic vertical section of an apparatus according to the present invention;
FIG. 5a is a fragmentary top-plan view, showing the inserting element provided with thread cutters;
FIG. 6 is a partial top-plan view of FIG. 5;
FIG. 7 is an end view of FIG. 8, looking towards the left;
FIG. 8 is a side elevation of FIG. 7, looking towards the right;
FIG. 9 is a fragmentary perspective view, illustrating a further feature of the invention; and
FIG. 10 is a view similar to FIG. 9, but showing still another feature of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Discussing now the drawing in detail it will be seen that FIGS. 1-3 and 4 show three different operational stages of effect-thread insertion. In these Figures, reference numeral 1 identifies the fabric composed of the elongated warp 2 and the inserted weft threads, into which the effect weft thread (or threads) 3 is to be inserted. After a certain number of weft threads has been inserted transversely of the elongation of the warp 2, those warp threads 2' are raised to the illustrated position in FIG. 1 across whose width the effect weft thread 3 is to be visible on the finished fabric (compare FIG. 3). The effect weft thread 3 is then inserted by an inserting element, here illustrated as a needle 4 which has a recessed leading end portion as shown, being inserted into the shed formed between the raised warp threads 2' and the remaining non-raised threads of the warp 2.
When the element 4 has been inserted to the maximum extent as shown in FIG. 1, thereby forming a loop in the effect thread 3, an engaging and retaining element 5 enters from the opposite side of the warp 2 and moves into the loop. In this embodiment the element 5 is a form of a slightly forwardly conically tapering wire. It is pointed out that of course the directions of insertion of the effect thread 3 and of the element 5 could be reversed within the concept of the present invention.
Before proceeding with a description of FIGS. 1-3 and 4, a discussion of FIGS. 5 and 6-8 is necessary to facilitate an understanding of the invention.
FIGS. 5 and 6 show in more detail a loom which is provided with the novel arrangement according to the invention. The loom frame is identified with reference numeral 8, and the sley with numeral 9. The sley 9 is mounted on the shaft 10 and driven via connecting rods 13 by a crank drive 11 which turns about the main shaft 12. The opening and closing of the warp 2, 2' is effected by five shafts 14 which are urged downwardly (in FIG. 5) by springs 14' and are operated to move in the direction indicated by the double-headed arrow a, by the conventional and well-known apparatus 27 which is driven from the main shaft 12 via belts or chains 28, 29.
The weft threads 15 are for instance inserted by needle-like inserting elements 16, and the weft threads 15 are bound by a binding needle 17, for instance a latch needle. The element 16 moves in the direction of the double headed arrow b and the needle 17 in the direction of the double-hadded arrow c. The movement of the element 16 is so controlled that it is not simultaneously inserted into the warp 2, 2' with the insertion of the element 4 for the effect thread 3, which element 4 moves in the direction of the double-headed arrow d.
The movement of the element 5 in the direction of the double-headed arrow e is coordinated with that of the element 4 and the finished fabric 1 is deflected downwardly about the breast beam 18 where it is withdrawn by a take-up.
Control of the elements 4 and 16, the element 5 and the needle 17 is effected in a manner known per se, for instance via linkages 19, 20, 21, 22 by means of suitable eccentrics 23, 24, 25 and 26.
The element 5 moves in at least substantial parallelism with the beating-up edge of the weft threads and effect thread, and moves above the plane of the warp 2 to approximately the opposite lateral edge thereof. Thereupon the element 4 is withdrawn so that the loop of the effect thread 3 is tightened about the element 5, being prevented from withdrawal out of the warp by the element 5. After the warp has been closed the reed or beating-up device 7 can now beat up the newly-inserted effect thread 3 against the preceding weft threads and/or effect threads, forming a new beat-up edge 6. This clamps the newly inserted effect thread 3 in the fabric whereupon the element 5 is withdrawn from the loop and is then in readiness for the next effect thread insertion, as shown in FIG. 3, which can take place either at once or after some further weft threads have first been inserted.
The small loops 3' remaining at the upper side of the fabric may be permitted to remain for further effect. They can, however, also be served or, to anchor them more firmly to the fabric, they may be adhesively bonded or welded thereto, or thickened (e.g. by application of a drop of hardenable resin material to the respective loop).
The width of the various effect threads 3 can differ, as evident from FIGS. 1-3. In other words, one effect thread may be exposed at the upper fabric side for a short distance, and the next one for a longer distance, or vice versa. This is governed only by the width of the space between the laterally outermost ones of the raised warp threads 2'. No adjustment to the structure or movements of the elements 4 or 5 is necessary, nor to the means controlling their operation. To repeat: To effect such variation it is not necessary to change the length or direction of movement either of the elements 4 or 5, because the variation effect is determined exclusively by the number and arrangement of raised warp threads 2'.
In FIGS. 1-3 no attempt has been made to show the devices for inserting the weft threads or other components, in order to avoid confusion and to facilitate an understanding of the invention.
Details of how the movement of element 5 is controlled, are shown in FIGS. 7 and 8. The element 5 is reciprocated in direction of the double-headed arrow e by the arm 20, which receives motion from the eccentric 24 (see FIG. 6). In addition, the element 5 performs a part-circular movement which is indicated by the double-headed arrow f in FIG. 7. To make this possible, the element 5 is not directly connected with the arm 20; instead, it is secured to a ring 30 which in turn is connected with arm 20 via a bearing 31. The ring 30 slidably surrounds a rod 32 which is fixedly mounted on the loom frame (e.g. in the region of its right-hand end which is not visible in FIG. 8). At its free end (i.e. the left-hand end in FIG. 8), the rod 32 is provided with an abutment 33. A helical expansion spring 34 surrounds the rod and bears upon the abutment 33 and the ring 30, respectively. The latter is provided with a guide projection 36 which extends into a groove 35 formed in and extending longitudinally of the rod 32. In the region where it approaches the abutment 33, the groove 35 has a portion 35' which twists helically about the rod and which merges into a substantially straight end portion 35" extending towards the abutment 33.
When the element 5 assumes the position shown in FIG. 8, (i.e., the twelve o'clock position shown in FIG. 7) its left-hand free end is withdrawn from the warp thread. If, now, the arm 20 is shifted towards the left in FIG. 8, it displaces the element 5 in the same direction, via bearing 31 and ring 30. This movement of element 5 is initially a straight-line movement, as long as the projection 36 sliding in the groove 35 has not reached the portion 35' thereof. During this part of its movement the element 5 can advance freely above the plane of the warp 2.
Just before the projection 36 enters the groove portion 35', the element 5 is in the position shown in FIG. 1 in which its free end has passed the effect weft thread 3, so that the latter is in contact with the element 5.
During further leftward movement of element 5 (in FIG. 8), the projection enters the groove portion 35'. This causes the ring 30, and with it the element 5, to turn first in counterclockwise direction (see arrow f in FIG. 7) in order to clear the raised warp threads 2' and then to advance slightly further towards the left as the projection 36 slides in the groove portion 35", until ring 30 contacts abutment 30 and element 5 is in the ten o'clock position shown in FIG. 7. At this time (see FIG. 2), element 5 is in contact with the upper side of the warp 2 adjacent the beating-up edge 6 and forms in the effect weft thread 3 the loop 3', aided by the right-hand raised weft thread 2' which tends to push the loop further onto element 5 during the final advancement of the same along groove portion 35".
The element 5 remains in this position until the needle 4 is retracted. At this time, the warp shed is closed and the arm 20 moves in the opposite direction, causing the element 5 to start its retracting movement towards the starting position (see FIG. 3). This retracting movement is aided by the biasing force of spring 34. At this time, also, the beating-up device 7 begins to approach the beating-up edge 6. The projection 36 is still sliding in the groove portion 35".
FIG. 4 shows the effect warp thread 3 in fully beaten-up condition. The free end of element 5 has not yet cleared the loop 3', but the projection 36 has passed through the groove portion 35' into the groove 35. During its further movement in groove 35 to the starting position of FIG. 8, the element 5 will move out of loop 3' and the latter will be retained in place due to the closing of the warp sled. The next loop-forming sequence can now begin.
FIG. 5a shows that the element 5 can be provided adjacent its free end with one or more thread cutters 5", if it is decided to sever the loops rather than have them intact. These cutters 5" will then cut the thread forming the loop, as the element is retracted from the position shown in FIG. 4.
If it is desired to fix the loops 3' positively, then a device such as that shown in FIG. 9 may be provided. In this embodiment, a receptacle 38 containing an adhesive 37 is mounted above the fabric 1. A rotary roller 39 is provided which receives a layer of adhesive 37 on its periphery from the receptacle 38. The roller 39 may be driven and is so positioned above the fabric 1 that as the latter moves beneath it, only the upstanding loops 3' come in contact with the adhesive on the roller periphery, so that each loop 3' receives a drop 3" of the adhesive. These drops then become bonded to the fabric 1 and positively secure the loops 3'.
Another possibility for positive fixing of the loops 3' is shown in FIG. 10. This embodiment can be used when at least the effect weft thread 3 is of a thermoplastic synthetic material. It involves the provision of a resistance wire to which is arranged above the fabric 1 at such a distance that the heat emanating from the energized wire will melt the material of the loops 3', causing the molten material to bond with the fabric 1 or resolidification, whereby again the connecting points or spots 3" are formed.
Of course, modifications of the illustrated embodiment will offer themselves to those skilled in the art. Thus, the element 4 may instead of the recessed illustrated leading end be provided with an eye or hook.
It is also possible to provide a separate element which takes over the thread 3 from the element 4 and places it about the element 5. Such a separate element makes it unnecessary to move the element 5 not only transversely of the warp but additionally in the direction of elongation of the warp or in other directions inclined to the plane of the warp.
The present invention makes it possible to provide effect threads in fabrics which are woven even on needle looms, and which can be inserted from any desired side of the fabric to any desired point of the fabric, that is part-way or all the way across the width of the latter, without requiring separate controls for the different widths desired for the effect thread, that is without having to have separate controls for controlling different movements of the elements 4 and 5 in dependence upon the width for which the effect thread is to be provided. By using the element 5, it is assured that the loops 3' will automatically be formed about the element 5 and located at the desired position, that is they will always form at the first warp thread in the upper part of the shed and they will always be of the same size. The quantity of effect thread used is limited exactly to the visible width of the effect thread in the fabric, meaning that no portions of the effect thread remain at the underside of the fabric where they can hange loose and provide an aesthetically pleasing pppearance, and also no thickening or other imperfections in the fabric will result.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of applications differing from the types described above.
While the invention has been illustrated and described as embodied in the insertion of an effect thread, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can by applying current knowledge areadily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention and, therefore, such adaptations should and are intended to be comprehended within the meaning and range of equivalence of the following claims.
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To insert an effect thread into a fabric being woven a warp is opened and an effect thread is inserted from one side into the open warp. It is then engaged from the open side of the warp and retained until such time as it can no longer be withdrawn from the warp due to its own tension.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C Section 119 from U.S. Provisional Patent Application No. 60/188,647 filed on Mar. 10, 2000, and under 35 U.S.C. Section 120 as a Continuation-in-Part of U.S. patent application Ser. No. 09/804,135, filed Mar. 12, 2001, now abandoned, which are incorporated herein by reference for all purposes.
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The present invention relates to a rescue device and emergency apparatus. More specifically, the present invention comprises a weighted throwing portion secured to a length of rope, and an adjustable wrist loop secured a short distance from the throwing portion.
2. Background Art
Each year numerous lives are lost because aid was not quickly available, even when bystanders and emergency crews are present. Most rescue operations require a certain amount of time to prepare and execute—and time that can be fatal to a person in distress.
There are also hazards to the rescue personnel or bystander, especially if attempting the rescue without proper planning. Many tragic stories tell of the Good Samaritan that attempted to rescue a victim in distress only to become a victim of the same fate.
Persons in distress in water pose several problems to a rescuer. The distressed person will likely cling to whatever is within reach, including a prospective rescuer. A drowning person lacks the capacity of reasoning and can present a serious threat to an unqualified or unsuspecting rescuer. For this reason, lifeguards normally keep a safe distance between themselves and the victim. The lifeguard typically uses a buoy or other floatation device to present to the victim to grasp and can then safely haul the buoy and victim to shore. If there is no separation device, a lifeguard dives below the surface and positions the victim into a safe and controlled orientation before attempting to swim to shore. In the event that the victim does manage to grab hold of a lifeguard, the preferred escape is to dive under the water and break-away from the victim.
Rescue operations in ice present even greater danger to the victim and rescue persons. Hypothermia is a major concern, and a person that falls into frigid water only has a few minutes before the effects of hypothermia develop. Hypothermia causes the body to enter into a state of shock that inhibits coordination and muscular control. It also effects the mental state and a person may become unconscious. A further problem relates to the ice itself, the area surrounding a break is usually more susceptible to breaking, thus a rescue person that exerts too much pressure upon the ice may wind up stuck in the same predicament as the victim.
In order to reduce the aforementioned problems, attempts have been made to produce a suitable rescue device. The prior art devices have general short-comings and do not adequately address the problems and difficulties stated herein.
U.S. Pat. No. 4,661,077 discloses a spherical throwing device with integrated channels to form a loop that would restrict once the rope is pulled. This particular invention has no means of keeping the loop in an open position and there is no restriction on the rope to prevent slippage of the loop size during throwing and operation. Furthermore the loop is integrally connected to the throwing ball and it would be difficult to engage the loop.
A weighted throwing bag with a securing line is described in U.S. Pat. No. 3,981,526 that allows the weighted bag to be thrown in the vicinity of a distressed person. The bag has gripping portions that can be used to cling to until help arrives or to assist in pulling the person out of the water. The bag also employs a spike tool to enable the distressed person to climb to safety out of ice. This invention relies on the distressed person to be conscious and have good motor skills to rescue him/her self.
The invention of U.S. Pat. No. 6,019,651 describes a throwable disc-shaped device connected to a rope. The disc breaks apart to produce a harness that can be grabbed by the victim or the victim can slip his arms through the harness and the harness will go around the back and under the arms. A similar device is shown in U.S. Pat. No. 5,433,637 that shows a floatation device with gripping structures and straps. One problem with these inventions is that if they are held in the hands, the victim may lose consciousness and let go of the rope. It may also be difficult to grab onto the device or straps when wearing clothing and gloves. In addition, if the person fell into an icy body of water and the harness is placed around the back of the victim, the force of the pulling will bring the person's chest against the ice.
A life ring is illustrated in U.S. Pat. No. 4,976,642 having a semi-rigid inner ring and a flexible outer ring. The distressed person is supposed to be situated within the inner ring and as the pulling rope is pulled the outer ring changes in shape so as to grip the distressed persons arms. In U.S. Pat. No. 4,701,145 another circular shaped buoy device is disclosed with a center strap and buckling devices to secure the distressed person. An inflatable buoy device is shown in U.S. Pat. No. 5,980,158. These devices generally do not have a long range throwing capacity. These devices also require some physical dexterity on the part of the distressed person. In addition, these devices tend to occupy more space and cargo room.
There are many other devices that describe various discs and rings having certain features and attributes, but all generally require the distressed person to hold onto an object or otherwise secure him/her self to the object. What is needed is a device that is compact and easily stored in convenient locations. Such a device should be capable of rapid deployment and operable by anyone. This device should be inexpensive to purchase, yet sturdy and dependable. The device should allow the rescuer to deploy the rescue device a long distance from the rescuer so that the rescuer remains safe. This device should allow the victim a fast yet secure way to be secured to the device. Furthermore, this device should hold the person in an optimal position with the head above water, even if the victim loses consciousness.
SUMMARY OF THE INVENTION
The present invention has been made in consideration of the aforementioned background, and is for a compact life-saving rescue device. The invention, that contains the floatation throwing device and the rope having a hand loop restraint, is stored securely on a rigid carrying board. This provides a convenient and inexpensive rescue device that is versatile, lightweight, and compact and can be used in ponds, rivers, streams, lakes, brooks and similar bodies of water—especially if the water is frozen or partially frozen.
An object of the invention is to provide a life safety apparatus that can be used as a first response tool. The compact device can be stowed in a car trunk or carried along when venturing out in the outdoors. It can be used to stabilize a person in distress until help arrives and may be used to assist in pulling the person to safety. The invention is held conveniently on the retaining board and quickly and easily can be extracted and delivered to the distressed person, even by a person with no training in life-saving or rescue operations.
The wrist/arm securing feature retains a firm grip on the person even if the person loses consciousness or is otherwise unable to hold onto an object.
A further object of the invention is to provide a life-saving apparatus,that is capable of being delivered a long distance from the rescuer so that the rescuer remains safe and secure. The weighted portion of the present invention allows the rope to be accurately thrown an average of 75-85 feet. In one embodiment the weighted unit is a buoyant ball.
And another object is an emergency rescue device that employs a loop positioned a short distance from the weighted portion. The loop is designed such that it secures around the wrist/arm when the rope is pulled.
Yet another object is that the present invention is comprised of relatively inexpensive components so that the unit is affordable to rescue, fire, police and emergency personnel that are on tight fiscal budgets. The device is also affordable to the general public and can put such devices in the hands of those that are first to arrive at the scene of the rescue. This is especially important when time is a critical element of survival.
And a further object of the invention is to provide a floatation device in close proximity to a distressed person to be used to help the person locate the rope and wrist loop. The buoy is fluorescent in color. The device can also employ battery operated lighting means and electronics such as global positioning systems and emergency alerting devices.
An object of the invention is a throwable rescue device, comprising a length of rope having a base end and a throwing end. In one embodiment, the rope is stranded polypropylene. There is a weighted unit connected at an end of the throwing end and a loop forming assembly engaging the rope forming an adjustable loop in the rope with a slidable end and a fixed end. The loop forming assembly is designed such that the rope retains its loop during deployment. The loop secures when the rope is pulled by the rescuer, while the distressed person has their wrist/arm through the loop. The design of the loop forming assembly always remains open until the proper angle and resistance is attained.
An object includes a throwable rescue device, wherein the loop forming assembly is comprised of a pivoting retention block, a stop sleeve, spring ring, rubber retention washer and self tapping screws. The pivoting retention block is an L shaped machined high definition polyethylene part used to ensure proper length of the loop and provides proper placement of all parts of the loop forming assembly. There are beveled surfaces in the slidable side of the block to provide ease of engagement of the stop sleeve and proper angle to the rope when the rope is pulled. The bevel to the loop side of the loop forming assembly allows the friction to the rubber washer to be reduced when the rope is pulled. The stop sleeve is stainless steel cylindrical hollow tube used to set the loop length and help provide retention support to keep loop assembly open. The spring ring is a stainless steel double loop ring to secure the stop sleeve to the rope in a fixed position on the slidable end of the loop forming assembly and prevents the stop sleeve from sliding through the pivot retention block.
The rubber retention washer is made of neoprene rubber in order to set the loop length and help provide retention with the stop sleeve to keep loop assembly open. The inner diameter of the washer contacts the rope on the slidable end of the loop forming assembly wherein an outer edge of the washer contacts the rope on an inner side of the fixed end. This configuration ensures the ring sleeve stays in proper position and the loop stays open.
Another object is a throwable rescue device, wherein the means for resisting movement is an outer edge of the washer contacting the rope at the fixed end, wherein the washer is displaced when the base end is pulled. In one embodiment, the screws are stainless steel self tapping screws used to ensure the pivoting retention block to the rope in a fixed position.
An additional object is a throwable rescue device, further comprising a storage retainer for storing the rescue device. In one embodiment the storage caddy has a hollow circular section and the rope wraps around the circular section and the ball fits within the hollow section. There can be a base portion affixed to one end of the circular section and a mating lid assembly that covers the circular section and secures to the base portion.
An object of the invention is a throwable rescue device, comprising a length of rope having a base end and a throwing end. There is a weighted unit connected at an end of the throwing end and a loop forming assembly engaging the rope and forming an adjustable loop in the rope. The loop forming assembly has a means for providing resistance on the rope to maintain a size of the adjustable loop, and a means for providing no resistance when the base end is pulled.
A further object includes the throwable rescue device, wherein the loop forming assembly comprises an ‘L’ shaped member having a long section and a short section with a first passage through the long section and a second passage through the section, wherein a fixed end of the adjustable loop goes through the first passage and a slidable end of the adjustable loop goes through the second passage. And, wherein the means for providing resistance comprises a stop sleeve engaging the second passage and at least one washer installed on the slidable end. Furthermore, wherein the means for providing resistance is at least one plyable washer installed on the adjustable end wherein an outer edge of the washer contacts the fixed end of the rope. An additional object further comprises a stop to limit a size of the loop, wherein the stop is a spring ring affixed to a stop sleeve that is fixedly attached to the base end proximal the loop forming assembly.
An additional object is the throwable rescue device, further comprising a storage caddy for storing the rescue device, and also wherein the rope is stranded polypropylene, and further wherein the weighted unit is a buoyant ball
An object of the invention is a throwable rescue device, comprising a length of rope having a base end and a throwing end. A weighted unit is connected at an end of the throwing end and there is a loop forming assembly engaging the rope and forming an adjustable loop in the rope. The adjustable loop has a fixed end and a slidable end, and the loop forming assembly has a first passage engaging the rope on the fixed end and a second passage slidably engaging the rope on the slidable end, wherein the loop forming assembly has at least one washer installed on the slidable end.
And yet another object is the throwable rescue device, further comprising a stop affixed to the based end proximal the loop forming assembly and limiting a size of the loop when the stop contacts the loop forming assembly. The loop forming assembly may comprise an ‘L’ shaped member having a long section and a short section with the first passage through the long section and the second passage through the short section. In addition, the second passage can have a beveled surfaces engaging the rope. In contrast, the first orifice can employ self tapping screws affixing the rope to the loop forming assembly.
And a final object is a throwable rescue device, wherein at least one washer provides a means for resisting movement of the rope, wherein an outer edge of the washer contacts the rope at the slidable end, wherein the washer is displaced when the base end is pulled.
Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description, wherein only a preferred embodiment of the invention is shown and described, simply by way of illustration of the best mode contemplated by me on carrying out the invention. As will be realized, the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is susceptible of many variations, all within the scope of the specification, figures, and claims. The preferred embodiment described here and illustrated in the figures should not be construed as in any way limiting. The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:
FIG. 1 . illustrates the components of the invention including the rigid carrying board, weighted unit, rope and loop forming assembly and details rough dimensions and orientations from a top view
FIG. 2 shows the weighted end portion in more detail
FIG. 3 is a close-up of the loop forming assembly, showing the interaction between the rope, the pivoting retention block, the stop sleeve, spring ring, screws and the washer
FIG. 4 provides further details of the pivoting retention block forming assembly and highlights the beveled or countersunk holes
FlG. 5 shows the fully assembled unit stored on rigid carrying board
FIG. 6 demonstrates one method of throwing wherein an underhand lob is used
FIG. 7 shows the angular position of the rope to the loop forming assembly when unit is in flight
FIG. 8 illustrates the angular position of the rope to the loop forming assembly when unit is in wrist/arm is in the loop and unit is being pulled.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention refers to a rescue device that comprises a weighted object attached to a rope and having a means of securing to a person to facilitate rescue operations. A single preferred embodiment is illustrated with dimensions and particulars to demonstrate an enabled and functional description however the invention is in no way limited to this single embodiment.
Referring to FIG. 1 and FIG. 5, one embodiment of a layout of the invention is illustrated. In this embodiment, the invention is depicted in kit form that is easily mounted and stored on rigid carrying board 10010 . The rigid carrying board 10010 should be durable and lightweight, and one such material for the rigid carrying board 10010 is plexi-glass. The rigid carrying board 10010 is approximately 18½ inches long and 8½ inches wide with holes positioned about the perimeter of the board 10010 to secure the rope 10002 to the rigid carrying board 10010 and to mount plexi-glass rope retainers 10013 . The plexi-glass rope retainers 10013 are mounted at each corner approximately 1¼ inches from an end and a side of the rigid carrying board 10010 through cylindrical spacers 10012 using pan screw 10011 and nylon locking nut 10014 . The cylindrical spacers 10012 should be of a rigid durable material as nylon with dimensions approximately 1½ inches long by ⅜ inch in diameter.
The plexi-glass rope retainers 10013 are able to rotate such that plexi-glass rope retainers 10013 can be positioned outward from the center of the rigid carrying board 10010 and will securely hold the coiled rope 10002 and weighted end of the device or two or more of the plexi-glass rope retainers 10013 can be positioned in towards the center of the rigid carrying board 10010 where one could remove the rope 10002 and weighted end of the device for deployment.
FIG. 5 depicts the plexi-glass rope retainers 10013 positioned outward such the fully assembled unit is securely stored. The retainers 10013 are rotatable about the spacer 10012 so that they can be swung to be positioned pointing inward to allow the rope 10002 to slip off efficiently from the retainer 10013 for deployment mode. The rope 10002 is looped through one or more holes 10025 in the rigid carrying board 10010 such that the rope 10002 is secured to the rigid carrying board 10010 by a knot on the end of the rope 10002 . In one embodiment a loop 10026 is formed on the side opposing the retainers 10013 and makes a handle to be able to easily carry the device or position for deployment. A Velcro® loop 10009 or other hook and loop type fastener is further used to secure the weighted end of the device when stored. The combination of the rigid carrying board 10010 , plexi-glass rope retainers 10013 , cylindrical spacers 10012 , pan head screws 10011 and nylon locking nuts 10014 allows a means for safe storage, transportation and fast deployment of the device.
It should be apparent that the storage and packaging of the invention may occur in many forms that have been contemplated and within the scope of the invention. For example, the stowage can be accomplished upon a circular assembly having a hollow center for housing the weighted ball. Such an assembly can have raised edges or a sloping profile similar to a wheel rim that would maintain the rope 10002 centered about the assembly. In the rigid board scheme, a second board can be used in place of the retainers and one side of the boards can be displaced to free the rope for deployment. The apparatus can be stowed in a bag for easy transport and there are numerous other rope stowing methods already described in the prior art.
The rope 10002 in this embodiment is approximately 100 feet in length by ¼″ in diameter. This dimension tends to provide adequate distance for a rescue, sufficient strength for hauling, and light enough to optimize throwing distance. In the preferred embodiment the rope 10002 is a nylon polypropylene that also has the advantage of being a floatation material. Allowing the rope 10002 to float on the surface of water makes it easier to be located by a distressed person such as someone that is fully dressed and in cold water.
FIG. 2 illustrates the orientation of the fluorescent ball 10001 with respect to the loop forming assembly 10003 . It also illustrates the wrist adjustable loop that is used to grip the person in distress. The loop is adjustable in size and tightens when the weighted end of the rope is pulled.
FIG. 3 is a detailed view of the loop forming assembly that details the individual elements and shows the interaction of the rope 10002 , the pivoting retention block 10003 , the stop sleeve 10005 , spring ring 10006 , washer 10004 , and screws 10007 . The pivoting retention block 10003 is a manufactured piece that ensures the rope reacts properly during flight and when the carrying board end of the rope is pulled. In this embodiment it is made of High Density Polyethelene (HDPE).
The rope has a loop forming assembly 10035 as depicted in FIG. 2 and FIG. 3 comprised of a pivoting retention block 10003 , a stop sleeve 10005 , spring ring 10006 , rubber retention washer 10004 and self tapping screws 10007 . The loop forming assembly 10035 forms an adjustable loop 10030 in the rope 10002 . In the illustrated example, the adjustable loop 10030 is approximately 7″ in diameter and held together by the loop forming assembly 10035 . The characteristics and dimensions of the rope 10002 affect the size of the adjustable loop 10030 to some extent, but the function of the adjustable loop 10030 is to remain an easy target for a victim to insert their hands or arm.
The rope 10002 is terminated in a throwing unit 10001 and affixed within the throwing unit 10001 by many means such as a knot, fastener and similar known techniques. In a preferred embodiment, a fluorescent rubber ball 10001 approximately 4 inches in diameter and weighing about 12 ounces is used. In one embodiment, the rope 10002 is slipped through a center of the ball 10001 and a knot or other fastener is used to fasten the ball 10001 to the rope 10002 . The rope 10002 is not intended to be slidable within the ball 10001 but rather to remain a fixed element. The ball 10001 is made to be buoyant so that it floats.
Many throwing units are also within the scope of the invention, including torpedo buoys, discs and rings. However, the intent of the throwing unit is to provide for optimal throwing distance and accuracy. The size and weight of the throwing unit 10001 are important characteristics in placing the adjustable loop 10030 in close proximity to the victim, even in less than desirable weather conditions. The throwing unit 10001 should also be of a material that has some impact absorbing qualities in the event that the object 10001 strikes the victim. Various electronics such as global positioning system (GPS) location tracking electronics can be incorporated into the throwing unit 10001 , if required.
The prior art discusses many different types of rescue throwing devices, including elliptical or disc-shaped devices. The present invention is equally applicable to usage of the disc shaped units, as these discs generally have less air resistance and ten d to provide a longer distance. However, throwing a discus requires more practice for accuracy whereas the present invention requires minimal training for distance and accuracy.
TABLE A
Weight
Throw
15.1 oz
13.4 oz
12.8 oz
12.0 oz
1
79.4
71.4
76.2
79.6
2
81.6
73.8
79.3
85.2
3
84.3
72.1
80.1
82.4
4
86.5
75.4
79.2
80.7
5
83
72.2
80
78.8
6
88.7
73.5
71
83.5
7
87.9
76.6
84.1
86.5
8
99.5
72.9
81.2
85.4
9
92.5
70
79.4
81.3
10
88.7
76.1
82
84
AVG
87.2
73.9
79.25
82.74
Distance
As shown in Table A, various weights were thrown ten times and the distance measured for each throw to establish an average distance. As depicted, all the weights tested produced distances in excess of 70 feet.
As depicted om FIG. 4, the pivoting retention block 10003 is shaped like an ‘L’ with approximate dimensions of 2 inches long, 1½ inches wide and ¾ inch thick. There is a first hole 10020 approximately ⅜ inches in diameter drilled through the pivoting retention block 10003 with counter sunk chamfers ⅝ inches in diameter by 90 degrees on each side 10021 . There is a second hole 10022 that is approximately ⅜ inches in diameter that is drilled through the pivoting retention block 10003 end to end of the long dimension of the L of the block. The holes 10020 , 10022 are positioned to separate the rope 10002 and to form the adjustable loop 10030 .
The rope 10002 from the weighted end goes through the hole 10022 that is drilled end to end of the long dimension of the pivoting retention block 10003 and is attached to the pivoting retention block 10003 with two stainless steel self tapping screws 10007 at approximately 11 inches from the ball 10001 . The two screws 10007 in the pivoting retention block 10003 intersect the rope 10002 at approximately 90 degrees and the screws 10007 go through the rope 10002 . The screw holes 10023 are drilled approximately ¾ inch apart through the flat side on the longer side of the L of the pivoting retention block 10003 into the hole 10022 that is that is drilled end to end of the long dimension of the pivoting retention block 10003 .
The adjustable loop 10030 is formed from the junction of the rope 10002 as it is attached to the pivoting retention block 10003 via the two screws 10007 and as it goes through the hole 10020 with counter sunk chamfers 10021 in the pivoting retention block 10003 and to the spring ring 10006 in the stop sleeve 10005 . The spring ring 10006 in this embodiment is approximately {fraction (9/10)} inches in outer diameter and ¾ inches inside diameter and made from stainless steel. The stop sleeve 10005 in this embodiment is a cylindrical hollow tube approximately {fraction (6/10)} inches by ⅜ inch. The stop sleeve 10005 is secured to the rope 10002 via a spring ring 10006 that goes through the stop sleeve 10005 and through the rope 10002 . The purpose of the stop sleeve 10005 is to set the loop length and help provide support to keep the loop assembly open.
The spring ring 10006 attaches the stop sleeve 10005 to the rope 10002 in a fixed position and prevents the stop sleeve 10005 from sliding through the pivoting retention block 10003 to the ball end of the rope. The attachment of the stop sleeve 10005 on the rope 10002 at approximately 40 inches from the ball 10001 and the attachment of the rope 10002 to the pivoting retention block 10003 at approximately 11 inches from the ball 10001 sets the proper dimensions for loop diameter 10030 and ensures throwing ease. Thus, the length of the loop portion of the rope is approximately 22 inches.
The retention washer 10004 is a closed cell neoprene washer approximately 1½″ in diameter and {fraction (1/16)}″ thick. The retention washer 10004 is designed to prevent slippage of the adjustable loop prior to the carrying board 10010 end of the rope 10002 being pulled. The retention washer 10004 also ensures that the stop sleeve 10005 stays located inside the chamfered hole in the pivoting retention block 10003 while the rope is being thrown.
The retention washer 10004 contacts the pivoting retention block 10003 where the rope 10002 goes through the chamfered hole 10020 in the pivoting retention block 10003 . As depicted, the outer edge of the washer 10004 is in physical contact with the weighted end of the rope 10002 while the other end of the rope 10002 has the stop sleeve 10005 and goes through the center of the washer 10004 . The dimension of the inner diameter of the hole in retention washer 10004 is {fraction (1/16)}″ smaller than the polypropylene rope 10002 to provide resistance to movement of the rope 10002 .
A single washer 10004 can be used of appropriate thickness and elasticity, or multiple washers 10004 can be utilized according to the desired qualities. The wider the surface area of the washer 10004 edge contacting the rope 10002 , the greater the resistance upon the rope 10002 while closing the adjustable loop 10030 . While a separate washer 10004 is depicted, incorporating the functionality of the washer 10004 as an integrated element of the pivoting retention block 10003 is an obvious variation of the present invention.
FIG. 6 demonstrates a preferred hand location for throwing the rescue device. The loop 10030 acts as a handle so the rescue device can be thrown using an underhand bowling or softball pitching motion. The combination of the position of hand location in the loop 10030 together with the pendulum motion of the thrower's arm allows distances of up to 75′ to be achieved with relative ease as shown in Table A.
FIG. 7 demonstrates the position and angle of the loop forming assembly with respect to the rope 10002 when the unit is in flight or when the carrying board 10010 end of the rope 10002 is pulled by the rescuer. It is the combination of the angular position of the pivoting retention block 10003 , the contact of the stop sleeve 10005 with the pivoting retention block 10003 , and the friction of the rubber retention washer 10004 to the rope 10002 that prevents the adjustable loop 10030 from closing. The washer 1004 adopts a concave form as it holds the rope in place. The stop sleeve is within the retention block and due to the angle of the rope to the user, has enough resistance to maintain the loop 10030 in place.
The tension provided by the propulsion of the ball 10001 during deployment, or the tension provided by the weight of the ball 10001 when the carrying board 10010 end of the rope 10002 is pulled by the rescuer, keeps the pivoting retention block 10003 angled such that the stop sleeve 10005 provides resistance to movement of the rope 10002 . The rubber washer 10004 ensures the stop sleeve 10005 stays positioned within the chamfered hole 10020 in the pivoting retention block 10003 and also provides resistance to movement of the rope 10002 .
FIG. 8 depicts the collapse of the loop 10030 upon the victim's or arm when the victim inserts their arm into the loop 10030 . When the victim inserts their wrist or arm into the adjustable loop 10030 , it provides movement to the loop portion of rope 10002 . This movement causes rotation or pivoting of the pivoting retention block 10003 such that the stop sleeve 10005 then is able to slide out the pivoting retention block 10003 . Once the stop sleeve 10005 has slid out of the pivoting retention block 10003 there is less friction to keep the loop open. The chamfered hole 10020 in the pivoting retention block 10003 reduces the friction of the rope 10002 on the pivoting retention block 10003 . The retention washer 10004 is flexed inward to the bevel in the chamfered hole 10020 and this also reduces the friction of the retention washer 10004 on the rope 10002 . This combination of events allows the adjustable loop to close without resistance and is essentially self-closing.
It should be noted that intention and motivation of the present invention is to be a low cost and simplistic unit and further enhancements are possible. In operation, the device is typically carried in a trunk of a car such as a rescue vehicle or police cruiser and is carried as close as possible to the site of the emergency and near the distressed person. The unit is typically stored in a ready-to-use state where the rope 10002 is coiled on the rigid carrying board 10010 .
The user can rotate two or more of the rope retainers 10013 , grasp the coiled rope 10002 and weighted end 20002 , then drop the rigid carrying board 10010 to the ground. The user can then drop the coil of rope 10002 to the ground approximately 5-6 feet away from the rigid carrying board 10010 . Then user can hold the rescue device as shown in FIG. 6 by holding the loop portion 10030 with the ball 10001 at an opposing end of the user's hand. The rescuer can then lob the ball 10001 to the person in distress and preferably within very close proximity. The loop forming assembly 10035 holds the loop open during flight to the person in distress.
Depending upon the weather conditions and experience of the rescuer, it may take more than a single attempt to place the rescue device in the proper location for the distressed person. Verbal commands can be issued to the distressed person if possible, but in most cases the person in distress will try to instinctively grab whatever is in reach. Once the person in distress inserts one or both wrists into the loop or otherwise grabs the loop rope, the rescuer pulls the rope. As the rope is pulled the loop forming assembly 10035 rotates and the loop 10030 collapses without resistance.
No warranty is expressed or implied as to the actual degree of safety, security or support of any particular specimen of the invention in whole or in part, due to differences in actual production designs, materials and use of the products of the invention.
The foregoing description of the preferred embodiment of the invention has been presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above writings. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.
The invention is susceptible of many variations, all within the scope of the specification, figures, and claims. The preferred embodiment described here and illustrated in the FIGS. should not be construed as in any way limiting.
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The invention in the simplest form is an emergency rescue device the stores conveniently and provides a rapid deployment. The invention comprises a length of rope interconnected to a weighted throwing unit having a loop portion with an automatic restraining system. The throwing unit is used to position the loop in close proximity to the distressed person, wherein the person only need to insert his/her hands within the loop. The rescue personnel pulls the rope which tightens the loop and firmly holds the wrists of the person in a hyper extended position.
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This is a continuation of Ser. No. 237,559, filed Feb. 24, 1981, U.S. Pat. No. 4,379,969.
BACKGROUND OF THE INVENTION
The present invention relates to corona charging devices, particularly as used for discharging electrostatic images.
Corona charging devices in the form of thin conducting wires or sharp points are well known in the prior art. Illustrative U.S. Pat. Nos. are Vyverberg 2,836,725; L. E. Walkup 2,879,395; P. Lee 3,358,289; Lee F. Frank 3,611,414; A. E. Jvirblis 3,623,123; P. J. McGill 3,715,762; H. Bresnik 3,765,027; and R. A. Fotland 3,961,564. Such devices are used almost exclusively in electrostatic copiers to charge photoconductors prior to exposure as well as for discharging. Standard corona discharges provide limited ion currents. Such devices as a rule achieve a maximum discharge current density on the order of 10 microamperes per square centimeter. Additionally, corona wires are small and fragile, and easily broken. Because of their high operating potentials they collect dirt and dust and must be frequently cleaned or replaced, in order to avoid fall-off of the emission current.
Corona discharges which enjoy certain advantages over standard corona apparatus are disclosed in Sarid et al. U.S. Pat. No. 4,057,723; Wheeler et al. 4,068,284; and Sarid 4,110,614. These patents disclose various corona charging devices characterized by a conductive wire coated with a thick dielectric material, in contact with or closely spaced from a further conductive member. Various geometries are disclosed in these patents, all fitting within the above general description. These devices utilize an alternating potential in order to generate a source of ions, and a DC extraction potential. The patents disclose a preferred biasing range of 2000-6000 volts, relatively high values which are required in order to obtain significant extraction currents and therefore higher charging rates. These current outputs are exponential in character, in contrast to the fairly linear outputs of the present invention. In addition, these devices are undesirably sensitive to variations in the gap width between the corona and the imaging member.
U.S. Pat. No. 4,153,093 discloses ion generating apparatus which may be used for charge neutralization as well as deposition of net charge. This apparatus is superior to standard corona apparatus, but is difficult to fabricate, and does not provide the high charging rates of the present invention.
Accordingly it is a principal object of the invention to provide charging and neutralizing devices employing corona discharges which have superior performance as compared with prior art corona devices.
Another object of the invention is to provide a corona charging device which achieves high current densities. A related object is the achievement of high charging rates. Another related object is the avoidance of high biasing potentials in providing such charging rates.
A further object of the invention is to provide a charging device having a rugged and compact structure. A related object is to provide a device having a longer operational life than is customary in corona ion generators. A further related object is the provision of corona apparatus which does not require frequent servicing.
Another object is to provide a corona charging device capable of charging or discharging a remote dielectric or photoreceptor surface to potentials within a few volts of a preselected potential.
Still another object of the invention is the avoidance of emission current fall-off as the ion generator becomes slightly dirty. A related object is the achievement of uniform emission currents. Yet another object of the invention is the provision of a corona charging device with a reliable output potential.
SUMMARY OF THE INVENTION
In achieving the above and related objects, the invention provides a corona charging device comprising an elongate conductor with a dielectric sheath, and an overlying conductive grid. The dielectric sheathed conductor and conductive grid are both mounted against an insulating substrate. This apparatus may be used for corona charging and discharging by means of a varying potential between the elongate conductor and the conductive grid. The conductive grid is maintained at ground potential for charge neutralization, and at a limiting bias potential for corona charging.
In accordance with one aspect of the invention, the grid electrode comprises a one or two directional array of fine conductive members. In the preferred embodiment, the grid electrode comprises a fine wire mesh screen. In an alternative embodiment, the grid comprises a parallel array of fine, closely spaced wires, transverse to the axis of the elongate conductor.
In accordance with another aspect of the invention, the elongate conductor may have a variety of cross sections. In the preferred embodiment, the elongate conductor comprises a cylindrical wire. In an alternative embodiment, this electrode comprises an etched foil. In accordance with a related aspect of the invention a variety of insulating materials, preferably inorganic, may be utilized in the dielectric sheath for the elongate conductor.
In accordance with a further aspect of the invention, the conductive grid and the dielectric sheathed conductor form substantially parallel electrodes. In accordance with a related aspect, the grid may have a variety of transverse cross sections wherein the grid contacts or is closely spaced from the dielectric sheath at or near its outer surface.
In accordance with an alternative embodiment of the invention, the corona charging apparatus may include a thin dielectric separating the conductive grid from the elongate conductor, but not completely covering the latter member.
In accordance with a further alternative embodiment of the invention, the insulating substrate may include a slot to house the dielectric sheathed conductor. In this embodiment, the dielectric sheathed conductor is embedded in the slot along its length, and the conductive grid is mounted over this member at a point at which it protrudes from the slot.
In accordance with yet another aspect of the invention, the varying potential is advantageously a continuous wave alternating potential in the range 600 to 1500 volts peak, with a frequency in the range 60 Hz to 10 MHz. Alternatively, the varying potential may comprise a pulsed voltage. In the embodiment for corona charging, the extraction potential preferably is on the order of tens or hundreds of volts.
In a preferred embodiment of the invention, the device is employed for the erasure of electrostatic images on a proximate member. In an alternative embodiment, the device is employed for charging such a dielectric member to a prescribed voltage. In the latter case the device of the invention provides automatic control of the charging level. In either embodiment, the corona device is advantageously disposed at a distance in the range 5-20 mils from the member to be charged or discharged.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and additional aspects of the invention are illustrated in the detailed description which follows, taken in conjunction with the drawings in which:
FIG. 1 is a sectional view of a corona charging device in accordance with a preferred embodiment of the invention;
FIG. 2 is a plan view of the charging device of FIG. 1;
FIG. 3 is a sectional view of a charging device with an alternative grid electrode profile;
FIG. 4 is a sectional view of the charging device of FIG. 1, deployed for charging or discharging an adjacent member;
FIG. 5 is a sectional view of an alternative charging device design;
FIG. 6 is a sectional view of a further charging device design;
FIG. 7 is a sectional view of a charging head with an alternative corona electrode construction; and
FIG. 8 is a plan view of a charging device with an alternative grid electrode.
DETAILED DESCRIPTION
Reference should now be had to FIGS. 1-10 for a detailed description of the corona charging apparatus of the invention. FIG. 1 is a sectional view of an illustrative corona device 10. The corona device includes a corona electrode 11 mounted on an insulating substrate or support 15, with a conductive grid electrode 17 overlying electrode 11. A characteristic feature of corona device 10, as shown in the plan view of FIG. 2, is that corona electrode 11, grid electrode 17, and substrate 15 form a linear structure.
Corona electrode 11 consists of a conductor 12 in the form of a wire (which may consist of any suitable conductive material) encased in a thick dielectric 13. Although a dielectric-coated cylindrical wire is illustrated in the preferred embodiments, the electrode 11 is more generally described as an elongate conductor having a cross-section of indeterminate shape and including a dielectric sheath. FIG. 7 illustrates an alternative corona electrode construction. Corona electrode 71 comprises a thin etched conductor 72 with dielectric encapsulation 73. The elongate conductor may rest directly in contact with the insulating support, as long as it is separated from the mesh electrode by the dielectric sheath.
Electrode 11 is placed against insulating substrate 15. Advantageously, the corona electrode 11 is constrained by grid electrode 17, but is not bonded to the insulating substrate. This arrangement permits relative movement of these structures due to thermal expansion and contraction. The substrate 15 consists of insulating material of sufficient rigidity to support the coated-wire electrode 11 and grid electrode 17.
Grid electrode 17 comprises an array of elongate conductors of minute thickness as compared with the diameter of dielectric-coated electrode 11. In the preferred embodiment of the invention, this electrode comprises a fine wire mesh screen, advantageously a screen with a mesh in the range 30-150 apertures/inch, and a wire thickness in the range 0.3-1.2 mils. Preferably, the wire mesh screen is characterized by a high percentage of open area. The screen may consist of any well known metal or metal alloy, such as steels, stainless steels, nickel-chromium alloys, copper alloys, and aluminum alloys. The use of a fine mesh provides a desirably high density of ion generation sites, and avoids overheating at crossover points. In an alternative embodiment, the grid electrode is fabricated by photoetching a screen pattern on a metal foil. In a further alternative embodiment illustrated at 80 in FIG. 8, grid electrode 87 consists of a parallel array of fine, closely spaced wires running perpendicular to corona electrode 81.
Returning to FIG. 1, the grid electrode 17 is wrapped over electrode 11, and is anchored to insulating substrate 15 at each side of electrode 11. The grid electrode 17 may describe any of a wide variety of profiles as seen from one end. In the preferred embodiment illustrated in FIG. 1, the grid electrode 17 is wrapped tightly over the apex of electrode 11, and is bonded to supporting substrate 15 so as to form a roughly V-shaped profile. An alternative arrangement is shown in at 30 FIG. 3, wherein a grid electrode 37 forms an arch over the corona electrode 31. The former profile is preferred, in that the closeness of the grid electrode 17 to the outer surface of dielectric 13 provides a desirably low cutoff voltage. For this reason, grid electrode 17 is advantageously bonded or attached to supporting substrate 15 in such a manner as to tension the mesh to provide firm contact with the electrode 11.
With reference to the sectional view of FIG. 4, the device 10 is employed for the generation of ions by application of a time-varying potential 19 between the elongate conductor 12 and grid electrode 17. This causes a pool of positive and negative ions to be formed in an air space in the vicinity of that portion of grid electrode 17 which is in contact with or close proximity to dielectric 13. This phenomenon is herein termed "glow discharge." With a periodically varying potential 19, air gap breakdown occurs during each half cycle if the excitation potential exceeds approximately 1400 volts peak-to-peak, if the dielectric sheath thickness is in the range of two to three mils. The dielectric 13 will receive a net charge, thereby extinguishing the discharge, and preventing the direct flow of an in-phase current between grid electrode 17 and elongate conductor 12.
With the switch in position x, the corona device 10 acts as a charge neutralizing device with respect to an electrostatic image carried on a proximate member. As seen in FIG. 4, the device 10 is disposed adjacent a dielectric layer 20 having a conductive substrate 25, and the grid electrode 17 is grounded to substrate 25. The electrical behavior of this device may be measured as a plot of output current, i, as a function of the voltage V between the surface of layer 20 and electrode 17. Typically, the devices of the invention are characterized by roughly linear i-V curves. It is preferable to have a low offset voltage V 0 , i.e. voltage at which i=0.
If dielectric layer 20 carries any net positive or negative charge, this charge on its surface, will establish an electrical field to grid electrode 17, causing the extraction of ions of the opposite polarity from the ion pool. If the corona device 10 is thus disposed for a sufficient period of time, the surface of layer 20 will be completely neutralized, so that the surface bears little or no residual charge under these circumstances. Another desirable feature is that of the typically high charging/discharge rates of this device.
Advantageously, the corona device 10 is disposed at a distance in the range 5-20 mils from layer 20, most preferably around 15 mils, as measured from the outer surface of grid electrode 17. A further advantageous feature of the invention is that the offset voltage of this device is relatively insensitive to changes in gap width within this range.
With further reference to FIG. 4, the device 10 may be utilized to deposit a net positive or negative charge on layer 20 when switch 21 is at position y. This places a DC bias potential 22 on grid electrode 17. With a positive bias to electrode 17, for example, a positive charge of equal magnitude will be deposited on surface 20. When operated in this mode, the corona device 10 provides automatic limiting of the charging potential.
In the preferred embodiment, time varying potential 19 comprises a high frequency, high voltage sinusoid. Preferably, excitation potential 19 has a magnitude in the range 1700-2500 volts peak-to-peak, most advantageously around 2000 volts peak-to-peak. Excitation potential 19 may comprise a continuous wave alternating potential, preferably of a frequency in the range 10 KHz to 1 MHz. Driving voltages at higher frequencies have been observed to cause overheating of the corona device, while lower frequency waveforms may provide inadequate output currents. A continuous wave frequency of 100 KHz provides desirably high emission currents without a serious risk of overheating device 10. Alternatively, excitation potential 19 may comprise a pulsed voltage which may be specified by the parameters of peak-to-peak voltage, repetition period, pulse width, and base frequency. The device 10 has been operated at frequencies as high as 1 MHz applied in short bursts having a duty cycle near 10 percent.
The dielectric 13 should have sufficient dielectric strength to withstand high excitation potentials without dielectric breakdown. It is desirable to minimize the onset voltage, i.e. the excitation voltage at which the dielectric begins to charge. This voltage increases with thicker dielectric layers 13, and decreases with lower dielectric constants of that layer. Organic dielectrics are generally unsuitable for this application, as most such materials tend to degrade with time due to oxidizing products formed in atmospheric electrical discharges. In the preferred embodiment, the dielectric 13 comprises a fused glass layer which is fabricated in order to minimize voids, having a thickness in the range 1-3 mils. Other suitable materials include, for example, sintered ceramics and mica.
An alternative construction of corona device is shown at 50 in FIG. 5. The insulating substrate 55 includes a slot 56 in which corona electrode 51 is fitted. The grid electrode 57 is wrapped over substrate 55 and electrode 51 as shown. This arrangement affords ease of positioning and supporting corona electrode 51.
As shown in FIG. 6, the conductive core of the corona electrode need not be encased in a dielectric sheath for effective operation. In an alternative device 60, the dielectric sheath is replaced by a thin, flexible dielectric strip 63. The elongate conductor 62 rests directly against insulating substrate 65, and is separated from grid electrode 67 by dielectric strip 63. This strip may comprise, for example, mica or a thin strip of glass.
The invention is further illustrated in the following nonlimiting examples:
EXAMPLE 1
A corona charging device of the type shown in FIG. 1 was constructed as follows. The insulating substrate was fabricated of glass epoxy G-10 laminate. The corona electrode consisted of a 7 mil diameter stainless steel wire having a 2 mil thick glass coating. After laying the coated wire on the substrate, a fine woven electrode screen was stretched over the wire and bonded with a thermoset adhesive to the sides of the substrate. The screen was composed of a plain woven 1 mil stainless steel wire, having a mesh count of 100 and an open area of approximately 90 percent. The coated wire electrode was not bonded to the substrate, and was constrained only by the overlying screen.
A 100 KHz, 2000 volt continuous wave alternating potential was placed between the coated wire electrode and the grid electrode. The outer surface of the grid electrode was located 15 mils from the surface of an imaging drum having a thin photoconductive surface layer, with a capacitance of 100 picofarads per cm 2 . The photoconductive surface was charged to 500 volts with a charging rate of 10 3 cm 2 /sec., by imposing a 500 volt direct current potential between the grid electrode and the drum's conductive core. This represented an average corona output current of 10 microamperes per cm. length of corona.
EXAMPLE 2
The apparatus of Example 1 was employed as a corona discharge device by grounding the mesh electrode to the photoreceptor drum's conductive core. In this mode, the device neutralized electrostatic images at rates comparable to the charging rates of Example 1, leaving virtually no residual electrostatic image.
EXAMPLE 3
The apparatus of Example 1 was modified as follows to provide a corona charging device of the type shown in FIG. 7. The corona electrode was fabricated by laminating a 1 mil stainless steel foil to the substrate using a pressure sensitive adhesive, and photoetching an electrode with a line width of 8 mils. The electrode was encapsulated with a 1.5 mil thick layer of glass by silk-screening a glass frit over the etched electrode, and sintering the glass at a high temperature to form a continuous glass coating.
This apparatus exhibited equivalent performance to the structure of Example 1, in both the charging and neutralizing modes.
While various aspects of the invention have been set forth by the drawings and the specification, it is to be understood that the foregoing detailed description is for illustration only and that various changes in parts, as well as the substitution of equivalent constituents for those shown and described, may be made without departing from the spirit and scope of the invention as set forth in the appended claims.
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A corona charging device including a dielectric-coated elongate conductor contacting or closely spaced from a grid electrode, mounted against an insulating support. A high voltage varying potential between the elongate conductor and grid electrode induces a glow discharge in the vicinity of the dielectric-coated electrode. The grid electrode may act as a ground plane to provide a corona discharge device with respect to a proximate member. Alternatively, the grid electrode may be maintained at a desired potential to provide a charging device with an automatically limited voltage.
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BACKGROUND OF THE INVENTION
Diflorasone diacetate, fluocortolone, fluocinolone acetonide, fluocinonide, paramethasone and fluprednisolone are 6α-fluoro-Δ 1 ,4 -3-keto steroids which are of pharmacological value primarily as topical anti-inflammatory agents.
Present technology requires that the production of these 6α-fluoro-Δ 1 ,4 -3-keto steroids necessitates the epimerization of the 6β-fluoro group of a steroid prior to Δ 1 -dehydrogenation. See, for example, U.S. Pat. Nos. 3,980,778, 3,014,938 and 3,126,375 and J. Am. Chem. Soc. 82, 4001 (1960).
It would be highly desirable to be able to epimerize a fluorine atom at the 6β-position in a Δ 1 ,4 -3 keto steroid. However, prior to the present invention there was no known procedure for accomplishing this process.
Others have reported that they have attempted to do this but were unsuccessful. For example, D. H. R. Barton et al. reported in Nouveau Journal De Chimie 1, 315 (1977) an unsuccessful attempt to epimerize a flourine atom at the 6β-position in a Δ 1 ,4 -3-keto steroid. Barton tried epimerization of a 6β-fluoro-Δ 1 ,4 -3-keto steroid by use of triphenylmethyl lithium. Instead of obtaining epimerization he obtained elimination of the fluorine atom. The present invention overcomes this problem.
H. J. Ringold and S. K. Malhotra in Tetrahedron Letters 669 (1972) reported deconjugation of a Δ 4 -3-keto steroid. However, the authors reported they were unable to deconjugate a Δ 1 ,4 -3-keto steroid, see page 672.
E. L. Shapiro et al. in Steroids 3, 183 (1964) reported deconjugation of a Δ 1 ,4 -3-keto steroid to give a Δ 1 ,5 -3-keto steroid. However, the reactant did not contain a fluorine atom at C-6. Barton, supra, reported an attempt to deconjugate a 6β-fluoro-Δ 1 ,4 -3-keto steroid. He reported that instead of obtaining deconjugation he obtained elimination. The present invention has solved this problem and permits deconjugation of 6β-fluoro-Δ 1 ,4 -3-keto steroids.
U.S. Pat. No. 4,188,322 claims a process for introduction of a fluorine atom in the 6α-position of a 9β,11β-epoxy-Δ 1 ,4 -3-keto steroid by first forming the corresponding 3-enol derivative by acylation or etherification followed by reaction with a suitable halogenating agent.
Great Britain Pat. No. 2,018,258 discloses virtually the same process as does U.S. Pat. No. 4,188,322.
Both U.S. Pat. No. 4,188,322 and Great Britain Pat. No. 2,018,258 differ from the process of the present invention in that these processes introduce a fluorine atom into the steroid at the C 6 position directly in the α configuration while the process of the present invention introduces a fluorine atom at the C 6 position in the opposite or β configuration followed by epimerization to the α position. In addition, the process of the present invention advantageously does not require that the C 3 keto group be protected as an enol ether or ester.
Polish Pat. No. 85,557 discloses a process for isomerization of a 6β-fluoro-Δ 1 ,4 -3-keto-11-oxygenated steroid to the corresponding 6α-fluoro-Δ 1 ,4 -3-keto-11-oxygenated steroid by use of isomerizing agents which are acids. In the process of the present invention the transformation of the 6β-fluoro-Δ 1 ,4 -3-keto steroid (IV) to the corresponding 6α-fluoro-Δ 1 ,4 -3-keto steroid is accomplished by a basic agent not an acidic one. In addition, the process of the present invention does not require an 11-oxygenated steroid.
BRIEF DESCRIPTION OF THE INVENTION
A process for preparing a 6α-fluoro-Δ 1 ,4 -3-keto steroid of formula VI which comprises (1) deconjugating a 6β-fluoro-Δ 1 ,4 -3-keto steroid of formula IV by reaction with a deconjugating agent, (2) quenching with a quenching agent to produce a 6-fluoro-Δ 1 ,5 -3-keto steroid of formula V, (3) isolating the 6-fluoro-Δ 1 ,5 -3-keto steroid (V), (4) isomerizing the 6-fluoro-Δ 1 ,5 -3-keto steroid (V) by reaction with an isomerizing agent and (5) neutralizing with an acid where R 9 and are defined as hereinafter.
A process for preparing a 6-fluoro-Δ 1 ,5 -3-keto steroid of formula V is also disclosed.
DETAILED DESCRIPTION OF THE INVENTION
The processes of the present invention permits the epimerization of a fluorine atom at the 6β-position of Δ 1 ,4 -3-keto steroid to the 6α-fluoro epimer. Most topical anti-inflammatory agents are Δ 1 ,4 -3-keto steroids and some also have a 6α-fluorine atom. Prior to the present invention the fluorine atom at the 6α-position of a 6α-fluoro-Δ 1 ,4 -3-keto steroid had to be introduced into the steroid prior to the Δ 1 double bond. The present invention therefore permits greater flexibility in the synthesis of 6α-fluoro-Δ 1 ,4 -3-keto steroids.
Chart A discloses that the very common Δ 1 ,4 -3-keto steroids can be transformed to the 6β-fluoro-Δ 1 ,4 -3-keto (IV) starting material by methods well known to those skilled in the art. The Δ 1 ,4 -3-keto steroid is deconjugated to the corresponding Δ 1 ,5 -3-keto steroid (II) followed by halogenation with an N-haloamide and hydrogen fluoride to give the 5α-halo-6β-fluoro-3-keto steroid (III) which upon elimination produces the desired 6β-fluoro-Δ 1 ,4 -3-keto (IV) starting material. In addition, the 6β-fluoro-Δ 14 -3-keto steroids (IV) are well known to those skilled in the art, see for example, D. H. R. Barton, Nouveau Journal De Chimie 1,315 (1977) and R. H. Hesse, Israel Journal of Chemistry 17, 60 (1978).
The 6β-fluoro-Δ 1 ,4 -3-keto steroid (IV) diagrams show not the entire steroid molecule but primarily rings A and B, since this is where the process of the present invention takes place. The in ring C between C 9 and C 11 means that ring C can have the following types of substitution: 9β,11β-epoxy, Δ 9 (11), 11β-hydroxy, 11-keto 11α-hydroxy, 9α-fluoro-11β-hydroxy and no substitution (hydrogen atoms at C 9 and C 11 ). It is preferred that the ring C substitution be 9β,11β-epoxy or Δ 9 (11). It is more preferred that the substitution be 9β,11β-epoxy. Likewise, the chemical formula diagrams for the 6β-fluoro-Δ 1 ,4 -3-keto steroid (IV) does not disclose ring D or C 17 side chain. This is because there are a large number of different ring D and C 17 side chain variations that are operable, see for example Chart E. The important point is that the hydroxyl groups, when present, at C 16 , C 17 , C 20 , and/or C 21 be protected as disclosed in Chart E. The use (formation and removal) of hydroxyl protecting groups is well known to those skilled in the art.
The 6β-fluoro-Δ 1 ,4 -3-keto steroid (IV) can be transformed to the desired 6α-fluoro-Δ 1 ,4 -3-keto steroid (VI) by two different but similar processes. One is a one-pot process which can be performed in either 2 or 3 steps involving epimerization followed by neutralization of the base by acid. The other is a two-pot process where the first step involves deconjugation of the 6β-fluoro-Δ 1 ,4 -3-keto steroid (IV) followed by quenching which permits isolation of the 6-fluoro-Δ 1 ,5 -3-keto intermediate (V) followed by isomerization to the 6α-fluoro-Δ 1 ,4 -3-keto steroid (VI).
In the two-pot process (Chart A), the 6β-fluoro-Δ 1 ,4 -3-keto steroid is deconjugated by reaction with a deconjugating agent which is a strong base selected from the group consisting of ORb.sup.⊖, acetylide or RαRβN.sup.⊖, or a means of producing ORb.sup.⊖ acetylide or RαRβN.sup.⊖. Rb is alkyl of 1 thru 4 carbon atoms. Rα and Rβ are the same or different and are a hydrogen atom, alkyl of 1 thru 4 carbon atoms, cyclohexyl or phenyl. It is preferred that the deconjugating agent is selected from the group consisting of methoxide, ethoxide or tert-butoxide. Preferred dialkylamides include diethylamide and diisopropylamide. A means for producing ORb.sup.⊖ etc. is included because if a strong base not within the scope of the deconjugating agents is used in methanol, the actual species in situ will be methoxide generated from the methanol by the strong base. Generating a deconjugating agent in situ is equivalent to mixing one with the 6β-fluoro-Δ 1 ,4 -3-keto steroid (IV). In general an aprotic solvent is used for the deconjugating reaction. The aprotic solvent is used so as not to protonate the intermediate enolate generated by the deconjugating agent. Preferred solvents include for example THF, DMSO, dioxane, DMF, tetramethylurea, dimethylacetamide and tert-butanol. Both tert.-butanol and tert-amyl alcohol are protic solvents but they do not protonate the enolate so they are suitable. When the solvent is tert-butanol, about 10 equivalents of deconjugating agent/equivalent of steroid is preferred. If less is used, there is a cost savings but the reaction time will be longer. If greater than 10 equivalents are used, the reaction is more costly but proceeds at a more rapid rate. After deconjugation the reaction is quenched by reaction with a quenching agent which is a compound that will supply a proton and protonate the enolate. Quenching agents include, for example, acetic acid, aqueous ammonium chloride, sulfuric acid, hydrochloric acid, phosphoric acid and water. It is more preferred that the quenching agent be acetic acid or aqueous ammonium chloride. Following quenching the 6-fluoro-Δ 1 ,5 -3-keto intermediate (V) can be isolated if desired. The 6-fluoro-Δ 1 ,5 -3 -keto intermediate (V) is useful in producing and is isomerized to 6α-fluoro-Δ 1 ,4 -3-keto steroid (VI) by reaction with an isomerizing agent. Isomerizing agents include compounds selected from the group consisting of ORb.sup.⊖ or hydroxide or a means of producing ORb.sup.⊖ or hydroxide. A means for producing ORb.sup.⊖ or hydroxide is included because use of sodium diethylamide in methanol actually produces methoxide in situ and therefore is an equivalent of methoxide. The isomerizing agent removes a proton, isomerization takes place and the steroid obtains a proton from the protic solvent. Hence, preferred agents include methoxide in methanol and ethoxide in ethanol. This two-pot process is performed at 20°-25° and can be monitored by TLC as exemplified in Examples 1 and 2.
The isomerizing agent is neutralized with an acid. It is preferred that the acid be selected from the group consisting of acetic, hydrochloric, sulfuric, phosphoric and ammonium chloride. Alternatively, instead of neutralization of the isomerizing agent, the reaction mixture can be diluted with water and the steroid recovered as is well known to those skilled in the art such as by filtration or extraction.
The 6β-fluoro-Δ 1 ,4 -3-keto steroid (IV) can be epimerized to the desired 6α-fluoro-Δ 1 ,4 -3-keto steroid (VI) in a one-pot process either in three steps or by two steps. The three-step process involves reaction of the 6β-fluoro-Δ 1 ,4 -3-keto steroid (IV) with an deconjugating agent in the presence of a solvent selected from the group consisting of THF, DMSO, DMF, diethylacetamide, dioxane, tert-butanol and tert-amyl alcohol. The deconjugating agent is selected from the group consisting of ORb.sup.⊖, acetylide and RαRβN.sup.⊖ or a means of producing ORb.sup.⊖, acetylide or RαRβN.sup.⊖. It is preferred that the deconjugating agent is methoxide, ethoxide or tert-butoxide. Following the reaction of the steroid (IV) and the deconjugating agent, a primary or secondary alcohol of the formula Rb-OH is mixed with the steroid reaction mixture. The reaction of the deconjugating agent and the primary or secondary alcohol (Rb-OH) forms an isomerizing agent in situ. When the reaction is complete, the base is neutralized by reaction with an acid preferably selected from the group consisting of acetic, hydrochloric, sulfuric, phosphoric and ammonium chloride. Instead of neutralization the reaction mixture can be diluted as explained previously.
Alternatively, the one-pot process can be performed in two steps. First, the steroid (IV) is mixed with the deconjugating agent in the presence of a primary or secondary alcohol (Rb-OH) followed by neutralization with an acid or dilution with water as explained previously.
In both the one-pot processes, the reaction is performed at 20°-25° and is monitored by TLC.
In both the two-pot and one-pot processes disclosed in Chart A for the transformation of the 6β-fluoro-Δ 1 ,4 -3-keto steroid (IV) to the desired 6α-isomer (VI) it is preferred that the substitution in ring C be the 9β,11-epoxide or Δ 9 (11). It is more preferred that the substitution be 9β,11β-epoxy, since for some unknown and unexpected reason the reactions proceed much faster. For example, the epimerization reaction of a 9β,11β-epoxide (IV) in methanol (methoxide) is complete in 2-4 hours, whereas if the 9β,11β-epoxide is absent, the same reaction takes about 80-90 hours.
The processes of the present invention are useful in producing a 6α-fluoro-Δ 1 ,4 -3-keto steroid (VI) from a 6β-fluoro-Δ 1 ,4 -3-keto steroid (IV) which can readily be obtained from the readily available Δ 1 ,4 -3-keto steroids (I).
The 6α-fluoro-Δ 1 ,4 -3-keto steroid (IV) functionality is common to a number of steroids which are useful because of their topical anti-inflammatory activity. These topically anti-inflammatory steroids include, for example, diflorasone diacetate, fluocinonide, fluocinolone acetonide, paramethasone, fluprednisolone and fluocortolone. The introduction of the various functionalites of these compounds such as 11α-hydroxy, 16α-hydroxy or 9α-fluoro groups, acetonide formation, transformation of Δ9.sup.(11) to 9α-fluoro-11β-hydroxy can take place either before or after the introduction of the 6α-fluoro group as is well known to those skilled in the art.
For example, starting with 6β-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 20,21-acetonide (IV') the process of the present invention produces 6α-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 20,21-acetonide (VI'), see Examples 1 thru 2a. By known process chemistry (Chart B) this 6α-fluoro-Δ 1 ,4 -3-keto (VI') steroid is converted to diflorasone diacetate (U.S. Pat. No. 3,980,778) which is a commercially marketed topical anti-inflammatory agent. The acetonide is removed (U.S. Pat. No. 3,725,392, Examples 9-11) to form the 20,21-dihydroxy steroid (VII'); the 21-benzoate (VIII') is formed (U.S. Pat. No. 3,725,392, Example 12); the 20-hydroxyl is oxidized to the 20-keto steroid (IX') by the process of U.S. Pat. No. 3,725,392, Example 13; the 11β-hydroxy-9α-bromo compound (X') is formed (U.S. Pat. No. 3,725,392, Example 15); the epoxide (XI') is formed (U.S. Pat. No. 3,725,392, Example 16); the orthoester (XII') is formed (U.S. Pat. No. 3,147,249); which permits formation of the 17-acetate (XIII') by the process of U.S. Pat. No. 3,152,154 and formation of the diacetate (XIV') by very well known methods and opening of the epoxide by the process of Example 8 of U.S. Pat. No. 3,980,778 to give diflorasone diacetate (XV).
Utilizing the generic process (Chart A), Chart B discloses the usefulness of a particular 6α-fluoro-Δ 1 ,4 -3-keto steroid (VI') when the process of the present invention is performed on a steroid where the C ring has a Δ 9 (11) -functionality. Subsequent to the transformation of the 6β-fluoro atom to a 6α-fluoro atom, the Δ 9 (11) -double bond is transformed by the usual method to the bromohydrin (X'), the epoxide (XI') and subsequently to the desired 9α-fluoro-11β-hydroxy C ring functionality (XV'). Chart C discloses generically the process of the present invention where the process is performed on a 9β,11β-epoxide (E) functionality in the C ring.
One of the products desired to be produced by the processes of the present invention is diflorasone diacetate, 6α,9α-difluoro-11β,17α,21-trihydroxy-16β-methylpregna-1,4-diene-3,20-dione 17,21-diacetate (XV'). The starting material would be 6β-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 20,21-acetonide (IV').
To produce diflorasone diacetate (XV') from the starting material (IV') by the process of Charts A and B, the 6-fluorine atom is epimerized (V and VI) to give the desired 6α-fluoro-Δ 1 ,4 -3-keto functionality of rings A and B and then (Chart B) the side chain is modified to the desired 17α,21-dihydroxy-20-one (VI'-IX'), the Δ 9 (11) double bond is transformed to the 9β,11β-epoxide (IX'-XI'), the side chain is transformed to final form, 17α,21-dihydroxy-20-one 17,21-diacetate (XI'-XIV') and the epoxide is opened to give the desired 9α-fluoro-11β-hydroxy ring C functionality (XIV'-XV').
To produce the same diflorasone diacetate (XV') from the same starting material (IV') by the process of Chart C, the process of Chart D is followed, the side chain is modified to the desired 17α,21-dihydroxy-20-one 21-acylate (IV'-IXβ'), the Δ 9 (11) double bond is transformed to the 9β,11β-epoxide (IXβ'-E') and the 21-ester of the side chain is hydrolyzed to give (XI'), which is exactly the same compound of Chart B, see Example 12. Compound (XI') is then transformed to diflorasone diacetate in the identical manner as in Chart B. Hence, the starting material (IV') can be transformed to diflorosone diacetate (XV') two different ways, by the processes of the present invention. These two processes overlap somewhat in that the end portion (XI'-XV') is identical; the beginning portion differs in that in one process the epoxide is formed prior to epimerization, while in the alternative process, the 6β-fluorine atom is epimerized prior to the epoxide formation. Both processes produce the desired result.
DEFINITIONS
The definitions and explanations below are for the terms as used throughout the entire patent application including both the specification and claims.
All temperatures are in degrees Centigrade.
TLC refers to thin-layer chromatography.
THF refers to tetrahydrofuran.
THP refers to tetrahydropyranyl.
DMSO refers to dimethylsulfoxide.
DMF refers to dimethylformamide.
SSB refers to an isomeric mixture of hexanes.
DMAC refers to dimethylacetamide.
Saline refers to an aqueous saturated sodium chloride solution.
When solvent pairs are used, the ratio of solvents used are volume/volume (v/v).
R is methyl or ethyl.
R 5 is a chlorine or bromine atom.
R 9 is a hydrogen or fluorine atom.
R 16 is a hydrogen atom or methyl or hydroxyl group.
R 17 is methyl or phenyl.
R 21 is methyl or phenyl.
Rb is alkyl of 1 thru 5 carbon atoms.
Rα refers to a hydrogen atom, alkyl of 1-4 carbon atoms, cyclohexyl and phenyl.
Rβ refers to a hydrogen atom, alkyl of 1-4 carbon atoms, cyclohexyl and phenyl.
˜ indicates the attached group can be in either the α or β configuration.
is a single (no substitution) or double bond [Δ 9 (11) ], 9β,11β-epoxy, 11-keto or 11β-hydroxy.
When the term "alkyl of thru carbon atoms" is used, it means and includes isomers thereof where such exist.
EXAMPLES
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, practice the present invention to its fullest extent. The following preferred specific embodiments are, therefore, construed as merely illustrative, and not limiting of the preceding disclosure in any way whatsoever.
Example 1
6-Fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,5,9(11)-trien-3-one 20,21-acetonide (V)
A mixture of 6β-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 20,21-acetonide (IV, 1.0 g.) and tertiary butyl alcohol (25 ml.) is stirred at 20°-25° under nitrogen. A solution of potassium tertiary butoxide (20%, 16 ml.) is added to the above mixture, which is then stirred at 20°-25° while monitoring the reaction by TLC. After stirring for 90 minutes the reaction mixture is treated with aqueous acetic acid (20%, 63 ml.) and is then transferred to a separatory funnel containing water (100 ml.). This mixture is extracted with ethyl acetate (2×50 ml.). The ethyl acetate extracts are combined, washed wth aqueous potassium bicarbonate (10%, 2×100 ml.) washed with water (100 ml.), washed with half saturated aqueous sodium chloride solution (80 ml.), dried over anhydrous magnesium sulfate and evaporated to dryness under reduced pressure, while warming at 50°. The residue is treated with acetone and the resulting slurry filtered. The solids are washed with cold acetone and dried under reduced pressure at 70° to give the title compound, m.p. 188°-192°.
Example 2
6α-Fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 20,21-acetonide (VI')
A slurry of 6-fluoro-17α,20-21-trihydroxy-16β-methylpregna-1,5,9-(11)-trien-3-one 20,21-acetonide (V, Example 1, 0.40 g.) in methanol (10 ml.) is treated with sodium methoxide (0.010 g.) and stirred under nitrogen at 20°-25°. The reaction is monitored by TLC. After stirring for 80 minutes the reaction mixture is quenched by the addition of a solution of acetic acid (10%) in methanol. This slurry is concentrated to a small volume by reduced pressure. The thick slurry is cooled and filtered. The solids are washed quickly with methanol cooled to 0° and dried under reduced pressure at 60° to give the title compound, m.p. 232°-234°.
Example 2a
6α-Fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 20,21-acetonide (VI')
A mixture of 6β-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 20,21-acetonide (IV, 1.0 g.) in methanol (24 ml.) is stirred at 20°-25°. Potassium t-butoxide (14.5 ml.) in THF is added and stirred. After 24 hours, a 50:50 mixture of the product (VI) and starting material (IV) are observed by TLC. After 90 hours, the reaction is greater than 95% complete as measured by TLC. The reaction mixture is then worked up as in Example 2.
Example 3
6α-Fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one (VII')
Following the procedure of U.S. Pat. No. 3,725,392 in general and more particularly the procedure of Examples 9-11 and making non-critical variations but starting with 6α-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 20,21-acetonide (VI', Example 2) the title compound is obtained.
Example 3a
6α-Fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one (VII')
A mixture of 6β-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 20,21-acetonide (IV, 30 g.), THF (90 ml.) and t-butyl alcohol (30 ml.) is stirred at 20°-25°. Potassium t-butoxide in THF (20%, 105 ml.) is added and the mixture stirred. After 10 minutes, the reaction mixture is cooled to 15°. Methanol (60 ml) is added while allowing the reaction temperature to rise to 25°.
The mixture is stirred for 15 minutes and then concentrated hydrochloric acid (15 ml.) in water (60 ml.) is added and the mixture refluxed for one hour. Water (60 ml.) is added and the mixture is concentrated under reduced pressure to a volume of 30 ml. This slurry is cooled to 0°-5° and filtered. The solids are washed with four 60 ml. portions and one 100-ml. portion of water. The solids are dried under reduced pressure at 50° to give the title compound.
Example 4
6α-Fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 21-benzoate (VIII')
Following the procedure of U.S. Pat. No. 3,725,392 in general and more particularly the procedure of Example 12 and making non-critical variations but starting with 6α-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one (VII', Example 3) the title compound is obtained.
Example 5
6α-Fluoro-17α,21-dihydroxy-16β-methylpregna-1,4,9(11)-triene-3,20-dione 21 benzoate (IX')
Following the procedure of U.S. Pat. No. 3,725,392 in general and more particularly the procedure of Example 13 and making non-critical variations but starting with 6α-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 21-benzoate (VII', Example 4) the title compound is obtained.
Example 6
9α-Bromo-6α-fluoro-11β,17α,21-trihydroxy-16β-methyl-pregna-1,4-diene-3,20-dione 21-benzoate (X')
Following the procedure of U.S. Pat. No. 3,725,392 in general and more particularly the procedure of Example 15 and making non-critical variations but starting with 6α-fluoro-17α,21-dihydroxy-16β-methylpregna-1,4,9(11)-triene-3,20-dione 21-benzoate (IX', Example 5) the title compound is obtained.
Example 7
6α-Fluoro-17α,21-dihydroxy-16β-methyl-9β,11β-oxidopregna-1,4-diene-3,20-dione (XI')
Following the procedure of U.S. Pat. No. 3,725,392 in general and more particularly the procedure of Example 16 and making non-critical variations but starting with 9α-bromo-6α-fluoro-11β,17α,21-trihydroxy-16β-methylpregna-1,4-diene-3,20-dione 21-benzoate (X', Example 6) the title compound is obtained.
Example 8
17α,21-(1'-Methoxy)-ethylidenedioxy-6α-fluoro-16β-methyl-9β,11β-oxidopregna-1,4-diene-3,20-dione (XII')
Following the general procedure of U.S. Pat. No. 3,147,249 and making non-critical variations and reacting 6α-fluoro-17α,21-dihydroxy-16β-methyl-9β,11β-oxidopregna-1,4-diene-3,20-dione (XI', Example 7) with methyl orthoacetate the title compound is obtained.
Example 9
6α-Fluoro-17α,21-dihydroxy-16β-methyl-9β,11β-oxidopregna-1,4-diene-3,20-dione 17-acetate (XIII')
Following the general procedure of U.S. Pat. No. 3,152,154 and making non-critical variations but hydrolyzing 17α,21-(1'-methoxy)-ethylidenedioxy-6α-fluoro-16β-methyl-9β,11β-oxidopregna-1,4-diene-3,20-dione (XII', Example 8) the title compound is obtained.
Example 10
6α-Fluoro-17α,21-dihydroxy-16α-methyl-9β,11β-oxidopregna-1,4-diene-3,20-dione 17,21-diacetate (XIV')
6α-Fluoro-17α, 21-dihydroxy-16β-methyl-9β,11β-oxidopregna-1,4-diene-3,20 -dione 17-acetate (XIII', Example 9) is heated with acetyl chloride and pyridine to give the title compound.
Example 11
6α,9α-Difluoro-11β,17α,21-trihydroxy-16β-methylpregna-1,4-diene-3,20-dione 17,21-diacetate (XV', U.S. Pat. No. 3,980,778).
Following the procedure of Example 8 of U.S. Pat. No. 3,980,778, 6α-fluoro-17α,21-dihydroxy-16β-methyl-9β,11β-oxidopregna-1,4-diene-3,20-dione 17,21-diacetate (XIV', Example 10) is converted to the title compound.
Example 12
6α-Fluoro-17α,21-dihydroxy-16β-methyl-9β,11β-oxidopregna-1,4-diene-3,20-dione (XI')
Step 1: 6β-Fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one (VIIβ')
Following the general procedure of Example 3 and making non-critical variations but starting with 6β-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one-20,21-acetonide (IV'), 6β-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one is obtained.
Step 2: 6β-Fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 21-benzoate (VIIβ')
Following the general procedure of Example 7 and making non-critical variations but starting with 6β-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one (VIIβ', Step 1), 6β-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 21-benzoate is obtained.
Step 3: 6β-Fluoro-17α,21-dihydroxy-16β-methylpregna-1,4,9(11)-triene-3,20-dione 21-benzoate (IXβ')
Following the general procedure of Example 8 and making non-critical variations but starting with 6β-fluoro-17α,20,21-trihydroxy-16β-methylpregna-1,4,9(11)-trien-3-one 21-benzoate (VIIIβ', Step 2), 6β-fluoro-17α,21-dihydroxy-16β-methylpregna-1,4,9(11)-triene-3,20-dione is obtained.
Step 4: 9α-Bromo-6β-fluoro-11β,17α,21-trihydroxy-16β-methylpregna-1,4-diene-3,20-dione 21-benzoate (Xβ')
Following the general procedure of Example 9 making non-critical variations but starting with 6β-fluoro-17α,21-dihydroxy-16β-methylpregna-1,4,9(11)-triene-3,20-dione 21-benzoate (IXβ', Step 3), 9α-bromo-6β-fluoro-11β,17α,21-trihydroxy-16β-methylpregna-1,4-diene-3,20-dione 21-benzoate is obtained.
Step 5: 6α-Fluoro-17α,21-dihydroxy-16β-methyl-9β,11β-oxidopregna-1,4-diene-3,20-dione (XI')
9α-Bromo-6β-fluoro-11β,17α,21-trihydroxy-16β-methylpregna-1,4-diene-3,20-dione 21-benzoate (Xβ', Step 4) is stirred with methylene chloride (106 ml.) and methanol (222 ml.) at 3°. A solution of potassium tert-butoxide in THF (20%, 57.5 ml.) is added to the steroid mixture and the temperature rises from 3° to 11°. After stirring for 1.75 hours, the reaction mixture is warmed to 20°-25° and the epimerization appears complete as measured by TLC. The reaction is quenched by the addition of glacial acetic acid. The slurry is concentrated to a volume of 164 ml. Water (100 ml.) is added and the resulting slurry is concentrated under reduced pressure to 164 ml. Water (431 ml.) is added slowly and the resulting slurry is cooled to 5° and filtered. The solids are washed with water and dried under vacuum at 55° to give the title compound. ##STR1##
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Two processes are disclosed (one-pot and two-pot) for the transformation of a 6β-fluoro-Δ 1 ,4 -3-keto steroid (IV) to a 6α-fluoro-Δ 1 ,4 -3-keto steroid (VI). These processes permit the introduction of a fluorine atom at the 6α position of a Δ 1 ,4 -3-keto steroid where previously the Δ 1 double bond could not be introduced until after the 6α-fluorine atom was present. The 6α-fluoro-Δ 1 ,4 -3-keto steroids (VI) are intermediates useful in the production of pharmacologically active steroids.
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This Application is a continuation of International Application No. PCT/FI99/00078, filed Feb. 3, 1999.
FIELD OF THE INVENTION
The invention relates generally to implementation of services in a telecommunications network, particularly an intelligent network. The service may be any service produced in the network for a network user or another object.
BACKGROUND OF THE INVENTION
The rapid evolvement of the telecommunications field has afforded operators the capability of providing many different types of services to users. A network architecture that provides advanced services is called an intelligent network. The common abbreviation for intelligent network is IN.
The functional architecture of an intelligent network is shown in FIG. 1 where the functional entities of the network are shown as ovals. This architecture is described briefly below, because the invention will be described hereinafter with reference to the intelligent network environment.
The access of the end user (subscriber) to the network is handled by the CCAF (Call Control Agent Function). The access to the IN services is implemented by making additions to existing digital exchanges. This is done by using the basic call state model BCSM which describes the existing functionality used to process a call between two users. The BCSM is a high level state automaton description of the call control functions CCF required for establishing and maintaining a connection route between users. Functionality is added to this state model by using the service switching function SSF (cf. the partial overlap of the entities CCF and SSF in FIG. 1) so that it is possible to decide when it is necessary to call the services of the intelligent network (the IN services). After these IN services have been called, the service control function SCF that contains the service logic for the intelligent network handles the service-related processing (of the call attempt). The service switching function SSF thereby connects the call control function CCF to the service control function SCF and allows the service control function SCF to control the call control function CCF. For example, SCF can request that the SSF/CCF perform specific call or connection functions, for example charging or routing operations. The SCF can also send requests to the service data function SDF which handles the access to the service-related data and network data of the intelligent network. The SCF can thus for example request the SDF to retrieve specific service-related data or update this data.
The functions described above are further complemented by the specialized resources function SRF which provides the special functions required for implementing some of the services provided by the intelligent network. Examples of these services are protocol conversions, speech recognition, voice mail, etc. The SCF can, for example, request the SSF/CCF functions to first establish a connection between the end users and SRF and then it can request the SRF to give voice announcements to the end users.
Other functional entities of the intelligent network are various functions that relate to control, such as the SCEF (Service Creation Environment Function), SMF (Service Management Function), and SMAF (Service Management Access Function). The SMF includes, among other things, service control, the SMAF provides the connection to the SMF, and the SCEF makes it possible to specify, develop, test and feed IN services via the SMF to the SCF. Because these functions only relate to the operation of the network operator, they are not shown in FIG. 1 .
The role of the functional entities described in FIG. 1 as relating to the IN services will be briefly described below. The CCAF receives the service request given by the calling party. The service request usually consists of lifting the receiver and/or a series of digits dialled by the calling party. The CCAF further transmits the service request to the CCF/SSF for processing. The call control function CCF does not have the service data but it has been programmed to recognize the need of a service request. The CCF interrupts the call setup for a moment and notifies the service switching function SSF about the state of the call. The task of the SSF is, using predefined criteria, to interpret the service request and thus determine whether the request is a service request related to the IN services. If this is the case, the SSF composes a standardized IN service request and sends the request to the SCF along with information about the state of the service request. The SCF receives the request and decodes it. After that it cooperates with the SSF/CCF, SRF, and SDF to provide the requested service to the end user.
The physical level architecture of the intelligent network describes how the functional entities described above are located in the physical entities of the network. The physical architecture of the intelligent network is illustrated in FIG. 2, where the physical entities are-described as rectangles or circles and functional entities as ovals. The signalling connections are described by dashed lines and the actual transport which is for example speech, by continuous lines. The optional functional entities are denoted with dashed line. The signalling network shown in the Figure is a network according to SS7 (Signalling System Number 7 is a well-known signalling system described in the CCITT (nowadays ITU-T) blue book Specifications of Signalling System No. 7, Melbourne 1988).
The subscriber equipment SE which can include, for example, a telephone, computer, or telefax, are connected either directly to a service switching point SSP or to a network access point NAP.
The service switching point SSP provides the user with access to the network and handles all necessary selection functions. The SSP can also detect any IN service requests. Functionally, the SSP includes the call control and service selection functions.
The network access point NAP is a traditional telephone exchange that includes the call control function CCF, for example, the Applicants' DX 220 exchange which can differentiate calls that require IN services from traditional calls and route the calls that require IN services to the appropriate SSP.
The service control point SCP includes the service logic programs SLP that are used to produce the IN services. The shorter term service program will also be used for service logic programs in the following.
The service data point SDP is a database containing customer and network data which is used by the service programs of the SCP to produce tailored services. The SCP can use SDP services directly via the signalling or data network.
The intelligent peripheral IP provides special services, such as announcements and voice and multiple choice recognition.
The service switching and control point SSCP consists of an SCP and SSP located in the same network element (in other words, if the SSP network element shown in the drawing contains both an SCF and an SSF entity, the network element in question is an SSCP).
The tasks of a service management system SMP include the management of the database (SDP), network monitoring and testing, and collecting network data. It can connect to all other physical entities.
The service creation environment point SCEP is used for specifying, developing and testing the IN services, and for entering the services in SMP.
The service adjunct AD is functionally equivalent to the service control point SCP, but it is directly connected to SSP with a fast data connection (for example, with an ISDN 30B+D connection) instead of via the common channel signalling network SS7.
The service node SN can control the IN services and perform data transfers with users. It communicates directly with one or more SSPs.
The service management access point SMAP is a physical entity which provides certain users with a connection to SMP.
The above is a brief description of the intelligent network as a background to the description of the method according to the invention. The interested reader can get a more detailed description of the intelligent network in, for example, ITU-T specifications Q.121X or in the AIN specifications of Bellcore.
It should be possible to provide IN-based services to subscribers in fixed or mobile networks in a way enabling provision of tailored service in such a way that a specific subscriber-associated combination of service features can be offered to each individual subscriber. As stated previously, provisioning of a service is initiated in such a way that the SSF sends to the SCF a standard IN service request. The service request can be sent at certain stages of the call setup. The international standards, however, specify only one identifier for the service request sent by the SSF wherewith the desired service logic can be selected in the SCP. This identifier is called the service key.
The generally known technique for providing tailored services is such that the final service logic program SLP is selected in the SCP by means of the service key value, in which case more than one values can point to the same service logic program or there may be a dedicated service logic program for each service key value. When it is desired to add services, a new version of the existing service logic program into which more service features are encoded is produced. The new version is indicated with a new service key value. The subservices, for which the English term service feature is employed in the international standards, are termed features in the present context.
The drawback of such a solution is that as services and features contained in them increase, the service programs are rendered highly complex and their number increases. When such extensive programs, of which furthermore different versions exist, must be located in several network elements of the network, also the maintenance of the network becomes complicated.
SUMMARY OF THE INVENTION
It is an object of the invention to bring about an improvement to the above situation and to provide a solution wherewith the adding of new services and maintenance of services provided by the network is as simple and flexible as possible.
This object is achieved with the method in accordance with the invention, which is defined in the independent claim.
The idea of the invention is to use keys identifying the features and to construct the service programs from feature-related modules in such a way that by means of a given feature key, the part of the service program corresponding to said key is executed, and the entire service is provided by concatenating the desired feature modules in succession by means of feature keys. The SCP network element stores in connection with each feature information on which service program is capable of executing said feature, and by means of the service key arriving in the service request message, the set of desired features is defined, and thus the service can be provided by executing the parts of one or more service programs which correspond to said features in a given consecutive order.
On account of the solution in accordance with the invention, the program code required by the features can be placed very freely in one or more service logic programs. One service logic program preferably contains the code required to execute several features, even though it can contain the code required by one feature only. The services corresponding to some service key values can be located in a given SCP network element, and the services corresponding to some other values in another SCP network element. By dividing the features of the service e.g. among two different SCP network elements, no service logic program that is too extensive in view of the network resources or performance need to be located in either of the network elements. Thus, no SCP network element need contain all possible services or features, even though they are available to all subscribers.
With regard to network maintenance, the solution of the invention also enables a simple way of offering new services comprised of subscriber-specific feature combinations.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, the invention and its preferred embodiments will be described in greater detail with reference to examples in accordance with the attached FIGS. 3 . . . 12 in the accompanying drawings, in which
FIG. 1 illustrates the functional architecture of an intelligent network,
FIG. 2 illustrates the physical architecture of an intelligent network,
FIG. 3 illustrates the functional architecture of an SCP network element in accordance with the invention when parts essential to the service logic software are looked at,
FIG. 4 illustrates the content of an object-related data row,
FIG. 5 shows the structure of a request message sent to a service program instance,
FIG. 6 depicts the structure of an acknowledgement message sent by the service program instance,
FIG. 7 illustrates the functional configuration of one service program,
FIG. 8 illustrates the messaging block (i.e., messaging SIB) of the service program,
FIG. 9 illustrates the halt state block of the service program,
FIG. 10 illustrates the stop state block at the end of each feature,
FIG. 11 illustrates a feature module in accordance with a preferred embodiment of the invention, and
FIG. 12 illustrates a stop state block in accordance with a preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
When a network subscriber initiates a call, the terminal exchange of the subscriber first receives information on the calling subscriber's desire to place a call. This information can arrive at the exchange for example as a Setup message in accordance with standard Q.931. If the terminal exchange is not an SSP exchange, it can route the call attempt to an SSP exchange.
When the call control of the SSP exchange detects that a subscriber is concerned who needs IN services, transfer of the control to the IN is triggered and processing of the call attempt is “frozen”. The SSP exchange then sends to the SCP an Initial_DP message, which is a standard message between the SSF and SCP, generated by the SSF upon detecting at any detection point of the call state model that a service request is necessary (a detection point is a point in the call state model at which the control can be transferred to the IN). Initial_DP is thus the message that starts the dialog between the SSP and the SCP relating to the provision of each service. The information elements included in the message by the SSP exchange include at least the calling and called number and the service key.
An INAP (Intelligent Network Application Part) message set is used between the SSP and SCP. (The message set is described for example in the standard ETSI IN CS1 INAP Part 1: Protocol Specification, Draft prETS 300 374-1, November 1993, to which the interested reader is referred for a more detailed exposition.) No actual protocol has been defined in the standards, only the messages used. In addition to optional parameters, also so called extension parameters have been defined in the messages. Particularly the last-mentioned are parameters for which different operators desire data content definitions of their own. For this reason, the SCP network element must have a large number of service logic programs SLP for implementing different services. Hence, the different service logic programs may use messages of the same INAP message set, but in a different order and with different parameter values. The actual protocol level in the communication between the SSP and SCP is thus represented by these different service logic programs. Each service logic program sends to and receives from the network INAP messages.
FIG. 3 illustrates the functional architecture of an SCP network element in accordance with the invention seen from the point of view of the service programs. The service requests arriving at the network element come through a common channel signalling stack CCSS to the receiving program block SRP (SS7 Receiver Program). One such receiving program block is provided for each common channel signalling stack of the SCP network element. For simplicity, the example of the figure only shows one stack and one receiving program block.
If one SCP network element is connected to more than one SSP network element in which different versions of the INAP message set are used, the definition of the data content of the data messages received by the SCP is different depending on which SSP the SCP is communicating with. For this reason, further processing of the messages from the receiving program block onwards must in practice be differentiated in accordance with which INAP message set is concerned. Thus, what is also essential is that the receiving program block SRP is independent of the INAP message set employed.
The receiving program block SRP receives from the network (from SSF entities) standard TC_BEGIN messages. The task of the program block is to identify the relevant INAP message set version on the basis of the TC_BEGIN message and to forward the INAP messages contained in the component primitives further to the message distributor program block MDPi corresponding to said message set, wherein i=1,2, . . . j and j is the number of different INAP message sets used.
Hence, at the level next to the receiving program block the network architecture includes program blocks MDPi (i=1, . . . j), one for each INAP message set used. Each distributor program MDPI receives TCAP messages from the network and forwards INAP messages, receives INAP messages from the service logic programs, and sends TCAP messages to the network. (A TCAP message comprises a header and one or more component primitives. Each component primitive can contain one INAP message at most. Each component primitive also has a subheader of its own. All of these header parts are produced when messages are sent to the network and they are removed when messages are received from the network.)
When an initiation request for a service dialog—which arrives as a TC_BEGIN primitive (containing an Initial_DP message)—is received on a network element, a new instance of the receiving program SRP is created that will search the correct distributor program block, create an instance thereof for the use of said service request, and transmit a TCAP message to said instance. Thereafter the instance of the receiving program block is deleted. The distributor program instance receives all TCAP messages subsequently arriving from SSP. The search for the correct distributor program takes place in such a way that the receiving program block SRP reads from the header of the TC_BEGIN message either the identifier of the sending SSP network element (SPC, Signalling Point Code, or GT, Global Title) and additionally the identifier of the subsystem (SSN, SubSystem Number), or alternatively the relevant application context identifier AC, and searches on the basis thereof from the data table SRP_DT of the SRP level the name of the distributor program, MDP_NAME, corresponding to the INAP message set in question.
Thus, the architecture of the SCP exchange includes for each INAP message set a dedicated program block MDPi, the task of which is to decode the received messages (at least the Initial_DP message containing the service key parameter) and to distribute the messages to their correct receivers.
In the functional hierarchy of the network element, the main program blocks are located at the next hierarchy level after the distributor programs. These main program blocks are denoted by FMPi (Feature Manager Program). The main program blocks constitute the processes controlling the actual service logic programs SLP, supplying them with the data they need. Thus, the main program blocks are responsible for managing the services and features.
The message distributor programs distribute each service request to the correct main program block. To enable this, there is a dedicated data table MDP_DT for the distributor programs, in which the service key value SK is presented at the beginning of each data row as a search key. On the basis of the service key value that arrived in the Initial_DP message, the distributor program block searches from the data table the correct row in which it finds the identifier of the main program block (FMP_NAME) that serves as the recipient in the case of said service key value. The data table is preferably common to all distributor program blocks MDPi. Having found the correct main program block, the distributor block instance creates therefrom an instance for the use of said service request and forwards an INAP message to said instance.
Since service logic needs are different for different object types, it is advantageous to implement the SCP network element in such a way that it has separate main program blocks for the logically distinct main object classes contained in the SSP exchanges. Said classes may include calling subscriber class, called subscriber class, destinations (beginning of dialled number), sub-destinations (the entire dialled number), routes, circuit groups, etc. Furthermore, the subscribers may be in different classes according to which network they belong to (for example a fixed network or mobile network). Objects in this context denote such network-related entities to which information can be attached in the network element—e.g. in the case of an intelligent network in an SSP network element—indicating, for an individual call attempt, whether a service request is to be sent to the network element offering services (which in the case of an intelligent network is an SCP network element).
As stated previously, each distributor program block utilizes the service key parameter that arrived in the service request message to define the receiving main program block. This means that for service requests relating to a given main object class (e.g. calling subscribers), the SSP exchange has to set a service key value that is different from the service key value of objects belonging to another class (e.g. called subscribers) (even though service of the same type is concerned). A wide variety of service key values may correspond to a given main program block, but the service key value sets relating to two different main programs may not overlap.
Each main object class has a dedicated data table FMPi_DT (i=1,2, . . . n). These data tables will be termed main tables in the following. Thus, the SCP network element has a dedicated main table for each main program block. Each main table has one data row for each object belonging to said class. For example, the data table (FMP 1 _DT) used by the main program block FMP 1 relating to calling subscribers has one data row for each calling subscriber Ai (i=1, 2 . . . ), the data table (FMP 2 _DT) used by the main program FMP 2 relating to called subscribers has one data row for each called subscriber Bi (i=1, 2 . . . ), the data table used by the main program relating to sub-destination objects has one data row for each sub-destination in use, the data table used by the main program relating to destination objects has one data row for each destination in use, etc.
In each row of the main tables, information is stored in the manner shown in FIG. 4, defining what kind of feature set said object has activated. An object identifier OI is stored at the beginning of each row R as a search key. The main, program block searches the correct row from its data table by means of the value of the object identifier contained in the INAP message. The row contains successive subrecords SR, one for each feature. At the beginning of each subrecord, there is a field FK containing a feature key Fki (i=1,2 . . . ), indicating which feature is concerned. Thereafter the subrecord may have for example a status field ST, containing information on whether said feature is active or, passive, and a priority field PR, containing a priority number. These priority numbers of subrecords indicate the relative order of execution of the features. Each subrecord further has at least field SLP, containing the identifier of the service logic program that executes said feature. The service logic programs form the lowest hierarchy level of the network element.
Preferably there are dedicated service programs for each main object class. Furthermore, there is a clone of each program dedicated to each INAP message set (i.e., each distributor program). In the figure, the service programs are denoted with reference SLPxy-z, where x indicates the main object class to which the program belongs, y indicates the INAP message set to which the program belongs, and z indicates the consecutive number of the program within the main object class.
In accordance with the hierarchy of the network element, the instance (SLPi) of the lowest level of one service request dialog is called a child, the instance of the next level (FMPi) is called the parent, and the instance (MDPi) of the level next to that is called the grandparent. An older instance always begets the younger instance.
In practice, one feature implemented by a service logic program may be for example playing of an announcement to the subscriber (“play an announcement”) or an operation by which the calling subscriber is requested to dial additional numbers (“prompt and collect user information”), or a connect operation (a CONNECT message is sent to the SSP exchange, by which the SSP exchange is requested to connect the call to a given address).
The order of execution of the features can be indicated for example in the above-stated manner by adding a priority number field PR to the sub-records, in which case said numbers indicate the relative order of execution of the features. There are also other alternatives for achieving the correct order of execution, as will be seen hereinafter. This way, however, is simple and makes it possible that the same service key value can indicate a different order of execution e.g. for two different calling subscribers.
In addition, one or more separate data tables are provided for the main program blocks, having a data row for each service key value that is in use in the domain of several different main program blocks. The example in the figure has one data table FMP_DT 1 that is common to all program blocks (all main program blocks read said data table). At the beginning of each data row in the data table, the service key value SK is provided as the key. Each row contains data on the features Fki (i=1,2 . . . ) relating to said service key value, that is, on the services that are allowable features in the case of said service key value. Furthermore, the row may contain information as to in which order these features are executed, or the order of the feature keys may directly indicate the relative order of the features. The main program block reads from this data table the row corresponding to the received service key value, whereby it finds the set of features that are allowable features in the case of said value. Thereafter the main program block reads from its dedicated data table FMPi_DT (i=1,2 . . . ) the row corresponding to the identifier of said object (e.g. calling subscriber). From this row, the main program block finds the identifier of the service logic program SLPi (i=1,2 . . . ) that is to be started. From the row of the class-specific table FMPi_DT (for instance the table of calling subscribers), the main program block takes into consideration only those features which relate to said service key value (i.e. the ones belonging to the allowable set searched above), and of these eventually only those indicated as active at said object.
At this stage of execution of the service request, the features relating to the object and their relative order of execution are known. Thereafter the main program block produces an instance of the service logic program corresponding to the feature that is the first in turn and requests it to start execution of the service.
The FMP instance thus sends an Initial_DP message to the service program which has the highest priority and whose identifier the main program block read from the relevant subrecord of the object-related row. First, however, a separate request message REQREC is sent to said SLP instance, since the Initial_DP message must be sent in its standard format (ASN.1 format) in which its information content is not sufficient. The service-logic program thus needs also other data in addition to that contained in the INAP message, for example the value of the feature key, which it receives in the request message.
FIG. 5 shows an example of the data structure of the request message sent. The request message first has a field FMP_ID 1 , containing the identifier of the sending FMP instance. Thereafter follows a field RP_ID, containing the identifier of the program block to which the SLP should send its messages relating to this dialog. These acknowledgement messages can be sent both to the FMP instance (parent) and the MDP instance (grandparent). By sending acknowledgement messages to the distributor program instance, the load on the main program blocks can be diminished, since the MDP instance attends to the sending of outbound messages to the network in any case. The next field LAST_REQ contains a Boolean variable indicating whether still another request message is bound for the SLP instance after it has executed the features which were requested in that request message. The field SK contains the service key value obtained from the SSP network element. The next field, NoOfSFs, indicates the number of features contained in the request message, and the fields Fki (i=1,2 . . . ) subsequent to said field contain the keys of said features. The last field AT contains a description of how the service dialog is to be terminated if the execution of the features fails.
The structure of the service programs is such that they are composed of parts each of which executes a given feature. Thus each SLP executes only those features whose feature keys arrive in the request message. If more than one feature belonging to the allowable features is active in the object-related row and the same SLP identifier is related to all said features, the FMP can send all these feature keys in one request message (providing that it is otherwise allowable to execute all said features in succession). If the features contain the identifier of several different SLP programs, the FMP instance sends request messages to said SLP programs in the order indicated by the subrecords in the object-related row. The procedure may also be such that only one feature key is sent in one request message.
Having executed the feature, the SLP sends an acknowledgement message INFOREC to those elements (parent and/or grandparent) which are indicated in the request message REQREC. In the acknowledgement message, the SLP instance also indicates in what manner the feature was terminated. If, for example, the execution of the feature fails, the feature to be executed next can be different compared to a normal case in which the execution of the feature is successful.
FIG. 6 illustrates one possible structure of an acknowledgement message INFOREC sent by an SLP instance. The first field SLP_ID 2 indicates the identifier of the sending SLP instance. The next field WAIT contains for example information on whether a response is awaited from the network before the service can be continued. The field FLAG_D contains a Boolean variable indicating whether the SLP instance terminates itself after sending of an acknowledgement message or not. The field LAST_REQ again contains the same information that the child has last received from the parent in said field (the grandparent thus also receives said information). The next field LAST_INFO again contains a Boolean variable indicating whether the SLP instance has completed the last feature of the request message it received. The next field Fk contains the key of the feature in which said message arrives as an acknowledgement. The field CC contains the termination code of the feature just completed. The field ECC can indicate slight errors for which a separate error message need not be sent. The field EndDIg contains information on in which way said SLP instance desires its grandparent to terminate said dialog. The dialog can have different ways of termination, for example depending on whether a message is desired to be sent to the network, or if a message is sent, what information elements are included in the TC_END primitive to be sent.
In a preferred embodiment of the invention, the acknowledgement message further contains a field NFk, in which the key of the feature that should be executed next can be indicated. This field and its use relate to a preferred embodiment of the invention that will be described hereinafter.
Since the internal messaging within the network element does not relate to the actual invention, it will not be described in detail in this context. What is essential for the invention is that the service program instances receive both internal messages and messages arriving from the network (INAP messages), that the (internal) request and acknowledgement messages are used to attend to the execution and concatenation of the features, and that the acknowledgement message can also be used to indicate how the execution of the feature succeeded and possibly also which feature is to be executed next.
In the following, the basic configuration of one service logic program SLPi will be described with reference to FIG. 7 . Each service logic program comprises service independent building blocks SIB. The SIBs are blocks from which service designers assemble service features and services. In other words, the SIBs are the smallest blocks from which services and service features are assembled. A service consists of several service features and a service feature again consists of several SIBs, even though in some cases a service feature may consist of only one SIB.
Each SLP consists of a separate initial state block (i.e., initial state SIB), one or more feature modules FM, and a separate end state block ESB (i.e., end state SIB). There are typically several parallel feature modules, but the initial state block and end state block are common to all parallel feature modules of a service program. Of these blocks, the term state block is used, on the one hand because they contain a delay state in which a response from the outside is expected and on the other hand because the service programs do not elsewhere contain such delay states in which an event is awaited.
Each SLP starts with a generic initial state block ISB the task of which is to receive the service dialog initiation message arriving from the network and to direct the execution of the service to the start of the correct feature. The sending main program block sends a request message REQREC (containing, in accordance with the above, for example one or more feature keys Fk) and the related actual INAP message (that has arrived from the network) in succession. For this reason, the initial block has a delay state DS in which the SLP instance awaits after the request message the related Initial_DP message. When the Initial_DP message arrives, the execution of the program branches off to one of the feature modules FM in accordance with the key of the feature to be executed first. The initial state block further performs various initialization tasks that are the same for all service programs. Under the delay state DS the service logic also needs at least a branch for processing a timeout message possibly received, indicating that the INAP message has been awaited for too long, and a branch for processing a termination message internal to the network element, by means of which the execution of the service is terminated for example on account of an error. During the execution of the service, the network element may also receive from the network an error message relating to said service dialog, as a result of which the service has to be terminated. In these error situations, the routine enters the end state block ESB directly.
After receipt of the lnitialDP message in the initial state block, the service proceeds to one of the feature modules FM. The start of a feature normally comprises a function block FB in which the information contained in the initiation message is processed.
The execution of the service logic employs a dedicated messaging block (messaging SIB) for each message of different types that is sent from the service program to the network. In general, the function block at the start of the feature is succeeded by one or more of such messaging blocks. The purpose of the function block preceding the messaging blocks for its part is to prepare the data that is set in the information fields of the messages in the messaging blocks.
If any one of the messaging blocks is such that a specific response that is always received for said message in the case of faultless operation is awaited to said type of message, a generic halt state block HSB is added after the messaging block, in which the service logic awaits the response expected by the service logic (an INAP message of said type) from the network. Genericity means that the code used to implement the block is the same irrespective of at which point of the service program or in which service program the block is located. Only the variable given as entry information to the block, indicating the type of message awaited, is block-specific, since it is dependent on the type of the message sent to the network previously.
Some of the messages sent are such that they always receive a response message in connection with normal (faultless) operation, and one must await the response prior to proceeding with the execution of the service. Such response messages will be termed synchronous responses in the following. Some of the messages sent for their part are such that the execution of the service logic is continued without awaiting a response. When such responses arrive from the network on the SCP network element, the service program receives them in any suitable delay state, even though it is not awaiting in a specific halt state. Such response messages will be termed asynchronous responses. Some of the messages sent for their part are such that no response message to them arrives. Asynchronous messages also include error messages from the network, which can arrive at any time, and additionally such internal messages that can arrive at any time, for example internal termination messages. Each halt state block instance is capable of receiving, during waiting, any asynchronous response (possibly) arriving prior to a synchronous response.
Each feature module FM can contain one or more halt state blocks (and each halt state block can have one delay state in which a response is awaited).
Each instance of the halt state block is thus capable of receiving all possible messages that may arrive during the halt state. For this reason, the service logic must branch off at the end of the halt state block according to the type of the message received in the halt state. Consequently, it is possible to use in each such receiving branch a generic message preprocessing block MB, containing the functions that transfer the information received in the message to the use of the service program. In other words, in the preprocessing block the values of the parameters received in the message are transferred to the corresponding variables. One such preprocessing block is provided for each message type.
Furthermore, at the end of each feature module FM there is always a separate stop state block SSB, which indicates the end of a given feature before the start of the next feature or before the termination of the SLP instance. An acknowledgement message INFOREC is sent from the stop state block about the execution of the feature. On the basis of the termination code Tc contained in the acknowledgement message (in field CC), the main program block may e.g. define the next feature module and send to the stop state block the next request message REQREC, which contains the keys Fk of the features to be executed next (one or more keys). Hence, at the end of the stop state block a (new) feature key acts as a branching variable. From the point of view of the service logic, the stop state block thus serves as a switch that switches the service to proceed at the correct feature module.
When there are no features to be executed and it is not necessary to await asynchronous responses, the process jumps to the generic end state block ESB, in which suitable termination messages can be sent to the network and for example storage operations for various counters can be performed and the SLP instance can be terminated. The end state block comprises the termination operations that are common to all services.
The number of different termination codes available is generally dependent on what feature is in question. In the simplest case, there may be only two termination codes: feature executed successfully or execution of feature failed. If the feature is connect, for example, the termination code may indicate e.g. these four different events: called subscriber free, called subscriber busy, called subscriber does not answer, and connection setup failed.
FIG. 8 illustrates the structure of one messaging block TB. In the messaging block, a value is first given to parameter PWAIT, which indicates whether a synchronous response is awaited to the message sent (step 80 ). This parameter receives e.g. the value one if a synchronous response is awaited and otherwise zero. Thereafter, values are set in the data fields of the outbound message (step 81 ) and the message is sent (step 82 ). When the message has been sent, the correct values are set for the control variables indicating the responses awaited (step 83 ). The message may e.g. be of the type ApplyCharging, which is used in charging and has the operation code 35 . To this message, an ApplyChargingReport message having the operation code 36 is awaited from the SSP. Thus, in step 83 the value of the variable indicating the type of the message awaited is set as 36 . There is one messaging block for each message type to be sent to the network, i.e. in practice there are about 15 messaging blocks, which is the number of (standard) message types sent from the SCF to the SSF.
FIG. 9 illustrates the functionality of the halt state block HSB. In addition to the above, what is essential is that this block can include functions that are inessential to the actual service logic (needed by the subscriber). Such functions include transmission and reception of data messages that are not network messages (INAP messages) but messages internal to the network element, wherewith for example the timeouts or acknowledgements performed within the network element are handled. The halt state block thus has one or more internal message transmission blocks IMT, wherefrom a message internal to the network element is transmitted and at least one delay state DS, in which a synchronous response (a specific INAP message) is awaited (which is hence called a synchronous halt state). Under the delay state there are additionally—as above—at least branches for processing (a) a timeout message indicating that one has awaited too long in the delay state, and (b) a termination message internal to the network element, wherewith the execution of the service is terminated for example on account of an error. If an internal timeout or termination message or for example an error message arriving from the network is received, the routine enters the end state block ESB directly. Thus, the branching variable used at the end of the halt state block is the type of the received message.
The value of the parameter PWAIT can be given in the halt state block as well.
FIG. 10 illustrates the stop state block SSB provided at the end of each feature module. It is tested at the start of this block (step 101 ) whether there are still features remaining, i.e. whether the value of the feature counter CTR is higher than zero. If this is the case, a timer measuring a given short time is set (step 102 ), an acknowledgement message INFOREC is sent (step 104 ), and a delay state is entered to await an entry event.
If there are no features remaining (CTR=0), an acknowledgement message INFOREC (step 103 ) is sent and a delay state DS is entered to await an entry event.
In step 104 , the acknowledgement message (field Fk) sent indicates to the main program that the service program still has features to perform, and thus the main program does not send a response message to the service program. Correspondingly, the acknowledgement message to be sent in step 103 indicates that the service program no longer has features to perform.
If there are still features to be executed, the entry event is a(n internal) message indicating that the timer set in step 102 has expired. In that case, the routine goes over to the start of the feature indicated by the next feature key.
If a new request message REQREC is received from the main program block in the delay state, the feature counter (step 105 ) is updated, whereafter the routine transfers to performing the features indicated by the new request message. As above, there are also branches below the delay state that are intended for the processing of the possible timeout and termination messages.
If the keys of all features were sent already in the first request message, the main program sends, after the acknowledgement it received from step 103 , a termination message in response to which the execution of the service logic transfers to the end state block.
If all feature keys are not sent at a time, but for example only one key per request message, and the service still has features to perform, a new request message containing the keys of the features to be performed next (one or more keys) is sent after the acknowledgement of step 103 .
To find one or more features to be performed next, another data table FMP_DT 2 (FIG. 4) common to a given set of main program blocks is used at the main program level. This data table indicates the mutual interaction of the features. The primary search keys in the data table are the feature key Fk and the termination code Tc. The table contains the possible features for each feature/termination code pair. In other words, the table always contains the set of features that is possible to perform next when the executed feature and its termination code are known. When the set of features that can succeed the feature just executed has been found in the table, the feature having the highest priority in the object-related data row (or in data table FMP_DT 1 ) is selected from among said features as the one to be executed next. When this feature has been executed, a termination code is again received in the acknowledgement message, and thus a new feature set is again found on the basis of the termination code and the feature key, and the feature to be executed next is selected from this set on the basis of the object-related data.
To minimize the number of messages to be transmitted, it is advantageous to proceed in such a way that several feature keys can be sent in one request message every time it is known that said features can be applied in succession irrespective of what their termination code is. In that event, the main program must go through the non-executed features in the order of priority to check that the next feature is allowable with all termination codes of the preceding feature. If, on the other hand, the allowability of the next feature is dependent on the termination code of the preceding one, the main program must execute the above check and selection operations and subsequently send a new request message.
It is also possible that on the basis of the termination code, only such features (one or several) that are not in the object-related row are found in the data table. This happens in exceptional situations when the termination code indicates that the execution of the service has not succeeded in the normal way. In practice, for example, a connect feature may succeed in a normal situation, but if for instance a calling subscriber did not provide a sufficient number of digits, a feature can be executed whereby the calling subscriber is requested to dial more numbers, or if the termination code indicates for example that the dialled number is not found, the service can continue with a voice announcement feature.
Generally, it can be stated that a service feature is implemented with successive blocks which include an initial state block (only for the first feature), a first number of function blocks, a second number of messaging blocks, a third number of halt state blocks, a fourth number of message preprocessing blocks, and a stop state block. The number of the messaging, halt state, and preprocessing blocks may also be zero. From the end state block ESB, there is no return to the same or a new service feature. The service does not necessarily end, however, when the end state block is entered for the first time, since the FMP is capable of generating a new instance of a new or the same SLP, if this is necessary to complete the service.
In the simplest case, the feature module (i.e., feature) comprises one function block, one messaging block and one stop state block (no halt state block). This is the situation for example if an initiation message-arrives from the SSP exchange to the effect that the SCP network element need only send to the network a CONNECT type message (to which no synchronous response is awaited).
In addition to the building blocks described above, the service programs may comprise small auxiliary or special functions at most. A separate set of auxiliary building blocks can be defined for such auxiliary functions. Auxiliary blocks are thus blocks that comprise only very small functions, for example branching off in a service logic on the basis of individual data. Such branching off can be effected by means of one branching command, in which case the block containing said branching command is an auxiliary building block. One service independent building block belonging to this group, wherewith a jump directly to the end of the feature module is realized for example in an error situation, will be described hereinafter. This group may also include for example a SIB wherewith the identifier is compared to a reference value. Such a SIB is also defined in the international standards.
There can in practice be several dozens of different types of function blocks, but they are nevertheless such that no messages are sent therefrom to the network and no messages are received from the network (nor are internal messages received). A function block may be e.g. such that reads information from a database.
By means of the state blocks in accordance with the invention, service independent building blocks are formed for the reception of an initiation message (initial state block), reception of synchronous responses arriving from the network (halt state block), concatenation of features (stop state block), and for service termination operations that are the same irrespective of which service logic program is concerned (end state block). State blocks of the same type are similar in all service programs. Also the end state block terminating the service is called a state block, since in said block release messages must be sent to the network and a final response from the network (CallInformation Report, a message that the system must be capable of receiving even after a release message has been sent to the network) must be awaited (in delay state). Termination operations are carried out in the end state block also in cases where a jump is made from the middle of the feature module directly to the end state block to terminate the service.
The reception of all possible network messages is included in the initial state block, halt state block, stop state block, and end state block. More precisely, the reception of the initiation message is included in the initial state block and the reception of all other network messages in the other state blocks. The reception of synchronous responses is only included in the halt state block. Besides these four state blocks, there are no other delay states, and thus no delay states or reception logic relating to them need to be embodied in the other service independent building blocks.
The above is a description of the implementation of services in a case where all features can be executed in immediate temporal succession. However, some services are of such a nature that this is not possible, but one must wait between two successive features before the execution of the service can be continued. The service may be such for example to calling subscribers who are credit customers, in which-case the balance of the account must be checked in between during the call. During the service, one must possibly also await a specific event, for example the calling subscriber dialling more numbers. Even after all features have been executed, the SLP instance must possibly be kept alive because one must still await an asynchronous response from the network, for example information on the calling subscriber placing the receiver on hook.
It is advantageous to implement passing of such “idle time” in the service logic as a separate feature, in order that it can be constructed as a service independent building block. In accordance with a preferred embodiment of the invention, each service program has, in addition to the other feature modules, a special feature module for passing of such “idle time”. This feature module is called the idle module.
The start of the idle module comprises an instance of the halt state block HSB in which reception of asynchronous responses takes place in a halt state in which no specific response has been defined as the synchronous response (as in the halt state blocks of the other feature modules), but the parameter indicating the type of the awaited message has the value zero. It is to be noted in this context that it must be possible to receive asynchronous responses in each instance of the halt state block, since the duration of the halt state may be so long that an asynchronous response, e.g. one indicating that the calling subscriber has terminated the call, may arrive during it.
Thus, the idle module has the capability of receiving all possible asynchronous responses arriving from the network and additionally internal asynchronous responses, such as expiration of timers. The service logic must branch off from the halt state block according to the type of the asynchronous response that arrives. The processing of the asynchronous responses could be performed within the idle module, but it is nevertheless advantageous to carry out the processing exterior of the idle module in separate feature modules, preferably one being provided for each possible asynchronous response. The processing should preferably be carried out exterior of the idle module, since the processing of asynchronous responses is not necessarily similar in all service programs.
Hence, a preferred additional embodiment of the invention includes special exception blocks enabling a jump to the end of the feature module and therefrom further to the start of the desired feature module, where the asynchronous response that has arrived is processed and from the end of which one can return, when necessary, to the start of the idle module. There is a dedicated exception block instance for each possible asynchronous response. The use of exception blocks has the advantage that thereby the code of the idle module IFM can be made identical in all service programs.
FIG. 11 illustrates the structure of an idle module IFM provided with exception blocks EB. From the halt state block HSB′, in which all possible asynchronous responses can be received, the routine branches off after the message preprocessing block MB to a dedicated exception block instance EB according to the asynchronous response that has been received. As is shown in the figure for one exception block, in each exception block instance values are first given to parameters iERR and NextFk, and thereafter a jump is made directly to the start of the stop state block SSB located at the end of the feature module. The parameter iERR indicates whether the service logic has passed through the exception block and what kind of exceptional situation is concerned. The parameter NextFk again indicates the key of the service that is desired next.
The exception block can be used, in addition to the idle module, also in other feature modules if the service logic must branch off to an exception for example upon arrival of an error message. With the exception block, exceptions are handled in such a way that a jump is made to the end of the feature module and therefrom to the start of the given feature module.
The designer of the service program provides each instance having an exception block with an information parameter indicating the feature to whose start one must transfer next.
If exception blocks of the kind described above are used, a test has been added to the stop state block SSB in which it is tested whether the stop state block is entered directly from an instance of an exception block and if so, what kind of exception is concerned. FIG. 12 illustrates such a stop state block which is otherwise similar to that shown in FIG. 10, but steps 98 , 99 and 100 have been added to the start of the block, and steps 105 a and 106 have been added after the reception of the request message. At the start of the block, it is first tested (step 98 ) whether the stop state block is entered from an exception block. This can be effected in such a way that the parameter iERR has otherwise the value zero, but in the exception state block it receives a value higher than zero. For example the value one can indicate that an asynchronous response has been received that requires processing in a dedicated feature module, and the value two can indicate that an asynchronous response (for example a termination message) has been received that requires termination of the service (jump to the end state block). Hence, it is tested in step 98 whether the value of parameter iERR is smaller than or equal to zero. If this is the case (that is, the stop state block has not been entered directly from the instance of the exception block), the execution of the feature proceeds in the manner described above. If the parameter has a value higher than zero, step 99 is proceeded to, in which it is tested whether the parameter has a value smaller than or equal to one (i.e. whether the value is exactly one). If the parameter has previously been given the value one, the routine proceeds to step 100 , in which the value of the parameter NextFk is set in field NFk of the acknowledgement message and step 103 is proceeded to, in which an acknowledgement message is sent. If the parameter iERR has been given a value higher than one, the routine proceeds directly to the end state block ESB.
If the main program block permits the execution of the feature (NextFk) contained in the acknowledgement message as the next feature, it sends a request message REQREC containing said feature key.
In a situation where all features have been executed, the main program block can also send, instead of a termination message, a request message comprising no feature key. In such a case, it is checked from the request message (step 105 a ) whether it contains feature keys. If there are no feature keys, it is checked whether there are still asynchronous responses to be received from the network (step 106 ). If this is the case, the routine proceeds to the idle module to wait. If there are no pending responses, the routine proceeds to the end state block.
Thus, the service is terminated (the end state block is entered) when in the stop state block a situation is encountered in which (a) the main program block sends a termination message, or (b) there are no features remaining and no pending asynchronous responses either, or (c) if an internal timeout message indicating that one has awaited for too long in the delay state is received.
The feature to be executed next need not necessarily be defined in the acknowledgement message; if for example the parameter iERR is given the value 2 , the service logic proceeds directly to the end state block. Such values are used in situations in which the asynchronous response received in the halt state block HSB′ is such that the execution of the service is to be terminated immediately.
Each service program is thus constructed of SIBs that can be classified into the following classes according to how the different functions have been divided among them:
state blocks ISB, HSB, SSB and ESB,
messaging blocks TB of messages,
preprocessing blocks MB of received messages,
function blocks FB, and
auxiliary and special blocks.
By implementing the services as feature modules concatenated in the manner described above, both features and subscriber-specific feature combinations can be added flexibly, without changing the existing service logic programs.
Even though the invention has been described in the above with reference to the examples in accordance with the accompanying drawings, it is obvious that the invention is not to be so restricted, but it can be modified within the scope of the inventive idea set forth above and in the appended claims. The implementation of services in accordance with the invention can for example be applied irrespective of whether object-related services are produced or whether the service logic is the same for a given group or even all objects (subscribers). The different main object classes can also be located in different network elements, even though they have been presented in the above as all being located in the same network element. It is also possible that only the active features are stored in the object-related data row. Service programs can also be located in network elements of different types, for instance such that do not directly receive service requests.
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The invention relates to a method for service provision in a telecommunications network, specifically in an intelligent network. In accordance with the method, service programs (SLP) are stored in at least one network element of the network, service is provided by starting the desired service program in the network element offering services, and each service is produced from a set of successive features. In order to make the adding of new services and maintenance of services provided by the network simpler than heretofore, keys (Fk) for the features in use and additionally information on which of the service programs (SLP) is capable of executing said feature are stored in the network element offering services, at least some of the service programs are implemented in such a way that the part of the service program implementing the corresponding feature is defined by means of said key, and the service is offered by defining a given ordered set of feature keys and by executing in said order the parts of at least one service program corresponding to the feature keys.
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FIELD OF THE INVENTION
[0001] The present invention relates to a masonry wall system in which masonry blocks are interconnected using threaded mechanical fasteners.
BACKGROUND
[0002] Masonry block walls are presently constructed using concrete blocks stacked on top of each other. The blocks are bonded together using cement mortar (both in the horizontal and vertical joints). A wire-reinforcing ladder is installed in the periodic horizontal joints. Construction of a masonry block wall requires a skilled mason. The construction of a masonry block wall requires a controlled environment while the cement mortar cures.
[0003] In conventional masonry construction, the designer (the design engineer) has few means of knowing that the block wall is built in accordance with the designers specifications, for example: the mortar being correctly installed and having adequate strength, the concrete filled cores being completely filled and the reinforcing steel being placed correctly or being installed at all. The designer has to rely heavily on the integrity of the mason and the mason's workers that the masonry wall was properly built.
[0004] Traditional masonry units have vertical chases or conduits for installing plumbing lines, electrical conduits and other building services, but the vertical holes are often small and are commonly filled with cement grout or concrete and thus very often not continuous from top to bottom.
[0005] U.S. Pat. No. 1,499,483 (Simms), U.S. Pat. No. 5,685,119 (Zschoppe), U.S. Pat. No. 5,899,040 (Cerrato) and U.S. Pat. No. 6,244,009 (Cerrato) disclose various examples of a wall construction using masonry type blocks. In each instance, the block has an irregular shape for interlocking connection with adjacent blocks. The blocks thus require complex molds for manufacturing. Rods are used in some instances for interconnecting adjacent blocks, however the rods are intended to span plural rows resulting is a wall which permits some relative movement between the blocks. This relative movement is typically undesirable in a large static structure.
[0006] U.S. Pat. No. 5,787,675 (Futagi) discloses a log wall construction in which mechanical fasteners are used for interconnecting the logs of the wall. The fasteners include a washer formed integrally thereon which has cleats for bearing into the logs being fastened. The configuration of the cleats would interfere with the use of the fasteners on a masonry wall construction.
SUMMARY OF THE INVENTION
[0007] According to one aspect of the invention there is provided a masonry block for use with threaded masonry fasteners, the block comprising:
[0008] a rectangular body which is elongate in a longitudinal direction extending between ends of the body, the body having a pair of opposing, upright side walls spanning in the longitudinal direction between the ends; and
[0009] fastener apertures formed through the rectangular body to extend from a top side to a bottom side of the block for receiving the threaded masonry fasteners therethrough;
[0010] at least some of the fastener apertures being spaced from one another in a lateral direction extending between the opposing, upright side walls of the body.
[0011] By providing fastener apertures which are spaced apart from one another in a lateral direction extending between the opposing upright side walls of the block, the support area joining each block to the previous row is wider across the thickness of the wall structure to more evenly anchor each block to the previous rows. Furthermore the fasteners joining the rows are mounted closer to the outer walls under tension so that the fasteners provide better support to resist bending forces of the wall in either lateral direction.
[0012] According to a second aspect of the present invention there is provided a masonry block for use with threaded masonry fasteners, the block comprising:
[0013] a rectangular body which is elongate in a longitudinal direction between ends of the body, the body having a pair of opposing, upright side walls spanning in the longitudinal direction between the ends and a pair of web portions spanning in a lateral direction between the opposing, upright side walls;
[0014] a central conduit extending through the body from a top side to a bottom side of the body between the web portions;
[0015] a pair of partial conduits extending through the body from the top side to the bottom side of the body at the ends of the body, each partial conduit being located between a respective one of the web portions and a respective one of the ends of the body and substantially comprising half of a cross-sectional area of the central conduit; and
[0016] fastener apertures formed through the rectangular body to extend from the top side to the bottom side of the block for receiving the threaded masonry fasteners therethrough.
[0017] Construction of the block to include a pair of webs spanning between opposing side walls to define a central conduit therebetween and a pair of partial conduits at the ends of the block, results in an advantageous location of the fasteners in the webs being located approximately a quarter of the length of the block from each end of the block. In this configuration each block is connected to a pair of adjacent and overlapped blocks in the previous row by a fastener which is centrally located within the area of overlap between the blocks for optimum distribution of loads.
[0018] According to another aspect of the present invention there is provided a masonry block in combination with threaded masonry fasteners:
[0019] the masonry block comprising a rectangular body and fastener apertures formed in the rectangular body to extend from a top side to a bottom side of the block; and
[0020] each masonry fastener comprising:
[0021] an elongate body substantially corresponding in length to a height between the top and bottom sides of the block;
[0022] an externally threaded portion near a bottom end of the elongate body;
[0023] a nut portion formed near a top end of the elongate body; and
[0024] an internally threaded bore formed in the nut portion at the top end of the elongate body which is suitably sized to operatively receive the externally threaded portion of an additional masonry fastener of identical configuration.
[0025] The fasteners described herein are suitably arranged to span only a single row of blocks in the preferred embodiment. In this arrangement a much simpler block construction can be used as the blocks do not require any additional interlocking or alignment mechanism to connect to the previous row other than simply aligning the fasteners from one row to the next. The simplicity of the block design reduces manufacturing costs of the block when only fastener apertures are required and the top and bottom faces of the block can remain substantially flat and free of complex interlocking shapes. The fasteners are much easier to align with a previous row of fasteners when assembling only a single row at a time.
[0026] According to another aspect of the present invention there is provided a masonry wall system comprising rows of masonry blocks supported one above the other to form a wall structure in which each masonry block is connected to at least one masonry block immediately therebelow by at least one respective masonry fastener;
[0027] each masonry block comprising a rectangular body and at least one fastener aperture formed in the rectangular body to extend from a top side to a bottom side of the block and receiving said at least one respective masonry fastener therethrough; and
[0028] each masonry fastener comprising:
[0029] an elongate body;
[0030] a nut portion adjacent a top end of the elongate body which engages a top side the respective masonry block;
[0031] an internally threaded bore formed in the nut portion at the top end of the elongate body; and
[0032] an externally threaded portion near a bottom end of the elongate body in mating engagement with the internally threaded bore of the respective masonry fastener received through said at least one masonry block immediately therebelow.
[0033] According to yet another aspect of the present invention there is provided a corner block comprising:
[0034] a body having a first rectangular portion and a second rectangular portion which are formed integrally with one another;
[0035] the first rectangular portion having upright side walls which are elongate in a longitudinal direction between ends of the first rectangular portion and dimensions between top and bottom sides and between the upright side walls which are substantially identical to the masonry blocks;
[0036] the second rectangular portion having upright side walls extending outward from the first rectangular portion in a lateral direction oriented perpendicularly to the longitudinal direction of the first rectangular portion and having dimensions between top and bottom sides and between the upright side walls which are substantially identical to the first rectangular portion;
[0037] one of the side walls of the second rectangular portion being flush with one end of the first rectangular portion; and
[0038] a difference between dimension of the corner block in the longitudinal direction thereof and dimension of the corner block in the lateral direction thereof corresponding to approximately half a total length of the masonry blocks in the longitudinal direction thereof.
[0039] According to a further aspect of the present invention there is provided a method of assembling a masonry wall on a supporting surface, the method comprising:
[0040] providing a plurality of masonry blocks, each comprising a rectangular body and fastener apertures formed in the rectangular body to extend from a top side to a bottom side of the block;
[0041] providing a plurality of masonry fasteners, each comprising an elongate body; a nut portion integrally formed near a top end of the elongate body; an internally threaded bore formed in the nut portion; and an externally threaded portion near a bottom end of the elongate body;
[0042] forming a first row of blocks by placing the masonry blocks sequentially in an end to end configuration along the supporting surface;
[0043] connecting each of the masonry blocks of the first row to the supporting surface using the masonry fasteners by inserting each externally threaded portion through a respective fastener aperture until the nut portion engages the top side of the respective block and the externally threaded portion is anchored to the supporting surface; and
[0044] forming subsequent rows of blocks in which each subsequent row is formed by:
placing the masonry blocks sequentially in an end to end configuration along a previous row of blocks with the fastener apertures of the masonry blocks being aligned with respective fastener apertures of the previous row of blocks; and connecting each of the masonry blocks to the masonry blocks of the previous row of blocks using the masonry fasteners by inserting each externally threaded portion through a respective fastener aperture until the nut portion engages the top side of the respective block and the externally threaded portion is threadably received in the internally threaded bore of the respective masonry fastener in the previous row of blocks.
[0047] Preferably at least some of the fasteners are spaced in the longitudinal direction relative to one another in addition to being spaced in the lateral direction. Also preferably, some or all of the fastener apertures are located adjacent respective side walls of the block in the web portions.
[0048] Each fastener aperture preferably includes a counter bore formed at the bottom side of the block wherein a length and a diameter of the counter bore are respectively equal to or greater than a length and a diameter of the nut portion of the fastener. The counter bores and the nut portions of the fasteners may be near one another in diameter for snugly receiving the nut portion of one of the fasteners in each counter bore. In some embodiments, the counter bore may increase in diameter towards the bottom side of the body.
[0049] There may be provided a flat washer between the nut portion and the externally threaded portion which is greater in diameter than the counter bore and which is formed integrally with the nut portion.
[0050] A pair of laterally spaced fastener apertures may be spaced from each end of the block by approximately ¼ of a total length of the block in a longitudinal direction of the block for alignment of the fastener apertures when the blocks are stacked to overlap half a block length of the blocks immediately therebelow.
[0051] The masonry block may be used in combination with a shear plate spanning at least partway across one of the top or bottom sides of the body. The shear plate preferably includes a pair of apertures formed therein which are aligned with a pair of the fastener apertures in the body which are spaced from one another in the lateral direction.
[0052] There may also be provided a channel extending in the longitudinal direction along one of the top and bottom sides of the block for receiving an elongate reinforcement bar therein in a horizontal direction across a plurality of blocks.
[0053] The method of assembling a masonry wall described herein may include forming a supporting surface of concrete with some of the masonry fasteners embedded therein for alignment with the fastener apertures of the first row of blocks and anchoring the masonry fasteners received in the first row of blocks to the masonry fasteners embedded in the concrete.
[0054] As described herein, the masonry wall system results in a mortarless block wall comprising concrete block units that are connected together with steel connectors. The steel connectors main purposes are to provide tensile strength to the wall to resist bending stresses (created from lateral loads such as wind and eccentric vertical wall loading). The block walls are placed on top of the lower course of masonry units (the vertical joints are stagger from the block course below—running bond). The steel connectors also serve a secondary purpose of providing a guide for the masonry block units being placed.
[0055] The masonry wall system of the present invention (or mortarless block wall) possesses numerous benefits and advantages over the traditional masonry wall construction. Most significantly, the mortarless block wall can be built without the specialized skills and knowledge of a mason. As well, the mortarless block wall can be constructed in any weather conditions without affecting its structural integrity (unlike traditional masonry wall construction that is effected by weather condition that in turn affects its structural integrity such as frozen mortar in cold weather, baked mortar in hot weather or dried mortar in windy weather). As well, as the mortarless block wall is constructed it has immediate structural strength (unlike conventional masonry construction, which only has strength after the cement mortar has cured). Having instantaneous strength is beneficial when the walls are exposed to construction in windy conditions. Another benefit to the mortarless block wall is that the construction can be de-constructed by simply reversing the construction process. The masonry block units and the metal connectors can be re-used over and over again.
[0056] The mortarless block wall is lighter than traditional block walls and the walls have greater resistance to wind loads (both positive pressure loads and negative suction loads). As well, the mortarless block wall has greater horizontal shear resistance than traditional block walls (which relies on the strength of the cement mortar).
[0057] The mortarless block wall requires the use of the masonry fasteners of the present invention to work property and so there is no incentive or means for the wall builder to skimp on material or do shoddy workmanship.
[0058] Another advantage of the mortarless masonry block is that it has large continuous vertical holes in the center. These holes can be used for installing plumbing lines, electrical conduits and other building services and won't get plugged with mortar or concrete when installed due to the use of the masonry fasteners according to the present invention.
[0059] The masonry block wall's vertical holes must line up vertically and in fact are guide for the proper placement of the block units.
[0060] One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] FIG. 1 is a perspective view of the masonry wall system.
[0062] FIG. 2 is a front elevational view of the masonry wall system.
[0063] FIG. 3A and FIG. 3B are respective exploded and assembled elevational view of the masonry fastener for use in the masonry wall system.
[0064] FIG. 4 is a perspective view of the masonry block for use in the masonry wall system.
[0065] FIG. 5 is a bottom plan view of the masonry block.
[0066] FIG. 6 is a side elevational view of the masonry block.
[0067] FIG. 7 is a sectional view of the masonry wall system along the line 7 - 7 of FIG. 2 .
[0068] FIG. 8 is a perspective view of the shear plate for use in the masonry wall system.
[0069] FIG. 9 is a perspective view of the masonry wall system with the fasteners and the shear plates shown removed.
[0070] In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
[0071] Referring to the accompanying figures there is illustrated a masonry wall system generally indicated by reference numeral 10 . The system 10 includes a plurality of masonry blocks 12 which are mechanically coupled to one another using masonry fasteners 14 as described herein.
[0072] Each masonry block 12 comprises a rectangular body of pre-cast concrete which is elongate in a longitudinal direction between opposing ends 16 of the body. The height and width in a lateral direction perpendicular to the longitudinal direction are approximately equal to one another, having dimensions each of approximately 200 millimetres while the length is approximately double. The blocks each include opposing, upright and flat side walls 18 extending longitudinally between the ends and which form the surfaces of the wall structure being formed when the blocks are stacked on top of one another. Each block also includes a flat top side 19 and a flat bottom side 20 which permits stacking of the blocks on top of the other.
[0073] Each block includes a centrally located conduit 24 of generally octagonal cross section and having a lateral dimension which is more than half of the width of the block. The conduit 24 extends through the block from the top side to the bottom side thereof. The conduit is centered both laterally and longitudinally.
[0074] Each end 16 of the block also includes a partial conduit 26 which comprises a channel open to the exterior end of the block and which is shaped to correspond to half of the cross sectional shape of the central conduit 24 . Accordingly when two blocks are abutted in an end to end configuration two partial conduits 26 are opened to one another and form an assembled conduit which is identical in cross section to the central round conduit 24 .
[0075] Two webs 28 are integrally formed in each block to span in the lateral direction between the opposing side walls 18 of the block to divide the central conduit 24 from each of the partial conduits 26 at opposing ends of the block. Each web 28 is located spaced from a respective end of the block by approximately one quarter of a length of the block in the longitudinal direction so that the resulting space between the webs 28 locating the central conduit therebetween is approximately equal to double the space between each web 28 and the respective end of the block locating the partial conduits. The partial conduits are thus each defined between a respective one of the webs and a respective one of the ends of the block.
[0076] Fastener apertures 30 are also formed in the block for slidably receiving the masonry fasteners 14 therethrough. Each of the fastener apertures 30 comprises a through bore extending from the top side 19 to the bottom side 20 of the block. A counter bore 32 is formed at the bottom side of each fastener aperture 30 which is slightly larger in diameter than the through bore of the fastener apertures and to define an annular shoulder at the inner end of the counter bore. The counter bore 32 extends axially less then half a depth of the masonry block 12 . In the illustrated embodiment, the counter bore 32 has an increasing diameter from the inner end which snugly receives an end of the fastener therein towards an outer end at the bottom side of the block.
[0077] Two fastener apertures 30 are provided at spaced positions in the lateral direction within each web 28 so that the apertures 30 are located adjacent the side walls 18 and so that a set of four fastener apertures 30 are provided in each block in a rectangular configuration spaced both laterally and longitudinally relative to one another. By locating the apertures 30 spaced apart within each of the webs, the fastener apertures are similarly located so as to be spaced from a respective end of the block by approximately one quarter of a total length of the block in the longitudinal direction. Accordingly, the fastener apertures of the two webs are spaced apart from one another approximately twice the distance of the spacing of each fastener aperture from the respective end of the block.
[0078] Each masonry fastener 14 has a height which substantially corresponds in length to a height of the block between the top and bottom sides thereof so that the fastener spans the height of the block, but with some additional length for overlapping in a lengthwise direction the fastener of an adjacent row of blocks stacked thereabove when the fasteners are engaged with one another in a mating connection.
[0079] The fastener 14 includes an elongate shaft 33 having an external threaded portion 34 at both the bottom end and the top end. Diameter of the shaft 33 and threaded portions 34 is approximately equal to the diameter of the through bore of the fastener apertures 30 for slidably receiving the fasteners within the apertures in use. The external threaded potion 34 comprises a machine screw for threaded securement to a suitable mating nut.
[0080] A nut portion 36 is provided for mounting at the top end of the shaft 33 . The nut portion has a hexagonal cross section similar to conventional nuts for example for gripping with a wrench or socket tool and the like. Length and diameter of the nut portion 36 is approximately equal to or less than the respective length and diameter of the counter bore 32 so that the nut portion is receive within the counter bore when stacking blocks. The through bore and counter bore of the fastener apertures 30 are close enough in dimensions to the shaft defining the threaded portion 34 and the nut portion 36 of the masonry fasteners to provide a snug fit of the fasteners within the apertures to maintain proper alignment of the masonry blocks 12 relative to adjacent blocks. The increasing dimension of the counter bore provides ease of insertion at the outer end while snugly receiving the nut portion at the inner end where the nut portion and counter bore are near one another in diameter for aligning the blocks relative to one another.
[0081] The nut portion 36 includes an internally threaded bore 38 therethrough from the bottom end to the top end which is suitably sized for mating engagement with the threaded portion 34 at the top end of the respective shaft 33 and for mating engagement with threaded portion 34 at the bottom end of another masonry fastener 14 of identical configuration. A dimple is centrally located within the internally threaded bore in the nut portion for engaging the top end of the respective shaft 33 inserted therein and prevent over-threading of the shaft beyond a longitudinal centre of the nut portion.
[0082] A washer 40 is located between the nut portion 26 and the shaft 33 when assembling the nut portion on the shaft for abutment against the top side of the masonry block 12 which receives the threaded portion 34 through one of the fastener apertures 30 therein. An engaging surface of the washer 40 , which faces the threaded portion and which lies perpendicular to a longitudinal direction of the fastener, is flat for abutment with the top side of the masonry block 12 .
[0083] In further embodiments, the shaft 33 , the nut portion 26 and the washer may be formed as an integral body, in which the shaft is externally threaded at one end of the body and the nut portion 26 is internally threaded at the opposing end of the body.
[0084] When assembling a wall structure,shear plates 50 are mounted to span between opposed pairs of the fasteners where additional shear strength is desired. Each shear plate 50 comprises a flat plate of rigid metal which has a length which is near the width of the blocks 12 in the lateral direction. The plates 50 have a width which is only slightly greater than the webs 28 so that the conduits remain substantially unobstructed when the shear plates are mounted to span the top side of respective blocks 12 in alignment with respective webs 28 . The shear plates 50 span across a laterally spaced pair of the apertures 30 in the blocks and each include a respective pair of mounting apertures 52 therein. The mounting apertures 52 are spaced apart from one another by the same lateral spacing as the apertures in the blocks 12 for alignment therewith. The apertures 52 in the plate 50 have a diameter which closely fits the shaft 33 of the fasteners 14 therein so that the shear plates are commonly mounted with the blocks 12 to a previous row of blocks during assembly.
[0085] As best shown in FIG. 9 , a channel 54 is formed in the top side of each block, also when additional strength is desired. The channel 54 extends a full length of the block in the longitudinal direction, centrally located in the lateral direction between the side walls 18 . The channel 54 comprises a groove open to the top side of the block and which is suitably sized for receiving an elongate reinforcement member, commonly referred to as rebar, to extend through the channel and span a plurality of blocks along a given row of the wall structure. The reinforcement member is received in the channel 54 prior to attachment of the shear plates 50 so that the shear plates enclose the open top end of the channel 54 at each web 28 once installed.
[0086] As shown in FIGS. 1 and 9 , a corner block 60 is provided for joining to linearly assembled wall structures at right angles to one another. The corner block 60 has a body having a first rectangular portion 62 and a second rectangular portion 64 which are formed integrally with one another.
[0087] The first rectangular portion 62 has upright side walls 66 which are elongate in a longitudinal direction between ends 68 of the first rectangular portion. Dimensions of height between top and bottom sides and width in the lateral direction between the upright side walls which are substantially identical to the masonry blocks 12 described above.
[0088] The second rectangular portion 64 also has upright side walls 66 , but the side walls of the second rectangular portion extend outward from the first rectangular portion in a lateral direction oriented perpendicularly to the longitudinal direction of the first rectangular portion. The second rectangular portion has dimensions of height between top and bottom sides and of width between the upright side walls which are substantially identical to the first rectangular portion.
[0089] The first rectangular portion 62 corresponds in length to 1 and ¼ times a length of the blocks 12 in the longitudinal direction. Two complete conduits are provided in the first rectangular portion with a partial conduit being provided at only one end. The opposing end is enclosed by a flat end wall and is joined with the second rectangular portion so that one of the side walls of the second rectangular portion is flush with the enclosed end of the first rectangular portion.
[0090] The second rectangular portion 64 corresponds in length to ¾ a length of the blocks 12 in the longitudinal direction thereof. Accordingly, a difference between dimension of the corner block in the longitudinal direction thereof and dimension of the corner block in the lateral direction thereof corresponds to approximately ½ a total length of the masonry blocks 12 in the longitudinal direction thereof. Accordingly, by alternating position of the first and second rectangular portions of the corner block with each successive row, the blocks 12 abutted with the corner block at each row will be offset by ½ a length of a block in relation to the blocks of the adjacent rows thereabove and therebelow.
[0091] Using the masonry wall system 10 , a wall structure can be erected in which masonry blocks 12 are mechanically joined by masonry fasteners 14 as described herein. A base of concrete 42 is first formed where the wall is to be erected. Fasteners 14 are embedded in the concrete when the concrete is still wet. The fasteners 14 are embedded such that the threaded portion 34 is embedded into the concrete but the nut portion extends above the top surface of the concrete. A retention nut 44 can be secured to the bottom end of the bottom threaded portion 34 prior to insertion of the fasteners into the wet concrete. The fasteners are suitably spaced from one another for alignment with the fastener apertures 30 of the first row of blocks to be formed.
[0092] The first row is formed by placing the blocks in an end to end configuration in a longitudinal direction of the blocks so that the partial conduits 26 of each block join with those of adjacent blocks to form complete conduits. The counter bores 32 are inserted overtop of the nut portions which project up and outwardly from the concrete base 42 once the base has cured. The blocks in the first row are secured in place by inserting the threaded portion 34 of a masonry fastener 14 into each of the fastener apertures 30 so that the bottom end is matingly engaged with the internally threaded bore 38 of the fasteners embedded in the concrete therebelow.
[0093] As the fasteners 14 received through the blocks are threaded into the fasteners therebelow and tightened in place, the washer 40 and nut portion 36 thereabove clamp down on to the top side of the blocks. The close fit of the fasteners with respect to the through bore and counter bore of the fastener apertures 30 assists in proper alignment of the masonry blocks.
[0094] Each subsequent row is place above the previous row by sequentially placing the masonry blocks in an end to end configuration in a longitudinal direction of the blocks along the previous row. The fist block is positioned so as to be offset in a longitudinal direction by half a block length relative to the previous row to form a staggered pattern. Due to the spacing of the conduits and fastener apertures, each pair of joined partial conduits 26 aligns with a central round conduit 24 of the rows thereabove and therebelow.
[0095] Similarly the fastener apertures of each masonry block align with fastener apertures of two separate blocks in the rows immediately above and below. As each subsequent row is formed, the masonry fasteners inserted therein are threadably engaged with the fasteners of the pervious row and tightened until the nut portion thereof clamps down onto the top surface of the respective blocks. The location of the masonry fasteners permits the first row of blocks to be anchored to the concrete base forming a supporting surface of the wall while each block in the subsequent rows is anchored to two adjacent blocks in the row above and two adjacent blocks in the row below. Accordingly, the finished wall structure includes blocks which are sufficiently interconnected by mechanical fasteners to be self supporting without any grout material being required to join the blocks.
[0096] As described herein, the masonry wall system 10 (or mortarless block wall) consists of a masonry block 12 and a masonry fastener 14 comprising a steel connector. Construction of the block wall starts with first installing a connector to a concrete base (concrete wall, slab, footing, etc) with a base steel connector. This base steel connector is either installed in wet concrete (not hardened yet) or installed in cured concrete (hardened concrete). If the base steel connector is installed in wet concrete, a nut is placed at the end of the steel connector to increase the tensile anchorage strength of the steel connector. If the steel connector is installed in cured concrete, then an oversized hole is drilled in the concrete and the connector is installed with an epoxy grout in the hole with the connector. In either installation of the base connector, care is required to place the connector in the correct location.
[0097] Once the base connector is installed, the standard masonry blocks 12 are installed over the base connector. The standard steel connectors are then inserted in the top of the masonry block (or unit) and after the wall has been straightened and plumbed, the steel connectors are tightened snug. After the first masonry course is placed the second course is installed and again the steel connectors are inserted in the top of the masonry unit. Again after the second course of masonry units have been straightened and plumbed, the steel connectors are tightened snug. The process is continued until the full height of the wall is completed.
[0098] A form can be placed at the ends of the wall, or at an opening, etc and the rough openings or ends of the wall can be finished with concrete. To achieve a greater fire resistance in the mortarless block wall, the vertical and horizontal joints in the wall can be caulked with a fire retardant caulking. The caulking serves another purpose, to straighten out vertical block unevenness.
[0099] The wall system as described herein is advantageous to owners as compared to conventional masonry walls as it is typically less expensive, faster to construct, and can be de-constructed and reused. Advantages to contractors include: (1) Does not need hoarding & heating (or cooler weather) to construct, (2) Less skilled labour to construct the wall, (3) The project schedule is not dictated by a masonry contractor, (4) Installation of plumbing line & electrical conduit can be done after wall is constructed (the vertical cores within the wall are continuous), (5) The wall has instant structure strength when the connectors are tightened (and so temporary lateral bracing is less likely), and (6) Construction of the wall can be done with only access with one side of the wall (and still achieve a similar exterior finish quality). Advantages to Architects and Engineers include: (1) More consistent quality in structural strength than a concrete or masonry wall, (2) Stronger lateral & vertical load capacity than a masonry wall, (3) More consistent wall strength than a concrete or masonry wall, (4) Better surface finish, and (4) More durable block than a standard masonry block.
[0100] Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without department from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
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The masonry block wall system comprises masonry blocks fastened together with interconnecting threaded steel fasteners. Four fasteners on each block connect with a pair of identical blocks immediately above and a pair of identical blocks immediately below the block. The resulting masonry wall is structurally sound and allows large vertical chases or conduits for electrical, plumbing and the like. Unlike conventional masonry, the construction of the present masonry wall does not require specialized knowledge and skill of a mason and is relatively easy to build. As well, the masonry wall system is not dependent upon weather during construction and can be de-constructed without demolition.
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TECHNICAL FIELD
[0001] The invention pertains to a device to support cardiac function. In particular, the device according to the invention serves to support a pumping function of a heart.
BACKGROUND
[0002] Due to illness, the pumping function of a heart can be reduced, which is also called cardiac insufficiency. Cardiac insufficiency is from the medical as well as from the economical standpoint of great and increasing importance. In the second decade of this century, 23 million people worldwide will suffer from cardiac insufficiency; the annual rate of new cases will be about 2 million people. In the US alone, 5 million people are currently suffering from cardiac insufficiency. Here, the annual rate of new cases is approximately 550,000 people. Already in this decade, the number of incidences in people over 50 years of age will double to more than 10 million. The same applies to the European continent.
[0003] Causes for cardiac insufficiency can be impaired contractility or reduced filling of the cardiac chambers due to damage to the myocardium. Hypertension can lead to an increased pumping resistance, which can also negatively affect the pumping function of the heart. The pumping function of a heart can also be reduced by leaking valves (e.g., a leaking aortic valve or mitral valve). Impairments of the cardiac conduction system generate arrhythmias, which can also lead to a reduced pumping function of the heart. If the movement of the heart is restricted from the outside, e.g., due to an accumulation of fluid in the pericardium, this can result in a reduced pumping function as well. Cardiac insufficiency often leads to shortness of breath (especially in the case of left ventricular insufficiency), or to water retention in the lungs or in the abdomen (in particular in the case of right ventricular insufficiency).
[0004] Different types of cardiac insufficiencies are treatable with medication or surgery. In some cases of arrhythmias, normal cardiac rhythm can be restored with a pacemaker. A leaking valve can be replaced surgically with a cardiac valvular prosthesis. A reduced pumping function can be assisted by an implanted heart pump. A treatment approach addressing the various causes of heart insufficiency is to assist the pumping function of the heart by means of an implant, which exerts mechanical pressure onto the heart and therefore improves its pumping performance.
[0005] Some known mechanical ventricular assist devices have been disclosed in U.S. Pat. Nos. 5,749,839 B1 and 6,626,821 B1, and in WO application 00/25842. These documents disclose mechanical ventricular assist devices that require open-chest surgery. Many cardiac assist systems are complex and can only be implanted by means of an elaborate surgical procedure. All cardiac assist systems are integrated into the blood circulation of the patients. Improved centrifugal or magnetically supported impeller systems carry blood continuously. The contact of the blood with the surface of the implanted systems poses a great engineering and medical challenge. Common complications of cardiac assist systems are strokes, hemorrhage and septicemia. They often lead to long-term hospitalization and frequent re-admissions of patients already released from the hospital.
SUMMARY
[0006] In various aspects of the invention a device for the support of the cardiac function includes a sheath configured to transition from a non-expanded state into an expanded state, with the sheath being self-expanding and being configured to be inserted into a delivery system, and which in the expanded state can at least partially enclose a heart. One potential advantage of the device is that it may be implanted using minimally invasive procedures.
[0007] In some implementations, the sheath can be made of a wire mesh, which can have diamond-shaped cells. Preferably, the mesh is made of a shape memory alloy. The crossing points of the wires of the wire mesh can be permanently attached to each other, thus increasing the stability of the sheath. The crossing points may also be separable, which increases the flexibility of the sheath and thereby can make the sheath easier to compress. Or some of the crossing points may be permanently interconnected while other crossing points are not permanently interconnected. By selecting suitable crossing points to be permanently interconnected, and crossing points that are not permanently interconnected, the stability and flexibility of the sheath can be adjusted.
[0008] According to one aspect of the invention, the sheath can also consist of a lattice structure, with the lattice structure consisting of links, and multiple links defining one cell. The lattice structure exhibits a diamond-shaped lattice structure. The links and the intersections of the links exhibit enforcements in order to increase the stability of the sheath. The effect of the enforcements is similar to the effect of the interconnected crossing points in embodiments of the sheath in the form of a wire mesh. The links and the intersections can also be made of a thinner or weaker material in order to increase the flexibility of the sheath. The effect of a thinner or weaker material at intersections is similar to the effect of the non-interconnected intersections in embodiments of the sheath in the form of a wire mesh.
[0009] The sheath can also be made of a solid material, from which parts have been removed. For example, the sheath can be made of a tube or an individually shaped sheath sleeve, into which holes have been formed or cut. The holes can be formed such that the sheath exhibits increased stability in some areas, and increased flexibility in other areas.
[0010] Generally, areas of increased stability are desired in situations, in which the sheath acts as an abutment. Areas of greater flexibility can enable the natural motion of the heart. Increased flexibility is also advantageous for compressing the sheath into a delivery system.
[0011] The sheath generally exhibits openings being created by the wires of the wire mesh, the links of the lattice structure, or by the holes formed in the sheath sleeve. The openings can be rectangular, diamond-shaped or round. The cells or holes can have a pin opening of 1 mm to 50 mm. A pin opening is defined as the largest diameter of a pin, which can be pushed through a cell or a hole. Using the holes, the stability and flexibility of the sheath can be adjusted individually. The holes also allow the exchange of substances from the inside of the sheath with the outer environment of the sheath.
[0012] The sheath can be covered with a membrane; the membrane may, in particular, be made of polyurethane, silicon or polytetrafluorethylene (PTFE). The membrane can reduce the mechanical stress exerted by the sheath onto the pericardium or the myocardium. The membrane can also increase the biocompatibility of the sheath. A coating of the membrane with an active substance is also conceivable.
[0013] Another aspect of the present invention features a method of manufacturing a cardiac assist device. The method includes using a virtual or real image of a heart and forming a sheath based on the shape of the heart image.
[0014] The method can be used to manufacture a custom-made sheath. The shape of the sheath can match the form of the 3D-image of the surface of the heart, spatially stretched by a factor. In particular, the stretch factor can range from 1.01 to 1.2. A sheath applied to a true-to-scale real or virtual 3D image of the heart should exhibit a distance to the 3D image of 1 to 10 mm, in particular 2 to 8 mm, in particular 3 to 5 mm.
[0015] Additional features and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0016] FIG. 1 shows a human torso with an implanted device and an extracorporeal supply unit.
[0017] FIG. 2 shows a human torso with an implanted device and a partially implanted supply unit.
[0018] FIG. 3 shows a human heart with the device.
[0019] FIGS. 4 a and 4 b show a cross-section through the heart with the device along line A-A in FIG. 3 .
[0020] FIG. 5 shows a step of the implantation of the device.
[0021] FIG. 6 shows a step of the implantation, in which a pericardium seal has not yet been screwed shut.
[0022] FIG. 7 shows a step of the implantation, in which a pericardium seal is screwed shut.
[0023] FIG. 8 shows a partially expanded sheath with a sleeve.
[0024] FIGS. 9 a - c show different views of a closed pericardium seal.
[0025] FIG. 10 shows a tool for the closing of a pericardium seal.
[0026] FIG. 11 shows a plug connector system of the device.
[0027] FIG. 12 a shows a heart with anatomical points of reference.
[0028] FIG. 12 b shows a cross-section of the heart from FIG. 12 a.
[0029] FIG. 13 a shows a 3D view of part of a heart with a system of coordinates.
[0030] FIG. 13 b shows a 2D-rollout of the 3D view from FIG. 13 a with a system of coordinates.
[0031] FIG. 14 a shows a 3D view of a sleeve with augmentation and positioning units.
[0032] FIG. 14 b shows a 2D rollout of a sleeve with augmentation and positioning units from FIG. 14 a.
[0033] FIGS. 15 a - b show one compressed and one expanded augmentation unit in the form of a chamber with a bellows-type section.
[0034] FIG. 16 a shows a 3D view of a sleeve with sensors and/or electrodes.
[0035] FIG. 16 b shows a 2D rollout of the sleeve with sensors and/or electrodes from FIG. 16 a.
[0036] FIG. 17 shows a sample embodiment for a sleeve with augmentation and positioning units.
[0037] FIG. 18 shows a sample embodiment for a sleeve with sensors and electrodes.
DETAILED DESCRIPTION
[0038] FIG. 1 shows an embodiment ( 10 ) of a device in the implanted state. In this example, the device is implanted into a human body. The device, however, can also be implanted into an animal body, in particular into the body of a mammal like a dog, a cat, a rodent, a primate, an even-toed ungulates or an odd-toed ungulate. Depending on the species, the form and the mode of operation of the device is adjusted, in order to accommodate anatomical and/or physiological needs of the individual species.
[0039] FIG. 1 shows a human torso with the device. The device includes a sheath ( 2 ), which can at least partially enclose the heart ( 61 ). Multiple components inserted in the sheath ( 2 ) support the cardiac function ( 61 ). The device also includes a supply unit ( 30 ).
[0040] The sheath ( 2 ), which can at least partially enclose the heart ( 61 ), is configured to transition from a non-expanded state into an expanded state. Preferably, the sheath ( 2 ) is self-expanding and can be inserted into a delivery system in the non-expanded state. The sheath ( 2 ) can be a mesh, in particular a wire mesh, whereby the wire mesh can be at least partially made of a shape memory alloy.
[0041] The sheath ( 2 ) at least partially encloses the heart ( 61 ) in the implanted state and is located inside the pericardium ( 6 ). Embodiments in which the sheath ( 2 ) is placed outside of the pericardium ( 6 ) are possible as well. These embodiments are not described separately; rather, the description for embodiments for implantation inside and outside the pericardium ( 6 ) (with the exception of the not-required pericardial seal ( 5 ) in embodiments of the sheath ( 2 ) for implantation outside the pericardium ( 6 )) is applicable. The architecture of the sheath ( 2 ) is explained in greater detail in a later section of the description.
[0042] Located inside the expandable sheath ( 2 ) is at least one expandable unit, which can be used to apply pressure to the heart ( 61 ). The expandable unit can be a mechanical unit, configured to transition between an expanded and a non-expanded state. Such a mechanical unit can include spring elements, which can be tensioned and released, or lever elements, which can be folded and unfolded. Preferably, the expandable units are chambers, which can be filled with a fluid. Suitable fluids for the filling of a chamber include liquids, gases, or solids (like nanoparticle mixtures, for example), or mixtures of fluids and/or gases and/or solids. The expandable unit can be secured inside the sheath ( 2 ). Preferably, the expandable unit is attached to a sleeve, which can be inserted into the sheath ( 2 ). The at least one expandable unit is described in greater detail with reference to FIG. 8 .
[0043] The sheath ( 2 ) can furthermore include at least one sensor and/or one electrode, which can be used to detect at least one parameter of the heart ( 61 ). The sensor can be configured to determine the heart rate, the ventricular pressure, the contact force between the heart wall and the expandable unit, the systolic blood pressure, the diastolic blood pressure, the pressure applied to a surface of the heart, the fluid presence, the acidity, the electrical resistance, the osmolarity, the oxygen saturation or the flow through a vessel. The sensor can also be configured to measure the pressure applied by an expandable unit onto a surface, the pH-value, the electrical resistance, the osmolarity of a solution, the oxygen saturation of tissue or blood or the flow through a vessel. The sensor can be attached inside or on the sheath ( 2 ). Preferably, the sensor is secured on a sleeve configured to be inserted into the sheath ( 2 ). In addition to the at least one sensor or in place of the sensor, the sheath ( 2 ) can also include at least one electrode configured to measure a parameter, like e.g. the action potential at the myocardium during the excitation process, or to stimulate a tissue with currents. The sensor can also be an electrode. The sensor and the electrode are explained in greater detail in a later section of the description.
[0044] FIG. 1 shows a supply unit ( 30 ), which can be worn outside the body. The supply unit can also be partially or completely implanted into the body, which will be explained in the following sections in greater detail. If the supply unit ( 30 ) is worn outside the body, it may be attached to a chest belt, to a hip belt, or to an abdominal belt. The supply unit ( 30 ) is equipped with an energy storage device allowing the expandable unit to be powered. The energy storage device can be available in the form of a rechargeable battery providing electrical energy to expand the expandable unit. The rechargeable battery is exchangeable. The supply unit ( 30 ) can also include a pressure storage device supplying a compressed gas, to inflate an inflatable chamber. Suitable gases are, among others, compressed air, CO 2 , or inert gases. The housing of the supply unit ( 30 ) itself can serve as a pressure storage housing. The supply unit ( 30 ) can furthermore contain pumps, valves, sensors and displays. The supply unit ( 30 ) can furthermore include a microprocessor configured to receive and process data from the at least one sensor. If the supply unit ( 30 ) is worn outside the body, the required energy can be transferred by direct connection via a cable ( 4 ) or connectionless via electromagnetic induction, for example. The data from the at least one sensor can also be transmitted directly via a cable ( 4 ) or connectionless via wireless technology like bluetooth, for example.
[0045] The device can furthermore include a cable ( 4 ) connecting the expandable unit and/or the sensor or the electrode to the supply unit ( 30 ). If the supply unit ( 30 ) is connected directly to the expandable unit and/or to the sensor, or the electrode, a cable ( 4 ) is not required. If the expandable unit is a mechanical unit which, using electrical energy, is configured to transition from a non-expanded state into an expanded state, or from an expanded state into a non-expanded state, the cable ( 4 ) includes lines configured to transfer the required energy from the supply unit ( 30 ) to the expandable unit. The sleeve can include internal chambers, configured to enable hydraulic alteration of the volume of at least one of the internal chambers of the sleeve. If the expandable unit is a chamber that can be filled by means of a fluid, the cable ( 4 ) includes at least one line allowing the flow of fluid from the supply unit ( 30 ) into the chamber. In some implementations, the cable ( 4 ) includes at least one pneumatic or hydraulic line. If the device includes one sensor or one electrode at, in or on the sheath, then the line leading to the sensor or the electrode can also be in the cable ( 4 ). Embodiments can also exhibit separate cables for providing energy for the expandable unit and for the sensor, or the electrode.
[0046] The cable ( 4 ) connecting the supply unit ( 30 ) to the expandable unit and/or the sensor, or the electrode, can be a single continuous cable or a multi-part cable. In the case of a continuous cable connection, the cable ( 4 ) can be attached to the expandable unit and/or the sensor or one electrode. A connector ( 90 ) can be attached to the end of the cable ( 4 ). The connector ( 90 ) can be connected to the supply unit ( 30 ) via the matching connector ( 91 ). Alternatively, a cable with a connector is only attached to the supply unit ( 30 ). In this case, the matching connector is installed on the sheath ( 2 ), on the expandable unit and/or on the sensor or electrode. In case of a multi-part cable, a cable ( 4 ) with a connector ( 91 ) can be attached to the expandable unit and/or at the sensor or the electrode, and a cable can also be attached to the supply unit ( 30 ), at the end of which can be a connector. The cable ( 4 ) and the connector ( 90 ) are described in greater detail in a later section of the description.
[0047] FIG. 2 shows an embodiment ( 11 ) of the device in the implanted state, where the supply unit ( 31 ) is implanted into the body. Preferred locations for the implantation of the supply unit ( 31 ) are the chest (thoracic) cavity and the abdominal (peritoneal) cavity, which are separated from each other by the diaphragm ( 63 ).
[0048] The sheath ( 2 ) shown in FIG. 2 , the pericardium seal ( 5 ), and the cable ( 4 ) of the device are essentially identical to the components shown in FIG. 1 . The supply unit ( 31 ) can include an energy storage device, which can be used to power the expandable unit located inside the sheath ( 2 ). The energy storage device can be provided in the form of a rechargeable battery, which supplies electrical energy in order to expand the expandable unit. The supply unit ( 31 ) can furthermore contain sensors and one or more microprocessors. If the expandable unit includes at least one chamber, which can be filled with a fluid, then the supply unit ( 31 ) can include pumps, valves, and a pressure reservoir. The pressure reservoir can provide a compressed gas in order to inflate an inflatable chamber. Suitable gases are, among others, compressed air, CO2, or inert gases. The housing of the supply unit ( 31 ) itself can represent the housing of the pressure reservoir. A preferred place for the implantation of the supply unit ( 31 ) is inside the right lateral chest cavity above the liver ( 62 ) and above the diaphragm ( 63 ). Alternatively, or in addition to the pressure reservoir ( 32 ) in the supply unit ( 31 ), the pressure reservoir ( 32 ) can be preferably implanted inside the right lateral abdominal cavity below the diaphragm ( 63 ) and above the liver ( 62 ).
[0049] The pressure reservoir ( 32 ) can be connected to the supply unit ( 31 ) with a tube ( 33 ), which penetrates the diaphragm ( 63 ). The opening in the diaphragm required for the tube ( 33 ) to pass through can be sealed with a seal. The seal can be designed similar to the pericardium seal, as previously described. The supply unit can be connected via a cable ( 4 ) directly with the expandable unit and/or the sensor, or the electrode. Alternatively, at the end of the cable ( 4 ) can also be a connector configured to connect via a matching connector to the supply unit ( 31 ) or to the expandable unit and/or to the sensor or the electrode.
[0050] The cable ( 4 ) runs preferably in the chest cavity above the diaphragm ( 63 ). In the case of a multi-part cable, a cable with a connector can be attached to the expandable unit and/or the sensor or one electrode, and a cable with a matching connector can be attached to the supply unit ( 31 ).
[0051] Alternatively or in addition to a rechargeable battery in the supply unit ( 31 ), a rechargeable battery ( 34 ) can be implanted subcutaneously, into the abdominal wall. The energy required in the supply unit ( 31 ) can be transferred, for example, by electromagnetic induction from an extracorporeal controller ( 35 ) transcutaneously to the rechargeable battery ( 34 ) and be transmitted by an electric cable ( 36 ) from the rechargeable battery ( 34 ) to the supply unit ( 31 ). The extra-corporeal controller ( 35 ) can include an exchangeable rechargeable battery and/or a charging device. The extracorporeal controller ( 34 ) can contain, among others, microprocessors and displays, which can be used for system monitoring of the device and for a display of the operating status. The data from the sensor can be transmitted connectionless via a wireless technology like bluetooth, for example, to and between the supply unit ( 31 ) and the controller ( 34 ).
[0052] FIG. 3 shows an example of a human heart ( 61 ), as well as a sheath ( 2 ), a sleeve ( 7 ) with expandable units ( 71 , 72 ), a sleeve ( 80 ) with sensors ( 81 ) and/or electrodes a cable ( 4 ) with a connector ( 90 ), a catheter ( 103 ) of a delivery system, and a pericardium seal ( 5 ) of the device.
[0053] In this embodiment, the sheath ( 2 ) is shown in the form of a wire mesh. Instead of a wire mesh, the sheath ( 2 ) can alternatively be formed as a lattice consisting of links. In this case, the links create a lattice structure with openings. The sheath ( 2 ) can also consist of a continuous material, from which parts have been removed; for example, the sheath ( 2 ) can consist of a tube and an individually shaped sheath sleeve, into which holes have been formed or cut.
[0054] The sheath ( 2 ) represented in FIG. 3 consists of a mesh made of wires. The wires form crossing points (intersections), which can be permanently interconnected. The wires could, for example, be welded together at their crossing points. Connecting the wires at crossing points increases the stability of the sheath ( 2 ). The crossing points can be free from each other, increasing the flexibility of the sheath ( 2 ) and therefore leading to an easier compressibility of the sheath ( 2 ). In some embodiments, the sheath includes wires that do not cross each other, forming longitudinally oriented struts. Increased sheath flexibility is especially helpful if the sheath ( 2 ) is to be inserted into a delivery system with a smaller diameter catheter ( 103 ). Some of the crossing points of the sheath ( 2 ) can also be permanently interconnected and others not. Through appropriate selection of crossing points that are permanently interconnected and crossing points that are separable, the stability and flexibility of the sheath ( 2 ) can be customized. Areas requiring increased stability in the implanted state can be stabilized by connecting the wires at the crossing points. These can be areas serving as bearing surfaces or abutments for expandable units ( 71 , 72 ). Such abutments can be located directly under an expandable unit ( 71 , 72 ) or next to areas with expandable units ( 71 , 72 ). Areas requiring increased flexibility can be areas which during insertion into a delivery system must be compressed more than other areas. Areas requiring increased flexibility can also be areas, in which an increased flexibility supports the natural movement of the heart. If the sheath ( 2 ) is not made of a wire mesh but of a latticework or a sheath sleeve with holes, the stability and/or the flexibility of selected areas of the sheath ( 2 ) can be adjusted as well. In these cases, adjustments can be brought about by choosing the width of the links and/or the thickness of the links, through the choice of the material to be used, through modifications of the material in certain areas through application of energetic radiation, like heat, for example. Preferably, the sheath ( 2 ) exhibits openings being formed by the wires of a wire mesh, the links of a latticework, or the holes in a sheath sleeve. These openings enable compression of the sheath ( 2 ); they allow the exchange of substances from inside the sheath ( 2 ) with areas outside the sheath ( 2 ) and vice versa; they reduce the amount of material being used for the sheath ( 2 ), and they allow an increased flexibility of the sheath ( 2 ). Shapes which are difficult to realize with solid materials are easier to achieve with mesh-type or lattice-type structures. The openings can be rectangular, round or oval. The openings defined by the wires, the links or the holes in a sheath sleeve have a diameter of approximately 1 to 50 mm, preferably 4 mm to 10 mm. The diameter of an opening is defined as pin opening, meaning that the diameter of the opening represents the largest diameter of a cylindrical pin that can pass through an opening (e.g., a cell or a hole).
[0055] The sheath ( 2 ) is preferably made of a material allowing expansion. Preferably, the sheath ( 2 ) is formed from a material selected from the group consisting of nitinol, titanium and titanium alloys, tantalum and tantalum alloys, stainless steel, polyamide (PA), polyurethane (PUR), polyether ether ketone (PEEK), polyethylene (PE), polypropylene (PP), polycarbonate (PC), polyethylene terephthalate (PET), polymer fiber materials, carbon fiber materials, aramide fiber materials, glass fiber materials and combinations thereof. A material suitable for forming a self-expanding sheath ( 2 ) is at least partially made of a shape memory alloy. Examples of shape memory alloys include NiTi (nickel-titanium; nitinol), NiTiCu (nickel-titanium-copper), CuZn (copper-zinc), CuZnAl (copper-zinc-aluminum), CuAlNi (copper-aluminum-nickel), FeNiAl (iron-nickel-aluminum) and FeMnSi (iron-manganese-silicon).
[0056] The sheath ( 2 ) preferably exhibits a form adapted to the individual shape of the patient's heart, or a cup-shaped form. The individual shape of the patient's heart can be reconstructed from CT or MRI image data. The sheath ( 2 ) is open at the top. The upper rim of the sheath ( 2 ) preferably exhibits loops of a wire or straps, which are formed by links. The loops or straps can serve as anchoring points for a sleeve ( 80 ) with at least one sensor ( 81 ) or one electrode, and/or for a sleeve ( 7 ) with at least one expandable unit ( 71 , 72 ). Positioned at the lower end of the cup-shaped sheath is preferably an opening, through which one or multiple leads of the sensor ( 81 ) or of the electrode, and/or of the expandable unit ( 71 , 72 ) can be passed. The shape of the sheath ( 2 ) at least partially represents the anatomical shape of a heart ( 61 ), in particular the lower part of a heart ( 61 ). Details regarding the shape of the sheath ( 2 ) are explained in greater detail in a later section of the description.
[0057] The sheath ( 2 ) can be covered by a membrane ( 21 ), in particular by a membrane ( 21 ) made of polyurethane or silicon. The membrane ( 21 ) is configured to reduce the mechanical stress applied by the sheath ( 2 ) onto the pericardium ( 6 ) or the myocardium ( 61 ). The membrane ( 21 ) can also increase the biocompatibility of the sheath ( 2 ). The membrane ( 21 ) can be attached to the inner surface or to the outer surface of the sheath ( 2 ). The membrane ( 21 ) can also be manufactured by dipping the mesh- or lattice-type sheath ( 2 ) into an elastomer-containing liquid, which subsequently envelops the latticework or the mesh. The membrane ( 21 ) can then stretch across the openings of the mesh or the lattice. A membrane ( 21 ) on the mesh or the lattice can also improve the abutment properties of an expandable unit ( 71 , 72 ). If an expandable unit ( 71 , 72 ) is, for example, an inflatable chamber, then a membrane ( 21 ) across, at or on the mesh or the lattice can prevent parts of the chambers being pressed through the mesh or the lattice while the chamber is expanding. The membrane ( 21 ) can furthermore prevent excessive widening of the sheath ( 2 ), in particular during inflation of an inflatable chamber. A membrane ( 21 ) on a mesh or a lattice can ensure that an expandable unit positioned on the lattice or the mesh expands into a direction from the mesh or lattice towards the inside only. The membrane ( 21 ) does not interfere with the compressibility of the sheath ( 2 ) while being inserted into a delivery system.
[0058] The sheath ( 2 ) and/or the membrane ( 21 ) can also include an active pharmaceutical ingredient, for example, an anti-thrombotic ingredient, an anti-proliferative ingredient, an anti-inflammatory ingredient, an anti-neoplastic ingredient, an anti-mitotic ingredient, an anti-microbial ingredient, a biofilm synthesis inhibitor, an antibiotics ingredient, an antibody, an anti-coagulating ingredient, a cholesterol-lowering ingredient, a beta blocker, or a combination thereof. Preferably, the ingredient is in the form of a coating on the sheath ( 2 ) and/or the membrane ( 21 ). The sheath ( 2 ) and/or the membrane ( 21 ) can also be coated with extra-cellular matrix proteins, in particular fibronectin or collagen. Bio-compatible coating can be advantageous if ingrowth of the sheath ( 2 ) is desired.
[0059] The expandable unit ( 71 , 72 ) is located inside the sheath ( 2 ). FIG. 3 shows a sheath ( 2 ), into which a sleeve ( 7 ) with expandable units ( 71 , 72 ) in the form of inflatable chambers is inserted. The expandable unit ( 71 , 72 ) is being supplied by a line ( 41 ) inside the cable ( 4 ). The expandable unit ( 71 , 72 ) can be a hydraulic or a pneumatic chamber. The expandable unit ( 71 , 72 ) can be attached directly to the sheath ( 2 ) without a sleeve ( 7 ). The expandable unit ( 71 , 72 ) can also be attached to a sleeve ( 7 ), and the sleeve ( 7 ) can be attached inside the sheath ( 2 ). The expandable unit ( 71 , 72 ) can be designed to apply pressure to the heart ( 61 ). The applied pressure can be a permanent pressure, or it can be a periodically recurring pressure. The device can include different types of expandable units ( 71 , 72 ). The device can include at least one augmentation unit ( 71 ). The device can include at least one positioning unit ( 72 ). The augmentation unit ( 71 ) and/or the positioning unit ( 72 ) can be attached directly to the sheath ( 2 ) or onto a sleeve ( 7 ), which is inserted into the sheath ( 2 ).
[0060] An augmentation unit ( 71 ) is a unit that can be periodically expanded and relaxed, and thereby applies a rhythmical pressure to the heart ( 61 ). The pressure is preferably applied in the areas of the heart muscle, under which a ventricle is located. By applying pressure on a ventricle by means of the augmentation unit ( 71 ) the natural pumping motion of the heart ( 61 ) is being amplified or substituted, and the blood inside the heart ( 61 ) is pumped from the ventricle into the discharging artery. A pressure applied by an augmentation unit ( 71 ) to a right ventricle assists the ejection of the blood from the right ventricular chamber into the pulmonary artery. A pressure applied by an augmentation unit ( 71 ) to a left ventricle assists the ejection of the blood from the left ventricular chamber into the aorta. The positioning of the augmentation unit ( 71 ) inside the sheath ( 2 ) is explained in greater detail in a later section of the description.
[0061] A positioning unit is preferably expanded during the operation of the device in support of the heart function more statically than periodically. The positioning unit ( 72 ) can be expanded in order to fix the device to the heart and to ensure proper fitting of the device. A positioning device ( 72 ) can also be used to respond to changes in the myocardium (e.g., shrinking of the myocardium due to lack of fluids or enlargement of the myocardium due to the absorption of fluids). If the size of the myocardium decreases or increases within a particular period of time, a positioning unit can be expanded or relaxed further in order to ensure a perfect fit. The positioning unit ( 72 ) may, for example, also be used to ensure that the device does not lose contact to the heart wall over the span of a heartbeat. Loss of contact can lead to impact stress between the myocardium and the device, and/or cause malfunction of the sensors ( 81 ) and/or electrodes. In some implementations, the positioning unit ( 72 ) can counteract the pathological, progressive expansion of the damaged myocardium in heart failure patients. The positioning of the positioning unit ( 72 ) inside the sheath ( 2 ) is explained in greater detail in a later section of the description.
[0062] Located at the lower end of the sheath ( 2 ) can be an opening, through which the lead ( 83 ) from the sensor ( 81 ) or the electrode and/or the line ( 41 ) of the expandable unit ( 71 , 72 ) can be passed. The opening can be installed at the lower distal end of the sheath ( 2 ). Alternatively, the opening can also be installed on one side of the sheath ( 2 ). Shown in FIG. 3 is an opening at the lower distal end of the sheath ( 2 ), through which one cable ( 4 ), which includes all leads ( 41 , 83 ), has been routed. Instead of one cable ( 4 ), there can be multiple separate cables. The cables can be routed through one opening of the sheath ( 2 ) or through multiple openings of the sheath ( 2 ). Attached to the end of the cable ( 4 ) is a connector ( 90 ), which is used to connect the sensor ( 81 ) or the electrode, and/or the expandable unit ( 71 , 72 ) to a supply unit. The sheath ( 2 ) is preferably brought inside the pericardium ( 6 ). The cable ( 4 ) is then passed through the pericardium ( 6 ). The device can include a pericardium seal ( 5 ). The seal can seal the opening of the pericardium, which is required for the cables to pass through. The pericardium ( 6 ) is a connective-tissue-type sac surrounding the heart ( 61 ), and which, due to a narrow lubricant layer, gives the heart ( 61 ) the ability to move freely. As a lubricant, it contains a serous fluid, also called liquor pericardii. In order to prevent this lubricant from escaping from the pericardium ( 6 ) through the cable opening, and to prevent any other fluids or solids (like, for example, cells, proteins, foreign matter, etc.) from entering the pericardium ( 6 ), a pericardium seal ( 5 ) can be installed around the cable ( 4 ). The pericardium seal ( 5 ) seals the opening of the pericardium ( 6 ) to the cable ( 4 ). The pericardium seal ( 5 ) can include a first sealing component with a first sealing lip, and a second sealing component with a second sealing lip. A cable ( 4 ) can be routed through a central lumen of the seal. The first sealing lip and/or the second sealing lip can seal the pericardium opening. Located inside the central lumen can be an additional sealing component, which seals the cable ( 4 ) against the pericardium seal ( 5 ) and, if necessary, fixes it as well. The first and the second sealing component can be combined. Preferably, the first and the second sealing component can be secured with a mechanism. Possible mechanisms to secure the sealing components are screw mechanisms, clamping mechanisms, or a bayonet mechanism. The first sealing component and/or the second sealing component can be expandable, or even self-expanding. The pericardium seal ( 5 ) is explained in greater detail in a later section of the description.
[0063] FIGS. 4 a and 4 b show a cross-section of the heart ( 61 ) and part of the device for the support of the cardiac function ( 61 ) along line A-A in FIG. 3 . Starting from the outside to the inside, the following layers are represented: The sheath ( 2 ) with a membrane ( 21 ), a sleeve ( 7 ) with at least one expandable unit ( 71 , 72 ), a sleeve ( 80 ) with at least one sensor ( 81 ) or one electrode ( 82 ), and a transverse cross-section of the heart ( 60 ). Three augmentation units ( 71 ) and three positioning units ( 72 ) are illustrated as examples. In FIG. 4 a , the expandable units ( 71 , 72 ) have been drawn in the non-expanded state. In FIG. 4 b , the augmentation units ( 71 ) have been drawn in the expanded state. The expandable unit ( 71 , 72 ) is located in an area adjacent to a ventricle. An expansion of the expandable unit ( 71 , 72 ) can reduce the volume of the ventricle and cause blood to be ejected from the ventricular chamber. The sensor ( 81 ) or the electrode ( 82 ) is installed in a particular location, where at least one parameter of the heart ( 61 ) can be measured. An electrode ( 82 ) can be installed in a particular location, where the myocardium can be stimulated. In FIGS. 4 a and 4 b , four sensors ( 81 ) in the sleeve ( 80 ) and three electrodes ( 82 ) at the inside of the sleeve ( 80 ) are illustrated as examples.
[0064] FIG. 5 shows a delivery system ( 100 ), which can be used to implant the device to support the cardiac function. The delivery system ( 100 ) includes a catheter ( 103 ), which has a lumen. Preferably, the catheter ( 103 ) is an elongated, tubular component, into which the device for the support of the cardiac function can be inserted in its compressed state. The cross-section of the catheter ( 103 ) and/or of the lumen can be circular, oval or polygonal. The delivery system ( 100 ) can further include a guide wire ( 101 ) and/or a dilatation component. The dilatation component can be soft cone-shaped tip ( 102 ) with a shaft. The guide wire ( 101 ) can be passed through a puncture of the chest wall ( 65 ) between the ribs ( 64 ) and of the pericardium ( 6 ). The soft, cone-shaped tip ( 102 ) can have at the center a circular, oval or polygonal lumen. The soft, cone-shaped tip ( 102 ) can be pushed over the guide wire ( 101 ) and the puncture can be dilated without injury to the epicardium. The distal section of the catheter ( 103 ) of the delivery system ( 100 ) can be passed through the dilated opening. At the distal end of the catheter ( 103 ), a first sealing component ( 51 , 52 ) of the pericardium seal can be snapped on or otherwise attached. The catheter ( 103 ) may, for example, be pushed onto a cone ( 55 ) located at the end of the first sealing component ( 51 , 52 ). Not shown is another embodiment, where a cone is located at the side of the catheter, onto which the first sealing component can be pushed. The catheter ( 103 ) with the attached first sealing component ( 51 , 52 ) of the pericardium seal can be guided via the shaft of the soft tip ( 102 ) and inserted into the pericardium ( 6 ).
[0065] Alternatively, the catheter ( 103 ) and the first sealing component ( 51 , 52 ) of the pericardium seal can be parts that are not interconnected to each other. In this case, the catheter ( 103 ) is initially inserted into the pericardium ( 6 ), and the first sealing component ( 51 , 52 ) can then be pushed into the pericardium via the catheter or withdrawn from the pericardium ( 6 ) through the lumen of the catheter ( 103 ). The first sealing component ( 51 , 52 ) can be a self-expanding sealing component, and is configured to unfold inside the pericardium ( 6 ). Alternatively, a non-expandable part ( 51 ) of the first sealing component contains a self-expanding sealing lip ( 52 ) or a sealing lip ( 52 ), which is configured to fold down while the first seal component ( 51 , 52 ) is being inserted, and which opens up inside the pericardium ( 6 ). The first sealing component ( 51 , 52 ) can expand into a mushroom or umbrella-like shape.
[0066] A second sealing component ( 53 , 54 ) can be inserted along the catheter ( 103 ) or through the catheter ( 103 ). For example, the second sealing component ( 53 , 54 ) can be moved via the catheter ( 103 ) of the delivery system ( 100 ) to the distal end of the delivery system ( 100 ), and then coupled with the first sealing component ( 51 , 52 ). The second sealing component ( 53 , 54 ) can be expandable or non-expandable. The second sealing component ( 53 , 54 ) can be coupled to the first sealing component ( 51 , 52 ). The second sealing component ( 51 , 52 ) is preferably self-expanding, and can in its expanded form assume the shape of a mushroom or an umbrella. The second sealing component ( 53 , 54 ) can be secured with the first sealing component ( 51 , 52 ). Shown in FIG. 5 is a screw mechanism. Other mechanisms to secure the sealing components ( 51 , 52 , 53 , 54 ) include a clamping mechanism or a bayonet seal. After securing the sealing components ( 51 , 52 , 53 , 54 ), the catheter ( 103 ) of the delivery system ( 100 ) can remain on the cone ( 55 ) of the first sealing component ( 51 ) or remain in the lumen of the sealing component ( 51 , 52 ). After the guide wire ( 101 ) and the shaft of the soft tip ( 102 ) have been pulled out of the catheter, the shell with the sensor or the electrode and/or with the expandable unit can be inserted through the lumen of the catheter ( 103 ). The sheath is preferably self-expanding and at least partially encloses the heart ( 61 ) after expansion. Located at the lower end of the sheath can be a connector or a cable with a connector. The supply unit can be directly attached to the sheath, or be connected to the sheath via a cable. After the sheath has been delivered, the delivery system ( 100 ) can be removed. The delivery system ( 100 ) is detached from the sheath by using a pre-weakened breaking point ( 104 ) of the delivery system ( 100 ) and/or on the catheter ( 103 ). Preferably, there are one or multiple pre-weakened breaking points ( 104 ) along a longitudinal axis of the delivery system ( 100 ). The pre-weakened breaking point ( 104 ) can be represented by a breaking line. When the delivery system ( 100 ) is broken open along a pre-weakened breaking point ( 104 ), the delivery system ( 100 ) can be split, unrolled and removed. The delivery system ( 100 ) can also include grasping components ( 105 ), which can be used to apply a force to the delivery system ( 100 ). Preferably, the grasping components ( 105 ) can be used to apply a force directed sideways from the catheter ( 103 ) onto the delivery system ( 100 ) suitable to break open the pre-weakened breaking point ( 104 ).
[0067] The delivery system ( 100 ) can further include a sensor ( 107 ). The sensor can be a temperature sensor ( 107 ) to measure the temperature within the catheter before and during the implantation of the sheath. The temperature sensor ( 107 ) can include a thermocouple, a crystal oscillator or an infrared camera. Alternatively, the sensor can be a sensor to measure at least one of the temperature, pH-value, osmolarity and oxygen saturation of a fluid within the catheter. The wall of the catheter ( 103 ) can further contain heating elements ( 108 ).
[0068] The heating elements ( 108 ) can be used to heat the catheter ( 103 ) and its content before or during implantation. The delivery system ( 100 ) can contain one, two, three, four or more heating elements ( 108 ). The heating elements ( 108 ) can be arranged along the circumference of the catheter wall ( 103 ) equidistantly or irregularly. The heating elements ( 108 ) can span the whole length of the catheter ( 103 ) or cover the length of the catheter only partially. The heating elements ( 108 ) can be adjacent to the catheter wall ( 103 ) at the inside or the outside or they can be within the catheter wall.
[0069] The heating elements ( 108 ) can include heating filaments, heating coils or heating wires, which produce heat via an electrical current. The heating elements ( 108 ) can further consist of ducts within the catheter wall that are perfused by a tempered fluid. The catheter can be heated by using a perfusion fluid whose temperature is higher than the ambient temperature. The ducts can also be perfused by a fluid whose temperature is lower than the ambient temperature, in this way the ducts are utilized to cool down the catheter and its content to a lower temperature. With a temperature sensor and the heating elements, the temperature within the catheter can be maintained at a specific level between −5° C. and +40° C.
[0070] FIG. 6 shows a step of the implantation of the device. After the first sealing component ( 51 , 52 ) in the pericardium ( 6 ) has assumed the expanded form, the sheath ( 2 ), which is preferably self-expanding, can be passed through the lumen of the catheter ( 103 ) of the delivery system and lumen of the first sealing component ( 51 ). After entering through the pericardium seal, the sheath ( 2 ) with the sensor or the electrode and/or the expandable unit expands inside the pericardium ( 6 ).
[0071] Shown in FIG. 6 is also the second sealing component ( 58 , 59 ) before being coupled with the first sealing component ( 51 , 52 ). In this embodiment, the second sealing component ( 58 , 59 ) is a ring-shaped component ( 58 ), e.g., a nut, on which a sealing disk ( 59 ) can be attached to its distal side. The second sealing component ( 58 , 59 ) can be expandable or non-expandable. The second sealing component ( 58 , 59 ) can be moved on the catheter ( 103 ). In this embodiment, the first sealing component ( 51 , 52 ) the sheath with the sensor or the electrode and/or with the expandable unit can be inserted through the lumen and the second sealing component ( 58 , 59 ) exhibit thread sections, which can be screwed together.
[0072] FIG. 7 shows a step of the implantation of the device. In this embodiment, the first sealing component ( 51 , 52 ) is coupled with the second sealing component ( 53 ). The pericardium ( 6 ) can thereby be sealed. The expandable sheath ( 2 ) is partially located inside the pericardium ( 6 ) and can be expanded. FIG. 7 shows markings ( 22 , 23 , 24 ) applied to the sheath ( 2 ). The device generally contains at least one marking ( 22 , 23 , 24 ), which can facilitate the correct placement of the sheath ( 2 ). The marking ( 22 , 23 , 24 ) can be a visual mark, in particular a color marking. The marking ( 22 , 23 , 24 ) can be a phosphorescent or fluorescent marking, making it easier to see in dark environment. Such environments can be present in the operating room itself, and can also be caused by the casting of shadows. Such environments can also be inside the body of a patient. The marking ( 22 , 23 , 24 ) can be made of a material able to be represented by imaging techniques. Suitable imaging techniques include X-rays, CT-methods, and MRI-methods. For example, the marking ( 22 , 23 , 24 ) can be formed of a more radiopaque material than the material of adjacent regions. The marking ( 22 , 23 , 24 ) can have the form of a point, a circle, an oval, a polygon, or the form of a letter. Other forms can be areas created by the connecting of dots. The form can be, for example, a half-moon or a star. The marking ( 22 , 23 , 24 ) can be applied to the sheath ( 2 ) or applied to a sleeve. The marking can be applied in the form of a line. The line can start at the upper edge of the sheath ( 2 ). The line can run from an upper edge of the sheath ( 2 ) to a point at the lower tip of the sheath ( 2 ). The line can run from the upper edge of the sheath perpendicular to the lower tip of the sheath ( 2 ). The starting point of the line at the upper edge of the sheath ( 2 ) can be located at a place, which in the implanted state is close to an area, or at an area, which is level with the cardiac septum. The marking ( 22 , 23 , 24 ) can be located at crossing points of the mesh or the lattice. If the sheath ( 2 ) includes a sheath sleeve, into which holes were formed, the marking ( 22 , 23 , 24 ) can be worked into the sheath sleeve. For example, a hole can be manufactured with a predefined form, which then serves as marking ( 22 , 23 , 24 ).
[0073] The delivery system and/or the catheter ( 103 ) of the delivery system can include one or multiple markings ( 106 ). A marking ( 106 ) on a delivery system can be formed like a marking on a sheath. The marking ( 106 ) can have the form of a dot or the form of a line. A marking ( 106 ) in the form of a line can be a line, which at least partially describes a circumference of the delivery system. A marking ( 106 ) in the form of a line can be a longitudinal line along an axis of the delivery system. A marking ( 106 ) in the form of line can be a straight line or a meandering line. A marking ( 106 ) in the form of a line can be a line running diagonally on a catheter ( 103 ) of a delivery system. A marking ( 106 ) can facilitate the orientation of the delivery system during implantation. A marking ( 106 ) at or on the delivery system can be in alignment with a line at or on a medical implant. For example, the medical implant can be a device for the support of the cardiac function, which can be compressed. In a compressed state, the device can be inserted into a delivery system. One or multiple markings ( 22 , 23 , 24 ) on or at the device can be aligned with one or multiple markings ( 106 ) on or at the delivery system. Such markings ( 22 , 23 , 24 , 106 ) facilitate the orientation of a medical implant. Markings ( 22 , 23 , 24 ) can also be located along an axis of a medical implant. Such markings ( 22 , 23 , 24 ) can be helpful in tracking the progress of the discharge of a medical implant out of the delivery system. The delivery system and/or a catheter ( 103 ) can be made of a transparent material, which allows the medical implant to be visually traceable during insertion.
[0074] FIG. 8 shows a step of the implantation of the device. In this example, the first sealing component ( 51 , 52 ) and the second sealing component ( 53 ) of the pericardium seal are interconnected. The device for the support of the cardiac function has already been partially discharged from the delivery system. Shown is a self-expanding sheath ( 2 ). In this embodiment, the sheath ( 2 ) is formed from a wire mesh exhibiting loops ( 26 , 28 ) at the upper edge and/or at the lower edge of the sheath ( 2 ). The sheath ( 2 ) can also be formed of a lattice structure and can exhibit links in the form of straps at the upper edge and/or at the lower edge of the sheath ( 2 ). If the sheath ( 2 ) is formed from a sheath sleeve, into which holes have been formed, the upper edge and/or the lower edge of the sheath ( 2 ) can be designed such that at least one strap is located at the upper and/or lower edge of the sheath ( 2 ). The sheath ( 2 ) represented in FIG. 8 includes a sleeve ( 80 ), which is inserted into the sheath ( 2 ). Another sleeve including at least one expandable unit can be located between the sleeve ( 80 ) and the sheath ( 2 ).
[0075] One or both sleeves can be fastened to the loops ( 26 , 28 ) or straps of the sheath ( 2 ). A sleeve can, in particular, be hooked onto the loops ( 26 , 28 ) or the straps of the sheath ( 2 ). In such case, the sleeve ( 80 ) can exhibit at least one pocket ( 27 ), which can be pulled over at least one loop ( 26 , 28 ) or at least one strap. Another embodiment can include a sleeve ( 80 ), which is turned inside out at its upper edge and/or at its lower edge. This inversion can form a pocket ( 27 ) around the entire sleeve ( 80 ) or around a part thereof, which can be hooked into the upper edge and/or the lower edge of the sheath ( 2 ). In FIG. 8 , the sheath ( 2 ) exhibits multiple markings ( 22 , 23 , 24 , 25 ). As previously described, these markings ( 22 , 23 , 24 , 25 ) can assume different forms or positions. In this case, the markings ( 22 , 23 , 24 , 25 ) are attached to the upper edge and the lower tip of the sheath ( 2 ).
[0076] FIGS. 9 a - c show different views of a pericardium seal ( 5 ). The pericardium seal ( 5 ) serves to prevent the loss of pericardium fluid or also as an option to apply artificial pericardium fluid, medications or other therapeutics. The prevention of loss of pericardium fluid also serves to prevent adhesions of the system with the epicardium. The pericardium seal ( 5 ) generally includes a first sealing component ( 51 ) and a second sealing component ( 52 ). The first sealing component ( 51 ) has a central lumen, and the second sealing component ( 53 ) has a central lumen. The first sealing component ( 51 ) can be coupled with the second sealing component ( 53 ). After coupling the first sealing component ( 51 ) to the second sealing component ( 52 ), the pericardium seal ( 5 ) exhibits a lumen running through the pericardium seal ( 5 ). The lumen can be formed exclusively by the central lumen of the first sealing component ( 51 ), or the lumen can be formed exclusively by the central lumen of the second sealing component ( 53 ). In another embodiment, the lumen can also be formed from both lumens of the two coupled sealing components ( 51 , 53 ). Located in the lumen can be a sealing gasket, an O-ring, a labyrinth seal or another sealing component ( 56 ). A sealing component ( 56 ) in the lumen of the pericardium seal can seal the pericardium seal ( 5 ) against an object protruding through the pericardium seal ( 5 ). For example, a cable can be passed through the pericardium seal ( 5 ), which is then sealed against the pericardium seal ( 5 ). A sealing component ( 56 ) in the lumen can serve not only to seal but also to fix an object protruding through the lumen of the pericardium seal. The sealing component ( 56 ) can be attached to both sealing components ( 51 , 53 ) or to one of both sealing components ( 51 , 53 ) only.
[0077] Using a mechanism, the first sealing component ( 51 ) can be secured with the second sealing component ( 53 ). A mechanism to secure a first sealing component ( 51 ) with a second sealing component ( 53 ) can include a screw mechanism or clamping mechanism. A mechanism to secure a first sealing component ( 51 ) with a second sealing component ( 53 ) can also include a bayonet catch. The first sealing component ( 51 ) and the second sealing component ( 53 ) can be made of the same material or made of different materials. Suitable materials for the first sealing component ( 51 ) and/or the second sealing component ( 53 ) include synthetic materials, metals, ceramics or combinations thereof.
[0078] Attached to the first sealing component ( 51 ) can be a first sealing lip ( 52 ). The first sealing lip ( 52 ) can be part of the first sealing component ( 51 ) or can be attached to the first sealing component ( 51 ). Attached to the second sealing component ( 53 ) can be a second sealing lip ( 54 ). The second sealing lip ( 54 ) can be part of the second sealing component ( 53 ) or can be attached to the second sealing component ( 53 ). The first sealing lip ( 52 ) and the second sealing lip ( 54 ) can be formed of the same material or of different materials. One or both sealing lips ( 52 , 54 ) can be part of the respective sealing component ( 51 , 53 ) and can be formed from the same material as the associated sealing component ( 51 , 53 ). The first sealing lip ( 52 ) and/or the second sealing lip ( 54 ) can be formed of a synthetic material (preferably of an elastomer), natural rubber, rubber, silicon, latex or a combination thereof. The first sealing lip ( 52 ) and/or the second sealing lip ( 54 ) can be disk-shaped. The first sealing lip ( 52 ) and/or the second sealing lip ( 54 ) can exhibit a concave or a convex curvature. Curved sealing lips ( 52 , 54 ) can better adapt to anatomic conditions. The pericardium exhibits a convex form in the area of the cardiac apex. With the sealing lips ( 52 , 54 ) exhibiting a curvature in the shape of the anatomically available form, an improved anatomic fit of the pericardium seal ( 5 ) can be achieved.
[0079] Curved sealing lips ( 52 , 54 ) can also be used to achieve better sealing properties. The first sealing lip ( 52 ) and/or the second sealing lip ( 54 ) can have reinforcements. With increasing radial distance from the lumen of the pericardium seal towards the outside, the first sealing lip ( 52 ) and/or the second sealing lip ( 54 ) can exhibit increased flexibility. Increased flexibility at the edges of sealing lip ( 52 , 54 ) can strengthen the sealing properties of the sealing lip ( 52 , 54 ) and can also support the anatomically correct positioning of the sealing lip ( 52 , 54 ). Increased flexibility at the edges of the sealing lip ( 52 , 54 ) can be achieved through the choice of material. Each sealing lip ( 52 , 54 ) can be made of one material or of multiple materials. Reinforcements of a sealing lip ( 52 , 54 ) can be concentric reinforcements or radial reinforcements. Reinforcements can be achieved by means of variable material thicknesses or by introduction of a reinforcing material. The reinforcing material can be the same material as the base material of the sealing lip ( 52 , 54 ), having been converted into a different form of the material. Alternatively, regions, that are not to be reinforced can be weakened by converting the material of the sealing lip ( 52 , 54 ) into a weaker form of the material. A weakening of the material can be induced by exposure to energetic radiation (e.g., heat). Reinforcements of the material can also be achieved by application of material, whereby the applied material can be the same material as the base material of the sealing lip ( 52 , 54 ), or whereby the applied material can be a material different from the base material of the sealing lip ( 52 , 54 ). Suitable materials for the reinforcement of sections of a sealing lip ( 52 , 54 ) are metals, ceramics, rubber, or a combination thereof.
[0080] One of the two sealing components ( 51 , 53 ) can exhibit a coupling mechanism, allowing the coupling of a sealing component ( 51 , 53 ) with the delivery system or a catheter of the delivery system. The coupling mechanism can consist, for example, of a cone ( 55 ) located at the first sealing component ( 51 ), onto which the delivery system or a catheter of a delivery system can be clamped. The clamping effect can be achieved by the diameter of the cone ( 55 ) being larger than the luminal diameter of the delivery system, for example. The coupling mechanism to couple the pericardium seal ( 5 ) to the delivery system can also be available at the second sealing component ( 53 ). The coupling mechanism can also be provided as a separate part in addition to the sealing components ( 51 , 53 ), and can link the delivery system to one of the two sealing components ( 51 , 53 ) of the pericardium seal ( 5 ). Other embodiments of the coupling mechanism may include, among others, a non-conical (e.g., cylindrical) extension on one of the sealing components ( 51 , 53 ), onto which the delivery system can be placed or glued. In some embodiments, the catheter of the delivery system and a sealing component form a single integrated part. In some embodiments, the catheter can after successful insertion and securing of the pericardium seal ( 5 ) be disconnected from the sealing component ( 51 , 53 ) or the pericardium seal ( 5 ) by means of a pre-weakened breaking point.
[0081] One or both sealing components ( 51 , 53 ) can exhibit engaging components ( 57 ). These engaging components ( 57 ) can be used to apply a force to one or both sealing components ( 51 , 53 ) appropriate to couple and/or secure the sealing components ( 51 , 53 ). Engaging components ( 57 ) on one or on both sealing components ( 51 , 53 ) can be holes, indentations or elevations. The engaging components ( 57 ) can be installed around the circumference of the sealing component ( 51 , 53 ) at an equal distance from each other. The circumferential distance between the engaging components ( 57 ) can also vary. FIGS. 9 a - c illustrate six engaging components ( 57 ) equidistantly disposed around the circumference. On the ring-shaped sealing component ( 53 ), the six engaging components ( 57 ) are installed at an angular distance of approximately 60°. In the case of two, three, four, five, six, eight or more evenly distributed engaging components ( 57 ), the angular distance is 180°, 120°, 90°, 72°, 60°, 45° or less, respectively. The engaging components ( 57 ) can also be installed in an unevenly spaced configuration.
[0082] FIG. 10 shows a pericardium seal ( 5 ) and a tool ( 11 ) to secure a pericardium seal ( 5 ). The pericardium seal ( 5 ) shown in FIG. 10 is essentially identical to the seal shown in FIG. 9 . As an example, the tool ( 11 ) is represented as an elongated tubular tool. Located at the distal end of the tool ( 11 ) are components ( 111 ), which can be at least partially engaged with the engaging components ( 57 ) of a sealing component ( 53 ). In the embodiment shown in FIG. 10 , the inside of the tubular tool ( 11 ) exhibits at the distal end six elevations ( 111 ) pointing to the inside, which can engage with the six engaging components ( 57 ) of the sealing component ( 53 ), for example, with six indentations on the sealing component ( 53 ). The tool ( 11 ) essentially exhibits the same number of components ( 11 ), which are complementary to the engaging components ( 57 ) of the sealing component ( 53 ). The tool ( 11 ) shown in FIG. 10 is a tubular tool, consisting of a complete tube. The tubular component of the tool ( 11 ) can also be half a tube, a quarter tube, or a third of a tube. In the extreme case, instead of the tube, only one shaft or multiple shafts can be attached to a distal, ring-shaped tool. A shaft can extend from the ring-shaped tool in longitudinal direction. A shaft can also extend laterally away from a longitudinal axis of the tool. Other embodiments of the tool ( 11 ) (not shown) can be provided in the form of a modified box wrench or a modified open-end wrench.
[0083] FIG. 11 shows a connector system consisting of two connectors ( 90 , 92 ). The device for the support of the cardiac function includes a sheath with at least one sensor or at least one electrode and/or at least one expandable unit, whereby the sensor or electrode and/or the expandable unit are connected to a supply unit. The sensor or the electrode and/or the expandable unit can be directly connected to the supply unit. The sensor or the electrode and/or the expandable unit can be connected to the supply unit via a cable ( 4 ). The sensor or the electrode and/or the expandable unit can be directly linked to the supply unit via the cable ( 4 ), or the sensor or the electrode and/or the expandable unit can be connected to the supply unit. The supply unit can include a connector ( 92 ). The connector ( 92 ) can be attached directly to the supply unit. The connector ( 92 ) can be connected to the supply unit via a cable ( 4 ). The sensor or the electrode and/or the expandable unit can include a cable ( 4 ). At the end of the cable ( 4 ) can be a connector ( 90 ). The connector ( 90 ) at the end of the cable of the sensor or of the expandable unit matches the connector ( 92 ) at the supply unit. The connector ( 90 ) of the sensor or of the electrode and/or the expandable unit can be a male or a female connector. A female connector on the side of the sensor or the electrode and/or the expandable unit can be advantageous, since the female connector in contrast to the male connector does not include any pins ( 951 ) or any other terminals, which can protrude and therefore could break. If an exchange of the supply unit is required, the connector system is disconnected, and a new supply unit is connected to the connector ( 90 ) of the sensor or the electrode and/or the at least expandable unit. The reconnection of the connector ( 90 ) with a supply unit might cause pins ( 951 ) or other terminals to break. If the pins ( 951 ) or terminals are located in a male connector on the side of the sheath with the sensor or the at last one electrode and/or the expandable unit, an exchange of the sheath may be required. A female connector on the side of the sheath with the sensor or the electrode and/or the expandable unit can be advantageous, since the breaking of pins ( 951 ) or other terminals cannot occur at a female connector. The connector system ( 90 , 92 ) usually includes two connectors. The device can consist of a connector system ( 90 , 92 ) for the sensor or the electrode and/or the expandable unit, or of multiple connector systems. If multiple connector systems are used, a connector system for electrical leads and a connector system for hydraulic and/or pneumatic lines can be provided. The connector system ( 90 , 92 ) represented in FIG. 11 is a connector system consisting of connections to supply the sensor or the electrode and the expandable unit. The number of connections depends on how many sensors or electrodes and how many expandable units are being used. In some implementations, the number does not necessarily have to correlate directly with the number of sensors or electrodes and/or the number of expandable units. Split leads/lines on both sides of the connector system ( 90 , 92 ) are possible, and a pneumatic or hydraulic line is configured to supply one, two, three, four, five, six or more fillable chambers. The filling of the multiple chambers by one line does not have to occur simultaneously; it can also occur individually by means of individually controllable valves. Likewise, one electrical lead inside the cable can be used for multiple sensors or electrodes, and switches can individually energize circuits. The connector system ( 90 , 92 ) represented in FIG. 11 includes four hydraulic or pneumatic connection ports ( 93 , 94 ) and one connection for electrical leads ( 95 , 96 ). The connecting port for electrical leads ( 95 , 96 ) shown in FIG. 11 exhibits 16 connecting components in the form of pins ( 951 ) and pin sockets ( 961 ). More or fewer connections for electrical leads ( 95 , 96 ) and/or pneumatic or hydraulic lines ( 93 , 94 ) can exist in one connector system. The pneumatic or hydraulic lines ( 93 , 94 ) can include one, two, three, four, five, six, seven, eight, nine or ten connections.
[0084] The electric leads ( 95 , 96 ) can include one, two, three, four, five, six, seven, eight, nine, ten, twelve, fourteen, sixteen, twenty or more connections. One electrical connector for electric leads ( 95 , 96 ) can have one, two, three, four, five, six, seven, eight, nine, ten, twelve, fourteen, sixteen, twenty or more connecting components in the form of pins ( 951 ) and pin sockets ( 961 ). The number of connecting components in the form of pins ( 951 ) and pin sockets ( 961 ), however, is identical for the respective pair of connections for electricals leads ( 95 , 96 ). Each of the connections ( 93 , 94 , 95 , 96 ) in one or in both of the connectors of the connector systems ( 90 , 92 ) can have its own seal ( 931 , 952 ). The seal ( 931 , 952 ) of the individual connections ( 93 , 94 , 95 , 96 ) can be a sealing tape or a sealing gasket. The connector system ( 90 , 92 ) can in addition or only one seal inside the connector system ( 973 ) or around the connector system. A seal via the connector system can be a sealing tape or a sealing gasket. The connector parts ( 90 , 92 ) can be interconnected in order to create the connector system ( 90 , 92 ). The connector parts ( 90 , 92 ) can have a guide peg ( 972 ) and a guide slot ( 974 ). The guide peg ( 972 ) and the guide slot ( 974 ) can prevent wrong connection of the two connector parts and/or turning the connector parts the wrong way during connection. The connector parts ( 90 , 92 ) can also include two, three, or more guide pegs ( 972 ) and guide slots ( 974 ). In the case of two or more guide pegs ( 972 ) and guide slots ( 974 ), unequal distances between the individual guide pegs ( 972 ) and guide slots ( 974 ) can be used. The interconnected connector parts ( 90 , 92 ) can also be secured with a mechanism ( 971 ). Such mechanism ( 971 ) can be a screwing mechanism or a clamping mechanism or a bayonet catch. A mechanism to secure the interconnected connector system ( 90 , 92 ) can also be a retainer nut, a clamp, a latch or a snap-lock mechanism. Securing the connector system ( 90 , 92 ) is advantageous, since any accidental partial or complete disconnection of the connector system ( 90 , 92 ) can interrupt the supply of the sensor or the at least one electrode and/or the expandable unit.
[0085] FIG. 12 shows a model for the preparation of a system of coordinates. The development of a system of coordinates can facilitate the manufacture of a device for the support of the cardiac function, since the position for the sensor or one electrode and/or the expandable unit and/or the marking can be exactly defined. FIG. 12 a shows a heart ( 61 ) with anatomical points of reference. The example illustrates the heart ( 61 ) with the aortic arch (AO) originating at the left ventricle (LV) (with head arteries, neck arteries, and subclavian arteries (TR, CL, SCL) branching off), and the pulmonary artery (PU) originating at the right ventricle (RV). Also shown are sections of the inferior vena cava (IVC) and the superior vena cava (SVC). The broken line ( 601 ) represents the height of the valve plane. The point ( 604 ) of the cardiac apex is defined by letting a perpendicular ( 603 ) fall from this plane ( 601 ) through the most distal point of the cardiac apex. The device includes a sheath, into which a sleeve with at least one sensor or one electrode and/or a sleeve with at least one expandable unit can be inserted. The dimension of the sheath and/or the sleeve can be designed such that the upper edge of the sleeve ( 602 ) runs parallel to the valve plane with a downward offset in the direction of the cardiac apex at a distance from the valve plane of 1 mm to 30 mm, 3 mm to 20 mm, 5 mm to 10 mm, preferably 5 mm. The upper edge of the sheath is shown by the line ( 602 ) in FIG. 12 a . The lower edge of the sheath ( 605 ) and/or the sleeve can be parallel to the valve plane with a distance to the most distal point ( 604 ) of 1 mm to 30 mm, 3 mm to 20 mm, 5 mm to 10 mm, preferably 5 mm. FIG. 12 b shows a cutting plane B-B along the line ( 602 ) shown in FIG. 12 a , i.e., along the line corresponding to the upper edge of the sheath.
[0086] FIG. 12 b shows the right ventricular chamber (RV) and the left ventricular chamber (LV), the heart wall and the septal wall separating the cardiac chambers. The points ( 608 ) and ( 609 ) are defined as the points of intersection of the centerlines of the heart wall with the septal wall. The point ( 608 ) is also called the anterior intersecting point of the centerlines of the heart wall with the septal wall. The point ( 609 ) is also called the posterior intersecting point of the centerlines of the heart wall with the septal wall. The center point on a line connecting points ( 608 ) and ( 609 ) is defined as point ( 607 ). These points can be used to define a system of polar coordinates. The z-axis ( 606 ) of the polar coordinate system is defined as the line connecting the most distal point ( 604 ) to the center point ( 607 ) of the line connecting points ( 608 ) and ( 609 ). The circumferential direction of the coordinate system is suggested by the reference numeral ( 610 ) and defined as angle measure φ, whereby a line radially running from the z-axis ( 606 ) through the anterior point of intersection ( 608 ) is defined as φ=0°.
[0087] FIG. 13 shows a sheath and/or sleeve with the coordinate system described above in conjunction with FIG. 12 . FIG. 13 a shows a 3D-model ( 611 ) of a sheath or sleeve with the z-axis ( 606 ) extending through the most distal point ( 604 ) and the center point ( 607 ) of the line connecting points ( 608 ) with ( 609 ). The points ( 608 ) and ( 609 ) are the anterior and the posterior point of intersection of the center lines of the heart wall with the septal wall, whereby the φ=0° line is drawn through the point ( 608 ). The broken line connecting the points ( 608 ) and ( 609 ) along an outer circumference of the sheath or the sleeve, represents the position of the septal wall of the heart as projected onto the sheath/sleeve. At the upper edge of the sheath or the sleeve, the angle measures starting at φ=0° are shown in 30° increments, whereby—viewed from above—the angles increase counterclockwise. Longitudinal lines ( 613 ) projected onto the sheath/sleeve respectively extend along these angles up to the cardiac apex ( 604 ). The angle measure of φ=360° then again corresponds to the angle measure of φ=0°. Contour lines ( 614 ) are indicated at distances of 15 mm increments. The contour lines ( 614 ) and planes are running perpendicular to the z-axis ( 606 ). The broken-dotted line ( 615 ) constitutes a cutting line, where the 3D shape ( 611 ) can be cut open and rolled out. FIG. 13 b shows a rolled-out sheath or sleeve ( 612 ), which has been cut along the line ( 615 ) in FIG. 13 a and then rolled out. The positions ( 608 , 609 ) and lines ( 613 , 614 , 615 , 616 ) shown in FIG. 13 b represent the same positions and lines that are shown in FIG. 13 a.
[0088] FIG. 14 shows a sleeve ( 7 ) with at least one expandable unit ( 71 , 72 ). The 3D-shape of the sleeve ( 7 ) in FIG. 14 a is comparable to the 3D-model explained in conjunction with FIG. 13 a and shows a coordinate system as described above. The sleeve ( 7 ) can at least partially enclose a heart. The sleeve ( 7 ) can at least partially have the shape of a heart. The sleeve ( 7 ) can have a shape similar to the sheath. The sleeve can be inserted into the sheath. The sleeve can be made of synthetic material, polymer, natural rubber, rubber, latex, silicon or polyurethane.
[0089] In FIG. 14 a , the sleeve ( 7 ) with at least one expandable unit ( 71 , 72 ) is shown as a sleeve ( 7 ) with a multiplicity of chambers. FIG. 14 b shows a 2D-rollout of the 3D-model from FIG. 14 a . The rollout represented in FIG. 14 b is essentially identical to the rollout of a 3D-model explained in conjunction with FIG. 13 b . Unlike in FIG. 13 a , the 3D-model in FIG. 14 a is rotated such that a view from above into the sleeve ( 7 ) is possible. In FIGS. 14 a and 14 b , four expandable units ( 71 , 72 ) are shown as examples, three of which are augmentation units ( 71 ) and one is a positioning unit ( 72 ). The expandable units ( 71 , 72 ) can be structurally similar but can serve different purposes, as described above.
[0090] Generally, an augmentation unit ( 71 ) can be periodically expanded and relaxed in order to be configured to apply pressure to the heart. This pressure is preferably applied in ventricular areas. By applying pressure to a ventricle via the augmentation unit ( 71 ) the natural pumping motion of the heart is supported or substituted, and the blood inside the ventricular chamber is pumped into the corresponding artery. A pressure applied by an augmentation unit ( 71 ) to a right ventricle leads to the blood being ejected from the right ventricle into the pulmonary artery. A pressure applied by an augmentation unit ( 71 ) to a left ventricle leads to the blood being ejected from the left ventricle into the aorta.
[0091] FIG. 14 shows three augmentation units ( 71 ), which are located at the upper edge of the sleeve ( 7 ). In this example, each of the augmentation units ( 71 ) is supplied by its own line ( 41 ).
[0092] In the case of augmentation units ( 71 ) in the form of inflatable chamber, the lines ( 41 ) are preferably pneumatic or hydraulic lines. Other embodiments include one, two, three, four, five, six or more augmentation units ( 71 ), which are supplied by one, two, three, four, five, six or more lines ( 41 ). The line ( 41 ) can be made of synthetic material, polymer, natural rubber, rubber, latex, silicon, or polyurethane. The line ( 41 ) can run above, adjacent to or below the augmentation unit ( 71 ). The line ( 41 ) can preferably run below a positioning unit ( 72 ), so that no pressure points result between the line ( 41 ) and the heart wall. The line ( 41 ) can also run above or adjacent to a positioning unit ( 72 ).
[0093] The augmentation units ( 71 ) A1, A2, and A3 shown in FIG. 14 are located in an area at the upper edge of the sleeve ( 7 ) and are each supplied by their own respective line ( 41 ). The augmentation units ( 71 ) A1 and A2 can—as illustrated in FIG. 14 —be positioned such that they can assist a left ventricle. Augmentation unit ( 71 ) A3 is positioned to assist a right ventricle. The individual augmentation units ( 71 ) A1, A2 and A3 can be expanded individually. Augmentation units ( 71 ) A1 and A2 can assist cardiac function for a heart with left ventricular insufficiency. Augmentation unit ( 71 ) A3 can serve to support a right ventricular insufficiency.
[0094] Augmentation units ( 71 ) A1, A2 and A3 can be used for support of a bilateral heart insufficiency. The augmentation units ( 71 ) can be expanded synchronously or asynchronously. Preferably, the expansion of the augmentation units ( 71 ) can be coordinated such that a natural pumping function of the heart is supported.
[0095] A positioning unit ( 72 ) is a unit, which can also be expanded. Preferably, a positioning unit is expanded during operation of the device for the support of the cardiac function more statically than periodically. The positioning unit ( 72 ) can be expanded in order to fix the device to the heart and to optimize the accuracy of the fit of the device. A positioning unit ( 72 ) can also help to respond to changes of the myocardium. If the size of the myocardium decreases or increases, a positioning unit can be expanded or relaxed further in order to ensure a perfect fit.
[0096] FIG. 14 illustrates a positioning unit ( 72 ), which essentially fills the spaces between the three augmentation units ( 71 ) on the sleeve ( 7 ). The positioning unit ( 72 ) can have a distance from one or multiple augmentation units ( 71 ) of 1 mm, 3 mm, 5 mm, 10 mm, 20 mm, 30 mm, 40 mm or more. The positioning unit ( 72 ) can be supplied by its own line ( 41 ), in the case of a chamber fillable with a fluid, by a pneumatic or hydraulic line. Other embodiments include one, two, three, four, five, six or more positioning units ( 72 ), which are supplied by one, two, three, four, five, six or more pneumatic or hydraulic lines ( 41 ). The line ( 41 ) can consist of a synthetic material, polymer, natural rubber, rubber, latex, silicon or polyurethane. The line ( 41 ) for the supplying of the positioning unit ( 72 ) can run below the positioning unit ( 72 ). The positioning unit ( 72 ), shown in FIG. 14 , fills the spaces between the augmentation units ( 71 ). The depicted positioning unit ( 72 ) has extensions that protrude into the spaces between the augmentation units ( 71 ).
[0097] FIG. 15 shows an expandable unit ( 71 , 72 ) in the form of a chamber ( 710 ). The depicted chamber is a bellows-shaped chamber ( 710 ). A bellows-shaped chamber ( 710 ) has at least one section in the form of bellows. Preferably, chamber 710 is a folding bellows consisting of one, two, three, four, five, six, seven or more folds. An outwardly bent edge ( 711 ) can be defined as a fold. An inwardly bent edge ( 712 ) can be defined as a fold. In some embodiments, the regions of the chamber wall between the folds are less stable than the folds. One, multiple or all bent edges ( 711 , 712 ) can be reinforced. A reinforcement of a bent edge ( 711 , 712 ) is advantageous, since the bent edge ( 711 , 712 ) can be exposed to increased stress due to the expanding and relaxing of the chamber ( 710 ). A reinforcement of one or multiple bent edges ( 711 , 712 ) can reduce or prevent material fatigue along the bent edge ( 711 , 712 ). Reinforcement of a bent edge ( 711 , 712 ) can be achieved through a greater wall thickness of the material at the bent edge ( 711 , 712 ). A bent edge ( 711 , 712 ) can also be reinforced through application of additional material, wherein the applied material can be the same material as the underlying material, or wherein the applied material can be a different material than the underlying material. A chamber ( 710 ) can exhibit a top side ( 713 ), a bottom side and a side surface, whereby the side surface is preferably designed in the shape of a bellows. The top ( 713 ) and/or the bottom side can be oval, circular, elliptical, or polygonal. The top side ( 713 ) can have a different shape than the bottom side.
[0098] A bellows-shaped chamber ( 710 ) can be inserted into a sheath of the type described above. The chamber ( 710 ) can be directly attached or fixed inside the sheath. The chamber ( 710 ) can be attached to structural components of the sheath, like, for example, a wire of a wire mesh, a strap of a latticework, or a structure on a sheath sleeve.
[0099] The chamber ( 710 ) can be attached to crossing points of a mesh or latticework. The sheath can be covered by a membrane, as described above. In these cases, the chamber ( 710 ) can also be attached to the membrane. The membrane can also be a bottom side of the chamber ( 710 ).
[0100] The bellows-shaped chamber ( 710 ) can also be fastened to a sleeve ( 7 ). Multiple bellows-shaped chambers ( 710 ) can be fastened to a sleeve ( 7 ). The sleeve ( 7 ) can at least partially have the shape of a heart. The sleeve ( 7 ) can have a shape similar to that of the sheath. The sleeve ( 7 ) can be inserted into the sheath. The sheath ( 7 ) can be fastened and/or fixed inside the sheath. The sleeve ( 7 ) can, in addition to one or multiple augmentation units like, for example, one or multiple bellows-shaped chambers ( 710 ), also exhibit one or multiple positioning units. The bottom side of the chamber ( 710 ) can be made of the same material as the sleeve ( 7 ). The sleeve ( 7 ) can be part of the chamber ( 710 ). The sleeve ( 7 ) can form the bottom side of the chamber. In those cases, only the lateral surfaces, which can be bellows-shaped, are applied to a sleeve ( 7 ). In addition, a top side ( 713 ) can be attached as well. The top side ( 713 ) can be a sleeve as well. Embodiments consist of two sleeves ( 7 ), whereby the sleeves ( 7 ) create the top side and the bottom side of the chambers, and lateral surfaces are formed between the sleeves. In this case, lateral surfaces can also be formed by joining, in particular by welding or gluing together of the two sleeves. The sleeves ( 7 ) can be joined together, in particular, welded or glued together, such that a chamber is formed. In some embodiments, the sleeves are connected to each other in a common edge region. In some embodiments, the chamber defines a gap of 0.1 mm to 5 mm. The line supplying the chamber can be formed similar to the chamber at least partially by joining the two sleeves ( 7 ), in particular by welding or gluing together of the two sleeves ( 7 ). Located on one of the two sleeves ( 7 ) or on both sleeves ( 7 ) can be one or multiple sensors or one or multiple electrodes.
[0101] The sleeve ( 7 ) with the expandable unit can at the upper edge and/or at the lower edge exhibit at least one pocket. The pocket can be at least partially pulled over a structural shape of a sheath. The pocket can, for example, be at least partially pulled over a loop of a wire mesh or a strap of a latticework.
[0102] The sleeve ( 7 ) with the expandable unit can contain an active agent. The sleeve ( 7 ) may, for example, contain an anti-thrombotic agent, an anti-proliferative agent, an anti-inflammatory agent, an anti-neoplastic agent, an anti-mitotic agent, an anti-microbial agent, a biofilm synthesis inhibitor, an antibiotic agent, an antibody, an anticoagulative agent, a cholesterol-lowering agent, a beta blocker, or a combination thereof. The agent is preferably provided in the form of a coating on the sleeve ( 7 ). The sleeve ( 7 ) can also be coated with extra-cellular matrix proteins, in particular, fibronectin or collagen.
[0103] FIG. 16 shows a sleeve ( 80 ) with at least one sensor ( 81 ) and/or at least one electrode ( 82 ). The 3D-shape of the sleeve ( 80 ) in FIG. 16 a is comparable to the 3D-model described in FIG. 13 a and shows a coordinate system as described above. The sleeve ( 80 ) can at least partially enclose a heart. The sleeve ( 80 ) can at least partially have the shape of a heart. The sleeve ( 80 ) can have a shape similar to that of the sheath. The sleeve ( 80 ) can be inserted into the sheath. The sleeve ( 80 ) can be made of a synthetic material, polymer, natural rubber, rubber, latex, silicon or polyurethane. The sleeve ( 80 ) can exhibit a thickness of 0.1 mm to 1 mm, preferably 0.2 mm to 0.5 mm. The sleeve ( 80 ) with the sensor ( 81 ) and/or the electrode ( 82 ) can be pressed against the myocardium by the sleeve with the expandable units. The sleeve ( 80 ) can be coated, in particular, with a lubricant, which reduces the friction between the myocardium and the sleeve ( 80 ) with the sensor ( 81 ) and/or the electrode ( 82 ). A coating, in particular, a coating with a lubricant can also be provided between the sleeve ( 80 ) with the sensor ( 81 ) and/or the electrode ( 82 ) and the sleeve with the expandable unit. The sensor ( 81 ) and/or the electrode ( 82 ) can be worked, molded or welded into the sleeve ( 80 ) or attached, glued onto or sewn onto the sleeve ( 80 ). The sensor ( 81 ) and/or the electrode ( 82 ) can be equipped with reinforcements configured to prevent bending during the compression of the device.
[0104] In FIG. 16 a , the sleeve ( 80 ) is depicted with at least one sensor ( 81 ) and/or at least one electrode ( 82 ) as a sleeve ( 80 ) with a multiplicity of sensors ( 81 ) and electrodes ( 82 ). FIG. 16 b shows a 2D-rollout of the 3D-model from FIG. 16 a . The rollout depicted in FIG. 16 b essentially matches the rollout of a 3D-model explained in conjunction with FIG. 13 b . Unlike in FIG. 13 a , the 3D-model in FIG. 16 a is rotated to allow a view from above into the sleeve ( 80 ). In FIGS. 16 a and 16 b , eight sensors ( 81 ) or electrodes ( 82 ) are shown as examples. Other embodiments can include one, two, three, four, five, six, seven, eight, nine, ten, eleven, twelve or more sensors ( 81 ) and/or electrodes ( 82 ). The sleeve ( 80 ) with the sensor ( 81 ) or at least one electrode ( 82 ) can be a net of sensors ( 81 ) or electrodes ( 82 ). The net of sensors ( 81 ) or electrodes ( 82 ) can at least partially enclose the heart. The sensors ( 81 ) or electrodes ( 82 ) in the net of sensors ( 81 ) or electrodes ( 82 ) can be interconnected. The sleeve ( 80 ) can function as the carrier of the net of sensors ( 81 ) or electrodes ( 82 ). The net of sensors ( 81 ) or electrodes ( 82 ) can also be only partially attached to a sleeve ( 80 ). The net of sensors ( 81 ) or electrodes ( 82 ) can also be inserted without a sleeve ( 80 ) into a sheath as the one described above.
[0105] The sensor ( 81 ) or the electrode ( 82 ) can determine a physical or a chemical property of its environment. The property can be detected qualitatively or quantitatively. The sensor ( 81 ) can be an active sensor or a passive sensor. The sensor ( 81 ) can detect at least one parameter of the heart. The sensor ( 81 ) can be configured to determine the heart rate, the ventricular pressure, the systolic blood pressure, the diastolic blood pressure, pressure applied to a surface of the heart, fluid presence, acidity, electrical resistance, osmolarity, oxygen saturation or flow through a vessel. The sensor ( 81 ) can be configured to measure the pressure applied by an expandable unit onto a surface, the pH-value, the electric resistance, the osmolarity of a solution, or the flow through a vessel. The sensor can also be used as an electrode.
[0106] The electrode ( 82 ) can be configured to electrically stimulate areas of the heart and/or to measure the electrical activity at the epicardium during the excitation process. The electrode ( 82 ) can be configured to stimulate the myocardium with the use of electrical impulses. An electrical stimulation can induce a myocardium to contract. The electrode ( 82 ) can be a pacemaker electrode. The electrode ( 82 ) can be an extra-cardial stimulation electrode. With an electrode ( 82 ), the myocardium can be stimulated before, during or after a support of the pumping function of the heart by a sheath with at least one expandable unit. The expansion of an expandable unit can occur before, during or after stimulation with an electrode ( 82 ). The device for the support of the cardiac function can be operated only with at least one expandable unit or only through stimulation with at least one electrode ( 82 ). Simultaneous operation of the expandable unit and the electrode ( 82 ) can be synchronous or asynchronous. The electrode can also be used a sensor.
[0107] The sensor ( 81 ) or the electrode ( 82 ) can be fastened to the sleeve ( 80 ). The sensor ( 81 ) or the at least one electrode ( 82 ) can be glued, sewed or welded to the sleeve ( 80 ). The sensor ( 81 ) or the electrode ( 82 ) can be attached to the inside of the sleeve ( 80 ), preferably welded in. The sensor ( 81 ) or the electrode ( 82 ) can be connected via a lead ( 84 ) to a supply unit. The data detected by the sensor ( 81 ) or the electrode ( 82 ) can be transmitted connectionless via wireless technology, like bluetooth, for example.
[0108] The contacts of the electrodes or sensors or the entire sleeve can be coated with a substance, which increases or improves conductivity. A graphite coating on the contacts, for example, can increase their conductivity.
Example #1
[0109] FIG. 17 shows an embodiment of a sleeve ( 7 ) with at least one expandable unit ( 71 , 72 ). FIG. 17 depicts a 2D-rollout of a 3D-model described in conjunction with FIG. 13 . The illustrated sheath includes three augmentation units ( 71 ) (A1, A2, A3) and a positioning unit ( 72 ) (P). In some embodiments, the augmentation units A1 and A2 each occupy an area of 28.6 cm 2 on the sleeve. The area occupied by augmentation unit A3 in this example is 34.5 cm 2 . The positioning unit ( 72 ) (P) occupies an area 114.5 cm 2 . Under normal conditions, the nominal expansion of the positioning unit (P) is 5 mm (e.g., the positioning unit is partially expanded and exhibits a thickness of 5 mm). The positioning unit can be a chamber, which can be filled and unfilled with a fluid. The thickness of the positioning unit can therefore be between 1 mm and 10 mm, preferably between 3 mm and 7 mm. By changing the thickness of the positioning unit ( 72 ) (P) an increase or decrease of the size of the heart can be compensated, and the correct fit of the sleeve ( 7 ) and/or the sheath essentially remains guaranteed.
[0110] In this example, the thicknesses of augmentation units A1 and A2 can be expanded by about 1.9 cm in order to build up a pressure onto a ventricle (here, the left ventricle). The effective volume expansion of the augmentation units A1 and A2 in this example is 40 ml. The effective volume expansion of the augmentation unit A3 in this example is 50 ml and leads to an effective expansion of the thickness by 1.45 cm. Every corner of an augmentation unit can be described by the coordinates of the corner points (vertices). The coordinate system has been explained in conjunction with FIG. 13 .
[0111] In this example, augmentation unit A1 extends from vertex 1 (φ=359°; z=100) via vertex 2 (φ=48°; z=85) and vertex 3 (φ=48°; z=40) to vertex 4 (φ=328°; z=56), and, in the implanted state, lies flat against the left ventricle. The connection of vertex 1 to vertex 2 essentially extends parallel to the upper edge of the sleeve ( 7 ) at a distance (d) of about 5 mm. The connection of vertex 2 to vertex 3 essentially extends along the φ=48° line. The connection of vertex 3 to vertex 4 essentially extends parallel to the upper edge of the sleeve ( 7 ) shown in the 3D-model. The connection of vertex 4 to vertex 1 essentially extends along the septal line ( 616 ). The corners of the augmentation unit A1 are rounded and describe a circular arc with a diameter of 4 mm.
[0112] In this example, augmentation unit A2 extends from vertex 1 (φ=116°; z=69) via vertex 2 (φ=182°; z=74) and vertex 3 (φ=212°; z=37) to vertex 4 (φ=116°; z=26) and, in the implanted state, lies flat against the left ventricle. The connection of vertex 1 to vertex 2 essentially extends parallel to the upper edge of the sleeve ( 7 ) at a distance (d) of about 5 mm. The connection of vertex 2 to vertex 3 essentially extends along the septal line ( 616 ). The connection of vertex 3 to vertex 4 essentially extends parallel to the upper edge of the sleeve ( 7 ) shown in the 3D-model.
[0113] The connection of vertex 4 to vertex 1 essentially extends along the φ=116° line. The corners of the augmentation unit A2 are rounded and describe a circular arc with a diameter of 4 mm.
[0114] In this example, the augmentation unit A3 extends from vertex 1 (φ=235°; z=92) via vertex 2 (φ=303°; z=108) and vertex 3 (φ=303°; z=64) to vertex 4 (φ=235°; z=48) and, in the implanted state, lies flat against the right ventricle. The connection of vertex 1 to vertex 2 essentially extends parallel to the upper edge of the sleeve ( 7 ) at a distance (d) of about 5 mm. The connection of vertex 2 to vertex 3 essentially extends along the φ=303° line. The connection of vertex 3 to vertex 4 essentially extends parallel to the upper edge of the sleeve ( 7 ) shown in the 3D-model. The connection of vertex 4 to vertex 1 essentially extends along the φ=235° line. The corners of augmentation unit A3 are rounded and describe a circular arc with a diameter of 4 mm.
[0115] The positioning unit P in the example of FIG. 17 is designed to essentially fill the spaces between the augmentation units ( 71 ) on the sleeve ( 7 ). The positioning unit ( 72 ) can also be described as a positioning unit ( 72 ) with extensions, which fill in the areas of the sleeve ( 7 ) that are not filled by the augmentation units. In this embodiment, the positioning unit P is essentially located at a lateral distance (d) from the augmentation units ( 71 ) and the upper edge of the sleeve ( 7 ) of about 5 mm. The positioning unit ( 72 ) is also located at a distance from the cutting line ( 615 ), which can be advantageous during manufacturing. If the sleeve ( 7 ) with the expandable unit is formed in a two-dimensional state, all augmentation units ( 71 ) and positioning units ( 72 ) can be attached to the sleeve ( 7 ) before the sleeve ( 7 ) is rolled into a three-dimensional form.
[0116] In the example of FIG. 17 , the lines ( 41 ) supplying the expandable units ( 71 , 72 ) are hydraulic or pneumatic lines ( 41 ) extending radially from the lower edge of the sheath to the augmentation units. The line ( 41 ) for the augmentation unit A2 extends along the line φ=15° and ends at the height of z=54. The line ( 41 ) for augmentation unit A2 extends along the line φ=165° and ends at the height of z=31. The line ( 41 ) for augmentation unit A3 extends along the line φ=270° and ends at the height of z=65. The line ( 41 ) for the positioning unit P extends along the line φ=330° and ends at a height of z=25.
Example #2
[0117] FIG. 18 shows an embodiment for a sleeve ( 80 ) with at least one sensor ( 81 ) and/or an electrode ( 82 ). Shown in FIG. 18 is a rollout as described in conjunction with FIG. 13 . The sleeve ( 80 ) of this embodiment includes eight sensors ( 81 ) or electrodes ( 82 ), whereby four of these are pressure sensors (force sensor FS1, FS2, FS3, FS4) ( 81 ), and four are electrocardiogram electrodes (e.g., ECG1, ECG2, ECG3, ECG4) ( 82 ). The sleeve ( 80 ) can be made of a synthetic material, polymer, natural rubber, rubber, latex, silicon or polyurethane. The sleeve ( 80 ) can have a thickness of 0.1 to 1 mm, preferably 0.2 mm to 0.5 mm. The four pressure sensors ( 81 ) can be integrated into the sleeve ( 80 ), for example, molded or welded to the inside surface of the sheath. The pressure sensors ( 81 ) can be equipped with reinforcements, which can prevent bending during the compression of the device. The ECG electrodes ( 82 ) can be attached at the side of sleeve ( 80 ) facing the heart. In the embodiment in FIG. 18 , a system of coordinates is depicted as described in conjunction with FIG. 13 . Using the coordinate system, the positions of the sensors ( 81 ) and electrodes ( 82 ) can be determined as follows: pressure sensor FS1 is located at coordinate (φ=17°; z=71), pressure sensor FS2 is located at coordinate (φ=158°; z=48), pressure sensor FS3 is located at coordinate (φ=268°; z=78), pressure sensor FS4 is located at coordinate (φ=67°; z=61). ECG electrode ECG1 is located at coordinate (φ=76°; z=54), ECG electrode ECG2 is located at coordinate (φ=352°; z=39), ECG electrode ECG3 is located at coordinate (φ=312°; z=93) and ECG electrode ECG4 is located at coordinate (φ=187°; z=18). For smaller or larger hearts, the angular coordinates for the sensors ( 81 ) and/or electrodes ( 82 ) essentially remain the same; while the z-value is scaled by a factor. For example, for smaller hearts, the scaling factor can be between 0.85 and 0.95, and for larger hearts, the scaling factor can be between 1.05 and 1.15.
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A method of sheathing a heart including inserting an expandable heart sheath into a living body with the sheath held in a collapsed state. The sheath is released to allow the sheath to expand inside the body. At least a portion of the heart within the body is surrounded by the expanded sheath. The method of forming a custom heart sheath includes determining a three-dimensional outer surface of a particular heart, determining a desired three-dimensional shape of a sheath for the particular heart, as a function of a shape of the determined outer surface of the heart and then forming a custom heart sheath to have the desired three-dimensional shape.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application 61/877,261 filed Sep. 12, 2013 and the benefit of U.S. Provisional Application 61/796,420 filed Nov. 10, 2012, the respective disclosures of which are incorporated herein by reference.
BACKGROUND
[0002] The present invention relates to acceleration sensing and, more particularly, acceleration sensors utilizing superconducting (SC) materials operating at cryogenic temperatures and useful, for example, for sensing acceleration caused by movement of the sensor relative to its surroundings and for sensing accelerations associated with the detection of gravitational fields and gravitational waves.
SUMMARY
[0003] Electrons, including normal (non-superconducting) electrons and superconducting (SC) electrons, have a measurable mobility attribute in vacuum and in media (including non-SC and SC media). Measurement of the charge attributes (e.g., charge accumulation, charge distribution, and motion of charge) and the magnetic fields produced by the SC electrons in SC media include measurement of non-uniform quantum mechanical phases of the SC electrons and currents including SC Cooper-pair currents. A detection or measurement system for the charge attributes may include well-known standard devices such as SQUIDS, Josephson junctions, electromagnetic radiation detectors (the radiation results from the motion of charges), and magnetic-field measurement devices. A detection or measurement system may also include the probing of the mobile charge containing/conducting system with magnetic fields or charges and currents (both DC and AC) and deliberately moving the charge containing/conducting system (including rotation thereof about an axis or orbiting thereof about an axis) or measurement device to augment and/or enhance the charge situation or magnetic field measurements.
[0004] The present invention relates to instrumentation that functions as accelerometers, gravity meters, gravity gradiometers, gravitational wave detectors, and gravitational field detectors or sensors and which employ superconducting elements as well as those which employ no superconductivity, but, instead, employ cooled and superconducting elements to achieve improve sensitivity.
[0005] The present invention also relates to devices which detect electric fields and shifts in charge in structures and currents within and between different structures. The basic structures or element of these instruments are bars (rods, wires, longitudinally extending cylinders, or other configurations) which, when accelerated or being acted upon by a gravitational field, are distorted (compressed or stretched) sufficiently to effect a charge redistribution. FIG. 1 illustrates two simple charge distribution states in conductive rods A 1 and A 2 , both of which are aligned in the local gravity field. In rod A 1 , the positive charge is upward; in rod A 2 , the positive charge is downward. An unchanged or nearly unchanged charge distribution and non-isotropic charge distribution state is also possible.
[0006] The present disclosure presents ways to detect the above-described charge distribution and any redistribution thereof as a result of the g-fields and changing g-fields. As explained in more detail below, the conducting bars A 1 and A 2 are connected by a wire and a switch at the top and another wire and switch at the bottom to create a closed shunting circuit that allows observation of the current or changes in current therein. Additionally, electric field sensing devices can be used to detect charge redistribution(s) within the device without the need to place the bars in a shunt circuit configuration.
[0007] FIG. 2 shows how charge is distributed in a conductive metallic rod at rest in the gravity field. The gravity field causes the lower portions of the rod to undergo axially compression relative to the upper portion of the rod; thus, gravity causes a density gradient in the rod that increases toward the bottom end of the rod. For many metallic conductors, this gravity-induced inhomogeneous deformation of the lattice creates a chemical-potential gradient, which redistributes the mobile electrons toward and to the top of the rod, as shown in FIG. 2 . As a consequence, the conductive metallic rod accumulates a negative charge on the top and a positive charge on the bottom. This charge distribution has been described by Dessler (Dessler et al 1968) and confirmed experimentally by Beams (Beams 1968). The same redistribution of charge occurs if the rod is suspended by a non-conductive strand from above, since it is the gradient of the density of the material which causes the charge redistribution.
[0008] If two different materials, A and B, are used for the rods, one may obtain a difference in E-field between the two different-material rods; FIG. 3 shows the basic difference in charge distribution in two different rods of two different materials, A and B.
[0009] As shown in FIG. 4 , the simplest way of detecting the difference is charge distribution is to connect the rods via switches in a parallel-circuit organization so that each rod shunts (i.e., shorts-out) the other rod. When both switches are closed, a current transients will flow through the current sensing device I, which can include a superconducting SQUID sensor and its related circuitry.
[0010] After the initial pulse of current, the charge will redistribute itself between the rods and the charge within the lattice structure of each rod with also redistribute. The momentary current spike is related to the charge distribution which is related to g; thus, measurements of the E-field may also be used to determine g and time-varying changes thereof.
[0011] When used as an accelerometer, the apparatus in FIG. 4 will be sensitive to motion of the detector circuit along an axis when the switches closed. Similarly, the detector circuit will be sensitive to the motion of a massive object moving in one direction or the other along a sensing axis. Further, the detector circuit will be sensitive to gravitational waves. A three axis (or more) detector “cluster” may be used to detect changes in the g-field in three orthogonal directions.
[0012] The basic elements may be used in several winding configurations and circuits both stationary and rotating or moving. Other circuit elements such as voltage sources may be added as needed. Further, piezoelectric elements may be used.
[0013] The electric field in the conductor is given by (Dessler et al 1968)
[0000] E=−αMg/e+m e g/e (1)
[0014] where α is a dimensionless number approximately between 0.1 and 1.0 and depends on the material, M is the ion mass of the lattice, g is the gravitational acceleration, e is the charge on an electron, and m e is the mass of an electron. Since M>>m e we have from Eq (1).
[0000] E≈−αMg/e (2)
[0015] For copper α≈1/7, and
[0000] E Cu ≈10 −6 Volt/meter (3)
[0016] FIG. 5 presents the values of pertinent parameters for several example conductors.
[0017] Adler, in a paper in Nature (Adler 1976), disclosed this phenomenon for detection of gravitational waves, where Adler's conductors were many kilometers in length and advocated superconductors only for noise reduction.
[0018] The total compression of a rod will be given by
[0000] Δ L=ρg/ (2 Y ) (4)
[0019] and the work done in deforming the rod is given by
[0000] W=ρ 2 g 2 SL 3 /(6 Y ) (5)
[0020] where ρ is the density, S is the cross sectional area, L is the length, and Y is Young's modulus of the rod.
[0021] Using the table shown in FIG. 5 , the values of ionic mass and Young's modulus for vanadium and lead indicates that these metals could provide a considerable difference in electric field and difference in charge distribution under the action of a gravitational field and thus be suitable elements for a sensing device. Furthermore, both of these elements become superconducting at sufficiently high temperature.
[0022] Experimental results indicate that for the rod in FIG. 2 , the energy of deformation in the rod is being transformed into electronic motion which results in the charge distribution shown therein. Rather than moving down, the electrons move up as a result of the ionic compression. The upward force on the electrons is much greater than the direct gravitational force on the electrons, and constitutes energy transfer from the lattice to electrons as shown in FIG. 2 . When the circuit is closed ( FIG. 4 ), some of the deformation energy is transferred into electric current; if the material is superconducting, this current will persist.
[0023] If all of the deformation energy of one conductor as given by Eq. (4) were converted into current, the current would be:
[0000] I=e (2 WnS/ ( m e L )) 1/2 (6)
where n is number density of electrons. Substituting the value for deformation energy into Eq (6), this current is:
[0000] I=eM Tot g ( n /(3 Ym e )) 1/2 (7)
[0025] where M Tot is the mass of the rod.
[0026] As an example, consider a Copper wire with diameter 0.1 micron and L=1 meter. The deformation energy is 10 −16 joule. Even if 1 percent of this energy is converted into current, the initial current, for a configuration shown in FIG. 4 , will be approximately 10 microampere. This will be somewhat reduced because the conductor on the left will resist this current, but current at this level is easily detectable. For much smaller values of g, or changes in g, multiple loops could be used as shown in the figures below (for example a toroidal winding or other winding may employ many thousands of loops). Copper was used here because a accurate value a for Copper is known since copper cannot become superconducting, other suitable materials are available.
[0027] An example of a basic single-axis accelerometer is presented in FIG. 6 and is designated generally by the reference character 10 . As shown, the accelerometer 10 is shown as a loop 12 of a superconducting wire (or foil strips) of length L and width W. Current detector D 1 is shown at the lower right of the loop 12 and, if desired, a second or further detectors, such as detector D 2 , located within the loop 12 , can be used. Detector D 1 senses any magnetic field immediately proximate the adjacent superconductor pathway while the second detector D 2 detects any magnetic field developed by the loop 12 . The detector or detectors are preferably of the SQUID type that measure magnetic fields. As is well-known, SQUID detectors in their simplest form include a closed superconducting path (typically, cryogenically cooled niobium having a plurality of Josephson junctions) cooperating with a pick-up coil that provides an output signal to a signal processing pathway. In FIG. 6 , the accelerometer 10 detects acceleration parallel to the longer sides L. The superconducting pathway on the left (dotted-line illustration) is fabricated in bar or wire form of a first superconducting material SC 1 having cross-sectional area S and, in a similar manner, the superconducting pathway on the right (solid-line illustration) is fabricated in bar or wire from of second superconducting material SC 2 , also having a cross-sectional area S. In an exemplary embodiment, tin (Sn) and lead (Pb) are suitable for use as the superconducting materials. The electrons in the superconductor materials SC 1 and SC 2 have respective effective masses m eff1 and m eff2 (assuming that effective masses are different than bare masses). The Cooper-pair number density of the superconducting electrons for the respective first and second superconductors are n 1 s and n 2 s and, in this example, n 1 s <n 2 . While not shown in FIG. 6 , the left and right superconducting pathways are attached to or formed on an underlying dielectric (i.e., non-conducting) substrate, as represented by the substrate 16 in FIG. 8 . While the left and right superconducting pathways of the bi-SC loop 10 are shown as of equal path-length, some applications may use non-equal path-lengths.
[0028] The left and right superconducting pathways can be formed by thin-film techniques in which the different materials are deposited on a non-conducting, dielectric substrate 16 ( FIG. 8 ) by sputtering, plasma deposition, chemical vapor deposition, atomic layer deposition, etc. with the ends of the different superconductor pathways overlapped or otherwise connected to form a closed current-conducting loop. If desired, thick-film techniques can be use in which pre-cursor materials are applied to the substrate and heated to form the desired pathway pattern. In some cases, thin foils fabricated from appropriate superconductor materials can be attached or adhered to the substrate to form the loop 12 , and, for elemental superconductors, atomic layer deposition (ALD) techniques are suitable.
[0029] FIG. 7 illustrates that the size and shape of the superconducting pathway can be different from that shown in FIG. 6 , such as the curved pathways shown, depending upon the particular application.
[0030] FIG. 8 shows the detector mounted to the substrate 16 or mounting plate. In that case where the arrangement of FIG. 8 is in alignment with the local gravity vector, changes in gravitational acceleration are subject to detection and, where the arrangement of FIG. 8 is accelerating relative to its surroundings, the acceleration is likewise subject to detection. In FIG. 8 , the acceleration of the electrons is in the clockwise direction so the rate of change of the current is in the counterclockwise direction, as shown.
[0031] FIG. 9 represents an equivalent circuit for the configuration of FIG. 6 , while FIG. 10 represents an equivalent circuit for to coupled sensing loops as shown in FIG. 11A .
[0032] The sensing devices consistent with the present invention have a number of practical applications including use as a rate gyro. Rotational motion of the SC loop will create a circular current that is caused by the absence of friction between the ionic lattice and the Cooper pairs. Moreover, if the wire diameter is chosen to be about the London penetration depth, then the Meissner effect will not zero the effect of Cooper pair motion delaying vs. the lattice motion. The overall situation corresponds to the London momentum of rotating superconducting bodies which was described as a gyroscope.
[0033] Other uses for the superconducting devices consistent with the invention include gravitational wave detection, as described below.
BRIEF DESCRIPTION OF THE DRAWING
[0034] FIG. 1 illustrates two simple charge distribution states in conductive rods, both of which are aligned in the local gravity field;
[0035] FIG. 2 illustrates charge distribution in a conductive metallic rod at rest in the gravity field;
[0036] FIG. 3 shows the basic difference in charge distribution in two different rods of two different materials;
[0037] FIG. 4 illustrates the rods of FIG. 3 in a shunting circuit;
[0038] FIG. 5 presents the values of pertinent parameters for several example conductors;
[0039] FIG. 6 is an idealized drawing of a basic single-axis accelerometer showing a superconducting loop having a length and a width;
[0040] FIG. 7 is a variation of FIG. 6 and indicates that the superconductors can be curved or curvilinear;
[0041] FIG. 8 illustrates an exemplary loop configuration attached to a mounting plate and subject to an acceleration force g(t);
[0042] FIG. 9 illustrates an equivalent circuit for the configuration of FIG. 8 ;
[0043] FIG. 10 illustrates an equivalent circuit for two magnetically coupled circuits of the type shown in FIG. 9 ;
[0044] FIG. 11A is an idealized drawing of a dual-loop single-axis accelerometer;
[0045] FIG. 11B is a detail view of loop portions in relationship to a detector;
[0046] FIGS. 12A , 12 B, and 12 C are respective front, side, and rear views of a single superconducting loop device showing an exemplary processing path;
[0047] FIGS. 13A , 13 B, and 13 C are respective front, side, and rear views of a dual superconducting loop device;
[0048] FIG. 14A is isometric view of a single superconducting device have a substantial depth dimension relative to its length and width dimensions;
[0049] FIG. 14B is a variant of the configuration shown in FIG. 14A ;
[0050] FIG. 15 is perspective view of a helically extending superconducting coil;
[0051] FIG. 16 is perspective view of a helically extending superconducting coil configured as a toroid;
[0052] FIGS. 17A , 17 B, 17 C, 17 D, and 17 E present a multi bi-loop superconducting arrangement;
[0053] FIGS. 18 and 19 represent a further configuration;
[0054] FIGS. 20A-20D represent different connection patterns;
[0055] FIGS. 21A , 21 B, and 21 C presents configurations incorporating the principles of the present invention as antenna structures for detecting gravitational waves;
[0056] FIG. 22A presents a further embodiment and includes two spaced-apart longitudinally extending antenna;
[0057] FIG. 22B illustrates the antenna of FIG. 22A as connected at their respective ends for form a loop;
[0058] FIG. 23 is an isometric view of two loops of the type shown in FIG. 22B ;
[0059] FIG. 24 is an isometric view of a plurality or a multitude of loops of the type shown in FIG. 22B ;
[0060] FIG. 25 is an isometric view of a detector array in which individual loops of the type shown in FIG. 23 are arrayed in a cylindrical pattern;
[0061] FIG. 26 illustrates different interconnection arrangements for the individual loops of the type shown in FIG. 23 ;
[0062] FIG. 27 illustrates the interdigitated pattern of sensing loops of FIG. 25 ;
[0063] FIG. 28 illustrates the manner in which plural detector arrays of FIG. 25 can be nested together for increased sensitivity; and
[0064] FIG. 29 illustrates an open loop connection circuit for the detector array of FIG. 25 .
DESCRIPTION
[0065] A single bi-loop device 20 is shown in respective front, side, and rear views in FIGS. 12A , 12 B, and 12 C. As shown, the left side of the loop device 20 in FIG. 12A is fabricated from a first superconductor SC 1 (e.g., tin), as represented by the hash marks, and the right side is fabricated from a second superconductor SC 2 (e.g., lead) with ends of the two different materials joined at 22 , for example, by overlapping the two materials. The SQUID detector D is of the classic “washer” profile with a downwardly extending tab (unnumbered, best shown in FIG. 12C ). As shown in the side view of FIG. 12B , the downwardly extending tab is positioned behind the loop 20 . The detector D includes a pick-up coil 24 that supplies a sensed electrical value to a signal processing unit 26 which provides an output to a suitable device, such as a display 28 . SQUID detector systems are well-known commercially available devices and typically include an integrated cryogenic cooling system (not shown) and program-controlled computer processing pathways. While SQUID detector systems are presently preferred, other systems using different technologies may be equally suitable.
[0066] A dual bi-loop device 30 is shown in respective front, side, and rear views in FIGS. 13A , 13 B, and 13 C. As shown, loop 1 is fabricated in the same manner as that of FIG. 13A and a second similarly fabricated loop, loop 2 , is positioned behind the loop 1 with the superconductor SC 1 in substantial registration or alignment with the superconductor SC 2 of the second loop, loop 2 . As shown in FIG. 13B , the tab of the detector D is positioned between the two loops.
[0067] In the embodiments of FIGS. 12A-12C and 13 A- 13 C, the superconducting pathways can be formed by thin-film techniques in which the different materials are deposited on a non-conducting, dielectric substrate by sputtering, plasma vapor deposition, chemical vapor deposition, etc. with the ends of the different superconductor pathways overlapped or otherwise connected to form a closed current-conducting loop. If desired, thick-film techniques can be use in which pre-cursor materials are applied to the substrate and heated to form the desired pathway pattern. In some cases, thin-foils fabricated from appropriate superconductor materials can be attached or adhered to the substrate, and, in other cases, elemental superconductors can be deposited by atomic layer deposition techniques (ALD).
[0068] A loop-type device having a substantial depth dimension is shown in perspective view in FIG. 14A and designated generally therein by the reference character 30 . As shown, a sheet-like structure having the profile shown is fabricated from a first superconductor SC 1 (as indicated by the dot pattern) and a second sheet-like structure is fabricated from a second superconductor and joined along seam lines 32 and 34 at the top and bottom to create a relatively narrow loop-like profile with a relatively substantial depth dimension. A slot 36 is formed in the upper portion of the device 30 for receiving the sense-tab of the detector D. As indicated at 36 ′ in FIG. 14A , the sense tab of the detector D can also be inserted into the open space between the two superconductors.
[0069] FIG. 14B illustrates a variant of the configuration of FIG. 14A ; as shown, the upper edges of each superconductor sheet, SC 1 and SC 2 , are connected by a conductor 38 with the detector D positioned in magnetic proximity thereto. If desired, the a transient response similar to that discussed above with respect to FIG. 4 and be obtained by placing a selectively operate switch in the conductor 38 .
[0070] FIG. 15 illustrates a device in the form of a wire (or foil strip) helically wound about a longitudinally extending axis A x and designated generally by the reference character 40 therein. While the helix is shown with six flights, the helix is extendible along the X axis and its diameter and interflight spacing can be changed for varied. The device 40 is formed from a linearly extending wire (or foil strip) having alternating segments of a selected length of the first superconductor SC 1 and selected lengths of the second superconductor SC 2 ; the multi-segment wire is then formed into a helix of selected diameter and interflight spacing for as many flights as desired with the junctions 42 between each alternating segment forming one-half of a flight. As shown at the top of the helix of FIG. 15 , the various junctions 42 align with one another, as do the junctions 42 at the bottom of the helix. When viewed in side elevation, the flights alternate between the first superconductor SC 1 and the second superconductor SC 2 . The opposite ends of the helix are connected by a superconducting segment 44 with the detector 44 (shown in schematic form) located in magnetic proximity thereto.
[0071] FIG. 16 illustrates a variant of the axially extending helix of FIG. 15 . In FIG. 16 , the device 50 is formed as a wire (or foil strip) helically wound about a circular toroidal axis with a selected diameter and interflight spacing. The device 50 is formed from a linearly extending wire (or foil strip) having alternating segments of a selected length of the first superconductor SC 1 and selected lengths of the second superconductor SC 2 ; the multi-segment wire is then formed into a helix of selected diameter and interflight spacing along the circular toroidal axis with the junctions 52 between each alternating segment forming one-half of a flight. As shown at the top of the helix of FIG. 16 , the various junctions 42 align with one another along a circular path, as do the junctions at the bottom of the toroidal helix (not shown). When viewed in side elevation, the flights alternate between the first superconductor SC 1 and the second superconductor SC 2 . The opposite ends of the helix are connected together with the detector D (not shown) inserted between any two flights in magnetic proximity thereto.
[0072] FIGS. 17A-17D illustrate a further design for the device, as indicated by the reference character 60 . A shown in the elevational view of FIG. 17A , the device 60 consists of a plurality of alternating wires (or foil strips) of the first superconducting material SC 1 (dotted-line illustration) and the second superconducting material SC 2 (solid-line illustration) to define sub-components 62 . As shown in FIGS. 17B and 17C , a wire (or foil strip) of the first superconducting material SC 1 (dotted-line illustration) and the second superconducting material SC 2 (solid-line illustration) are joined at their respective lower ends, as shown to form a sub-component 62 . The various sub-components 62 are aligned in substantial registration with each other along the linearly extending axis A x in an alternating interdigitated fashion as shown in FIG. 17D .
[0073] The upper ends of the various sub-components 62 are connected as shown in FIG. 17E . On the left in FIG. 17E , the upper ends of all the first superconductor materials SC 1 are connected together along a common connection path CCP 1 - 1 and, on the left in FIG. 17E , the upper ends of all the second superconductor materials SC 2 are connected together along a common connection path CCP 1 - 2 . In a similar manner and on the right side of FIG. 17E , the upper ends of all the first superconductor materials SC 1 are connected together along a common connection path CCP 1 - 2 and the upper ends of all the second superconductor materials SC 2 are connected together along a common connection path CCP 2 - 2 . The common connection path CCP 1 - 1 is electrically connected to the common connection path CCP 2 - 2 via the path “M”, and, in a similar manner, the common connection path CCP 1 - 2 is electrically connected to the common connection path CCP 2 - 1 via the path “N”. The detector (not shown) can be positioned in magnetic proximity to any on of the current carrying paths.
[0074] FIGS. 18 , 19 , and FIGS. 20A-20D illustrate a further variant of the sensor, designated generally therein by the reference character 70 . As shown, the sensor 70 includes multiple tines 72 at opposite ends of a connection path 74 . As shown in FIG. 19 , an upper sub-assembly overlies and is in substantial registration with a lower sub-assembly with one sub-assembly being formed from a first superconductor material SC 1 and the other sub-assembly being formed from a second superconductor material SC 2 with the distal or remote ends of the tines 72 connected together at 76 . The detector D is positioned along the connection path 74 between the sub-assemblies.
[0075] FIG. 20A illustrates a first connection pattern between the ends of the tines as shown in FIG. 19 . In FIG. 20B , the tines of the first and second superconducting materials are offset from one another, and in FIG. 20C , the tines are both offset in interdigitated. FIG. 20D presents a row/column array of first and second superconducting materials “A” and “B” which interconnects are made to from loops.
[0076] The above-incorporated U.S. Provisional Application 61/877,261 filed Sep. 12, 2013 and U.S. Provisional Application 61/796,420 filed Nov. 10, 2012 disclose a configuration for an antenna type structure of superconductors “A” and “B” (as shown in FIGS. 21A and 21B ) for detecting the h + and h x polarizations of gravitational waves. In the case of the h x configuration ( FIG. 21B ), when rotated, is capable of also detecting the h + gravitational wave ( FIG. 21C ).
[0077] The detection of the quadrupolar gravitational waves is dependent upon the gravitational wave potential on the distance from the center of mass of the antenna. However, the problem can be addressed by sufficiently large consecutive bimetallic structures as FIGS. 21A and 21B demonstrates the two possible polarizations of the gravitational wave.
[0078] FIG. 22A represents a further embodiment including two spaced-apart antenna each of which includes a first superconductor SC 1 , as represented by the solid black portion, and a second superconductor SC 2 with ends of the two different materials joined, as represented by the dotted-lines in FIG. 22A , at their opposite ends as shown, or, as shown in FIG. 22B , by overlapping the two materials to form a continuous loop 100 . Thus, the loop structure in FIG. 22A has four segments, i.e., the first superconductor SC 1 segment followed by a second superconductor segment SC 2 , followed by a first superconductor SC 2 segment, and followed by a second superconductor segment SC 2 to close the loop 100 .
[0079] As shown by the X symbol in FIGS. 22A and 22B , the loop 100 can be mounted for rotation about an axis that passes through the geometry of the loop 100 or, if desired, mounted for orbiting or revolution about another axis (not shown) that does not pass through the geometry of the loop 100 .
[0080] As shown in FIGS. 22A and 22B , a detector D, such as the SQUID detector discussed above, can be positioned adjacent to or within the geometry of the loop 100 for measurement of any a magnetic fields or variations thereof produced by superconducting currents within the loop 100 .
[0081] FIG. 23 illustrates the organization of a dual-loop arrangement in which a first loop 100 - 1 is mounted adjacent to a second loop 100 - 2 to provide increased sensitivity. FIG. 24 illustrates the organization of a multi-loop arrangement in which a first loop 100 - 1 is mounted adjacent to a second loop 100 - 2 , along with a multitude of successive loops terminating with loops 100 -m and 100 -n to provide a ‘stacked’ array of loops. The number of such loops can be large (i.e. 10 6 -10 8 ) to increase sensitivity. As in the case of FIGS. 22A and 22B , the loop array can be rotated about an axis that passes through the geometry of the array or revolved or orbited about an axis that does not pass through the geometry of the array, as represented in schematic form by the axis A x shown on the right in FIG. 24 .
[0082] In the array shown in FIGS. 23 and 24 , each first superconductor segment SC 1 is interdigitated or interposed between each second superconductor segment SC 2 and each second superconductor segment is interdigitated or interposed between each first superconductor segment SC 1 . As shown, each of the first superconductor segments SC 1 of the loop 100 - 1 face a second superconductor segments SC 2 of the loop 100 - 2 , and, in a similar manner, each of the second superconductor segments SC 2 of the loop 100 - 1 face a first superconductor segment SC 1 of the loop 100 - 2 with this organizational sequence being maintained for all loops in the array.
[0083] While not shown in FIGS. 23 and 24 , one or more detectors D can be associated with each array to sense magnetic fields generated consequent to superconducting currents in the various loops.
[0084] FIG. 25 illustrates another embodiment of a detector array. The detector array 200 includes a substrate 202 formed into a hollow cylinder with a plurality of loops 100 distributed about the cylindrical substrate, preferably at an equi-angluar distribution. In FIG. 25 , the SC 1 /SC 2 stripes not explicitly shown as connected at the respective bottom and top of the substrate 202 . As shown in FIG. 26 on the left, the lower ends and the upper ends of the superconductor stripes can be connect by end caps 206 fabricated from both SC 1 and SC 2 . In another arrangement, as shown on the right in FIG. 26 , a “via” or similar aperture can be etched through (or formed by other techniques with the ends of the SC 1 /SC 2 stripes interconnected therethrough.
[0085] As shown in FIG. 27 , the substrate 202 can be formed initially as a flat member upon which the various SC 1 /SC 2 stripes are formed with their upper ends connected a shown, for example, in FIG. 26 . Thereafter, the substrate 202 in formed into the cylindrical form shown in FIG. 26 with the edges thereof attached or secured together.
[0086] While FIG. 25 illustrates a single cylindrical detector array, further detector arrays can be nested therein. As shown in FIG. 28 , a smaller diameter array 200 - 2 can be nested into the array 200 - 1 and even smaller diameter arrays 200 -n (not shown) further nested there into. Additionally, a further detector array (not shown) having an inside diameter larger than the outside diameter of the detector array 200 - 1 can receive the detector array 200 - 1 and any detector arrays received therein.
[0087] In the various device disclosed above, the devices operate at cryogenic temperature depending upon that critical temperature T c at which the material become superconducting. While not shown, it is assumed that a supply of cryogenic liquid and the necessary storage tanks, cryogenic pumps, distribution conduits, controls, etc. are provided with the various detector devices to effect cooling below the critical temperature T c for the materials used. While also not shown, SQUID detection systems often are used in environments that are shielded (e.g., a mu-metal magnetic “bottle”) from magnetic, electric, and electromagnetic fields, depending upon the particular application.
[0088] While many materials that exhibit superconductivity are known, the following table presents example superconductor densities for typical elemental superconductors.
[0000]
TABLE
Table of example SC densities of typical elements
Difference
Summed
Element
SC density
from Nb
with Nb
Product
n-factor
Nb
5.56E+22 cm −3
Nio-
bium
Al
1.81E+23 cm −3
1.25E+23
2.37E+23
1.01E+46
5.33E+45
Alu-
minum
Sn Tin
1.48E+23 cm −3
9.24E+22
2.04E+23
8.23E+45
3.73E+45
Pb Lead
1.32E+23 cm −3
7.64E+22
1.88E+23
7.34E+45
2.99E+45
[0089] In the one preferred form of the various detector arrays, the various loops are closed current loops (of which FIG. 6 is an example) in which current within the loops is sensed via one or more SQUID sensors as described. In another preferred form of the various detector arrays, the loops are in-circuit with one another (as shown in FIG. 17E , for example. The closed current loop of the embodiment of FIGS. 25 and 26 can be configured as in-circuit with one another as shown in FIG. 29 . While the circuit arrangement of FIG. 29 is intended to interface with a measuring device, a switch of the type shown in FIG. 4 can be used to periodically ‘shunt’ the sensing loops to provide transient current pulses representative of the transient charge redistribution.
[0090] As will be apparent to those skilled in the art, various changes and modifications may be made to the illustrated embodiment of the present invention without departing from the spirit and scope of the invention as determined in the appended claims and their legal equivalent.
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This invention detects mass and mass motion of external objects by virtue of its action as a gravimeter, gravity gradiometer, and detector of gravitational fields. This invention is for devices which function as accelerometers and gyroscopes for the bodies to which they are attached.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from provisional patent application Ser. No. 61/185,556, filed Jun. 9, 2009, entitled Helical Structure and Method for Plasma Lamp, which is incorporated by reference herein for all purposes.
BACKGROUND OF THE INVENTION
This invention relates to lighting techniques. In particular, the invention provides a method and device using a plasma lighting device having a shaped resonator assembly including a helical or coil structure, which is coupled to a radio frequency source. Such plasma lamps can be applied to applications such as stadiums, security, parking lots, military and defense, streets, large and small buildings, vehicle headlamps, aircraft landing, bridges, warehouses, uv water treatment, agriculture, architectural lighting, stage lighting, medical illumination, microscopes, projectors and displays, and similar uses.
From the early days, human beings have used a variety of techniques for lighting. Early humans relied on fire to light caves during hours of darkness. Fire often consumed wood for fuel. Wood fuel was soon replaced by candles, which were derived from oils and fats. Candles were then replaced, at least in part by lamps. Certain lamps were fueled by oil or other sources of energy. Gas lamps were popular and still remain important for outdoor activities such as camping. In the late 1800, Thomas Edison, who is one of the greatest inventors of all time, conceived the incandescent lamp, which uses a tungsten filament within a bulb, coupled to a pair of electrodes. Many conventional buildings and homes still use the incandescent lamp, commonly called the Edison bulb. Although highly successful, the Edison bulb consumed much energy and was generally inefficient.
Fluorescent lighting has replaced incandescent lamps for certain applications. Fluorescent lamps generally consist of a tube containing a gaseous material, which is coupled to a pair of electrodes. The electrodes are coupled to an electronic ballast, which helps ignite the discharge from the fluorescent lighting. Conventional building structures often use fluorescent lighting, rather than the incandescent counterpart. Fluorescent lighting is much more efficient than incandescent lighting, but often has a higher initial cost.
Shuji Nakamura pioneered the efficient blue light emitting diode, which is a solid state lamp. The blue light emitting diode forms a basis for the white solid state light, which is often a blue light emitting diode within a bulb coated with a yellow phosphor material. Blue light excites the phosphor material to emit white light. The blue light emitting diode has revolutionized the lighting industry to replace traditional lighting for homes, buildings, and other structures.
Another form of lighting is commonly called the electrodeless lamp, which can be used to discharge light for high intensity applications. Frederick M. Espiau was one of the pioneers that developed an improved electrodeless lamp. Such electrodeless lamp relied upon a solid ceramic resonator structure, which was coupled to a fill enclosed in a bulb. The dielectric resonator (dielectric waveguide) coupled the RF energy from an RF source to the bulb fill to cause it to discharge high intensity lighting. Although somewhat successful, the electrodeless lamp still had many limitations. The dielectric material (such as Alumina) used for the dielectric resonator/waveguide must have low losses at RF frequencies resulting in higher material cost. Furthermore, the dielectric resonator/waveguide is difficult to manufacture resulting in an expensive lamp. As an example, electrodeless lamps have not been successfully deployed in high volume for general lighting applications. Additionally, electrodeless lamps are generally difficult to disassemble and assembly leading to inefficient use of such lamps. These and other limitations may be described throughout the present specification and more particularly below.
From the above, it is seen that improved techniques for lighting are highly desired.
BRIEF SUMMARY OF THE INVENTION
According to the present invention, techniques for lighting are provided. In particular, the present invention provides a method and device using an electrodeless plasma lighting device having a shaped resonator assembly including a helical or coil structure, which is coupled to a radio frequency source. Such plasma lamps can be applied to applications such as stadiums, security, parking lots, military and defense, streets, large and small buildings, vehicle headlamps, aircraft landing, bridges, warehouses, uv water treatment, agriculture, architectural lighting, stage lighting, medical illumination, microscopes, projectors and displays, any combination of these, and the like.
In a specific embodiment, the present invention provides a plasma lamp apparatus. The apparatus includes a post structure comprising a material overlying a surface region of the post structure, which has a first end and a second end. The apparatus also has a helical coil structure operably configured along one or more portions of the post structure according to a specific embodiment. In a preferred embodiment, the helical coil acts as an inductive coupling structure and also facilitates thermal energy transport. The apparatus has a bulb device configured to the first end of the post structure, which is coupled to the helical coil structure. In a preferred embodiment, the bulb device comprises a gas filled vessel that is filled with an inert gas such as Argon and a fluorophor or light emitter such as Mercury, Sodium, Dysprosium, Sulfur or a metal halide salt such as Indium Bromide, Scandium Bromide, or Cesium Iodide (or it can simultaneously contain multiple fluorophors or light emitters). The gas filled vessel can also include a metal halide, or other metal pieces that will discharge electromagnetic radiation according to a specific embodiment. The device has a resonator coupling element configured to feed radio frequency energy to at least the helical coil structure and to cause the bulb device to emit electromagnetic radiation. In a specific embodiment, the radio frequency energy has a frequency ranging from 1000 MHz to less than about 8 MHz, but can be others. As used herein, the terms “first” and “second” are not intended to imply order and should be interpreted by ordinary meaning. Additionally, such terms may be defined by at least the descriptions provided in the specification as well as by meanings consistent with one of ordinary skill in the art.
In an alternate embodiment of the present invention, a method for lowering the resonant frequency and improving the heat transfer characteristics of the device is created. The method includes creating a helical shaped RF output coupling-element that is either wrapped around a dielectric material, or simply coiled through air. The presence of a dielectric medium within the helical shaped RF output coupling-element serves to more efficiently absorb thermal energy that is generated by the bulb and subsequently transferred through the RF output coupling-element and the dielectric material. In creating a helical shaped RF output coupling element, the inductance of the resonant structure is increased leading to lower resonant frequencies at which the device operates at without substantially changing the size of the resonant structure. In lowering the operational resonant frequency, amplifiers with higher efficiencies can be used to operate the lamp. Alternatively the lower frequency resonator can be used to couple RF energy to larger bulbs and in conjunction with higher power amplifiers, higher lumens output lamps can be realized. Adding a dielectric material within the helical shaped RF output coupling element, helps in transferring the heat from the bulb to the resonator/lamp body.
Still further, the present invention provides an apparatus for a plasma lamp. The apparatus includes a gas filled vessel. The apparatus also includes a first coil structure comprising a first end and a second end. Preferably, the first end is coupled to the gas filled vessel. The apparatus also includes a second coil structure, which is coupled with one or more portions of the first coil structure.
Moreover, the present invention provides an alternative plasma lamp apparatus. The apparatus has a support structure having a first end and a second end and a coil structure configured along one or more portions of the support structure according to a specific embodiment. The apparatus also has a bulb device configured to the first end of the support structure according to a specific embodiment. The apparatus has a ground potential coupled to the second end of the support structure and a coupling element configured to feed at least radio frequency energy to at least the coil structure and to cause the bulb device to emit electromagnetic radiation. Still further, the present invention provides a method of improving heat transfer of an electrode-less plasma lamp according to an alternative embodiment. The method includes using a helical shaped element to draw thermal energy from a plasma lamp to a thermal sink region in a specific embodiment.
Benefits are achieved over pre-existing techniques using the present invention. In a specific embodiment, the present invention provides a method and device having configurations of input, output, and feedback coupling elements that provide for electromagnetic coupling to the bulb whose power transfer and frequency resonance characteristics that are largely independent of the conventional dielectric resonator, but can also be dependent upon conventional designs. In a preferred embodiment, the present invention provides a method and configurations with an arrangement that provides for improved manufacturability as well as design flexibility. Other embodiments may include integrated assemblies of the output coupling element and bulb that function in a complementary manner with the present coupling element configurations and related methods for street lighting applications. Still further, the present method and device provide for improved heat transfer characteristics, as well as further simplifying manufacturing and/or retrofitting of existing and new street lighting, such as lamps, and the like. In a specific embodiment, the present method and resulting structure are relatively simple and cost effective to manufacture for commercial applications. In a specific embodiment, the present invention includes a helical resonator structure, which increases inductance and therefore reduces the resonating frequency of a device. In a preferred embodiment, the resonating frequency may be about 250 MHz and less or about 100 MHz and less depending upon the type of coil, number of windings, and other parameters. In a specific embodiment, the present method and lamp device has a substantially exposed arc, in contrast to conventional plasma lamps where the arc of the bulb is substantially surrounded by the dielectric resonator/waveguide limiting the ability of the lamp to be used with typical luminaries. Depending upon the embodiment, one or more of these benefits may be achieved. These and other benefits may be described throughout the present specification and more particularly below.
The present invention achieves these benefits and others in the context of known process technology. However, a further understanding of the nature and advantages of the present invention may be realized by reference to the latter portions of the specification and attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a generalized schematic of a gas-filled vessel capacitively coupled to an RF source.
FIG. 1B is a generalized schematic of a gas-filled vessel inductively coupled to an RF source.
FIG. 2A is a simplified perspective view of an external resonator electrodeless lamp, including an RF amplifier.
FIG. 2B is a simplified perspective view of an alternate external resonator electrodeless lamp, including an RF source.
FIG. 2C is a simplified perspective view of an alternate external resonator electrodeless lamp.
FIG. 3A is a simplified perspective view of an integrated bulb/output coupling-element without a top coupling-element.
FIG. 3B is a simplified side-cut view of the integrated bulb/output coupling-element assembly shown in FIG. 3A .
FIG. 3C is a simplified perspective view of an alternate integrated bulb/output coupling-element assembly to the one shown in FIG. 3A .
FIG. 3D is a simplified side-cut view of the alternate integrated bulb/output coupling element assembly shown in FIG. 3C .
FIG. 4A is a simplified perspective view of an alternate integrated bulb/output coupling-element that is helically shaped in structure and encompasses air according to an embodiment of the present invention.
FIG. 4B is a simplified perspective view of an alternate integrated bulb/output coupling-element that is helically shaped in structure and encompasses a dielectric material with a metal insert that allows for the tuning of the resonance frequency according to an embodiment of the present invention.
FIG. 5A is a simplified cross section of a coil electrodeless lamp where the output support structure that contains the gas-filled vessel is separated from a grounded support structure by a single metal coil element according to an embodiment of the present invention. It is coupled to a resonator coupling element that is straight and adjacent to the output support structure.
FIG. 5B is a simplified cross section of a coil electrodeless lamp where the output support structure that contains the gas-filled vessel is separated from the grounded support structure by a metal coil element wound tightly to a non-conductive support structure according to an embodiment of the present invention. It is coupled to a resonator coupling element that is straight and adjacent to the output support structure.
FIG. 5C is a simplified cross section of a coil electrodeless lamp where the output support structure that contains the gas-filled vessel is separated from the grounded support structure by a metal coil element wound around but not touching a non-conductive support structure according to an embodiment of the present invention. It is coupled to a resonator coupling element that is straight and adjacent to the output support structure.
FIG. 5D is a simplified cross section of a coil electrodeless lamp where the output support structure that contains the gas-filled vessel is separated from the grounded support structure by a spiral coil strips attached or painted around a non-conductive support structure according to an embodiment of the present invention. It is coupled to a resonator coupling element that is straight and adjacent to the output support structure.
FIG. 6A is a simplified cross section of a coil electrodeless lamp where the output support structure that contains the gas-filled vessel is separated from a grounded support structure by a single metal coil element. It is coupled to a resonator coupling element that is a second coil that surrounds the first coil element according to an embodiment of the present invention.
FIG. 6B is a simplified cross section of a coil electrodeless lamp where the output support structure that contains the gas-filled vessel is separated from the grounded support structure by a metal coil element wound tightly to a non-conductive support structure. It is coupled to a resonator coupling element that is a second coil that surrounds the first coil element according to an embodiment of the present invention.
FIG. 6C is a simplified cross section of a coil electrodeless lamp where the output support structure that contains the gas-filled vessel is separated from the grounded support structure by a metal coil element wound around but not touching a non-conductive support structure. It is coupled to a resonator coupling element that is a second coil that surrounds the first coil element according to an embodiment of the present invention.
FIG. 6D is a simplified cross section of a coil electrodeless lamp where the output support structure that contains the gas-filled vessel is separated from the grounded support structure by a spiral coil strips attached or painted around a non-conductive support structure. It is coupled to a resonator coupling element that is a coil that surrounds the spiral coil strips according to an embodiment of the present invention.
FIG. 7A is a simplified cross section of a coil electrodeless lamp where the resonator coupling element is a coil and is separated by a gap from the output support structure according to an embodiment of the present invention. The output support structure can be any embodiment of the structures described in the preceding figures or it can be a straight metal structure that is grounded on one side.
FIG. 7B is a simplified cross section of a coil electrodeless lamp where the resonator coupling element is a coil and is a separated by a gap from the output support structure that is also in the from of a coil according to an embodiment of the present invention.
FIG. 8 is a simplified cross section of a coil electrodeless lamp where the output support structure that contains the gas-filled vessel is separated from a grounded support structure by a single metal coil element. It is coupled to a resonator coupling element that is a second coil that surrounds the first coil element. The second coil is fed from the side of the resonator body according to an embodiment of the present invention.
FIG. 9 is a simplified cross section of a coil electrodeless lamp where the output support structure that contains the gas-filled vessel is separated from a grounded support structure by a single metal coil element. It is coupled to a resonator couple element that is straight and adjacent to the output support structure. There is an adjustable metal insert within the coil output support structure that travels along the axis of the coil that allows for adjustment of the operating frequency of the resonator according to an embodiment of the present invention.
FIG. 10 is a simplified cross section of a coil electrodeless lamp where the output support structure that contains the gas-filled vessel is connected to the grounded support structure by a dielectric post as well as connected to the grounded support structure through the metal coil according to an embodiment of the present invention. It is coupled to a resonator coupling element that is a second coil that surrounds the first coil element.
FIG. 11 is a simplified cross section of a coil electrodeless lamp similar to FIG. 5A except that the top section of the resonator around the output support structure is filled with a dielectric material to further lower the resonant frequency of the resonator according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, techniques for lighting are provided. In particular, the present invention provides a method and device using a plasma lighting device having a shaped resonator assembly including a helical or coil structure, which is coupled to a radio frequency source. Merely by way of example, such plasma lamps can be applied to applications such as stadiums, security, parking lots, military and defense, streets, large and small buildings, vehicle headlamps, aircraft landing, bridges, warehouses, uv water treatment, agriculture, architectural lighting, stage lighting, medical illumination, microscopes, projectors and displays, any combination of these, and the like.
FIG. 1A illustrates a general schematic for efficient energy transfer from an RF source 111 to gas fill vessel 130 . This diagram as well as all of the other diagrams are intended to be illustrative of one implementation, which should not unduly limit the scope of the claims herein. One of ordinary skill in the art will recognize other variations, modifications, and alternatives. Energy from the RF source is directed to an impedance matching network 215 that enables the effective transfer of energy from RF source to resonating structure 220 . An example of such impedance matching network is an E-field or H-field coupling element, but can be others. Another impedance matching network 230 , in turn, enables efficient energy transfer from resonator to gas filled vessel 130 according to an embodiment of the present invention. An example of the impedance matching network is an E-field or H-field coupling element Of course, there can be other variations, modifications, and alternatives.
In a specific embodiment, the gas filled vessel is made of a suitable material such as quartz or other transparent or translucent material. The gas filled vessel is filled with an inert gas such as Argon and a fluorophor or light emitter such as Mercury, Sodium, Dysprosium, Sulfur or a metal halide salt such as Indium Bromide, Scandium Bromide, or Cesium Iodide (or it can simultaneously contain multiple fluorophors or light emitters). The gas filled vessel can also include a metal halide, or other metal pieces that will discharge electromagnetic radiation according to a specific embodiment. Of course, there can be other variations, modifications, and alternatives.
In a specific embodiment, a capacitive coupling structure 131 is used to deliver RF energy to the gas fill within the bulb 130 . As is well known, a capacitive coupler typically comprises two electrodes of finite extent enclosing a volume and couples energy primarily using at least Electric fields (E-fields). As can be appreciated by one of ordinary skill in the art, the impedance matching networks 215 and 230 and the resonating structure 220 , as depicted in schematic form here, can be interpreted as equivalent-circuit models of the distributed electromagnetic coupling between the RF source and the capacitive coupling structure. The use of impedance matching networks also allows the source to have an impedance other than 50 ohms; this may provide an advantage with respect to RF source performance in the form of reduced heating or power consumption from the RF source. Lowering power consumption and losses from the RF source would enable a greater efficiency for the lamp as a whole. As can also be appreciated by one of ordinary skill in the art, the impedance matching networks 215 and 230 are not necessarily identical.
FIG. 1B illustrates a general schematic for efficient energy transfer from an RF source 111 to gas filled vessel 130 . Energy from the RF source is directed to an impedance matching network 215 that enables the effective transfer of energy from RF source to resonating structure 220 . Another impedance matching network 230 , in turn, enables efficient energy transfer from the resonator to gas filled vessel 130 . An inductive coupling structure 145 is used to deliver RF energy to the gas fill within the bulb 130 . As is well known, an inductive coupler typically comprises a wire or a coil-like wire of finite extent and couples energy primarily using magnetic fields (H-fields). As can be appreciated by one of ordinary skill in the art, the impedance matching networks 215 and 230 and the resonating structure 220 , as depicted in schematic form here, can be interpreted as equivalent-circuit models of the distributed electromagnetic coupling between the RF source and the inductive coupling structure. The use of impedance matching networks also allows the source to have an impedance other than 50 ohm; this may provide an advantage with respect to RF source performance in the form of reduced heating or power consumption from the RF source. Lowering power consumption and losses from the RF source would enable a greater efficiency for the lamp as a whole. As can also be appreciated by one of ordinary skill in the art, the impedance matching networks 215 and 230 are not necessarily identical.
FIG. 2A is a simplified perspective view of an electrodeless lamp, employing a lamp body 600 , whose outer surface 601 is electrically conductive and is connected to ground. A cylindrical lamp body is depicted, but rectangular or other shapes may be used. This conductivity may be achieved through the application of a conductive veneer, or through the choice of a conductive material. An example embodiment of conductive veneer is silver paint or alternatively the lamp body can be made from sheet of electrically conductive material such as aluminum. An integrated bulb/output coupling-element assembly 100 is closely received by the lamp body 600 through opening 610 . The bulb/output coupling-element assembly 100 contains the bulb 130 , which is a gas-filled vessel that ultimately produces the luminous output.
One aspect of the invention is that the bottom of the assembly 100 , output coupling-element 120 , is grounded to the body 600 and its conductive surface 601 at plane 101 . The luminous output from the bulb is collected and directed by an external reflector 670 , which is either electrically conductive or if it is made from a dielectric material has an electrically conductive backing, and which is attached to and in electrical contact with the body 600 . Another aspect of the invention is that the top of the assembly 100 , top coupling-element 125 , is grounded to the body 600 at plane 102 via the ground strap 710 and the reflector 670 . Alternatively, the reflector 670 may not exist, and the ground strap makes direct electrical contact with the body 600 . Reflector 670 is depicted as parabolic in shape with bulb 130 positioned near its focus. Those of ordinary skill in the art will recognize that a wide variety of possible reflector shapes can be designed to satisfy beam-direction requirements. In a specific embodiment, the shapes can be conical, convex, concave, trapezoidal, pyramidal, or any combination of these, and the like. The shorter feedback E-field coupling-element 635 couples a small amount of RF energy from the bulb/output coupling-element assembly 100 and provides feedback to the RF amplifier input 211 of RF amplifier 210 . Feedback coupling-element 635 is closely received by the lamp body 600 through opening 612 , and as such is not in direct DC electrical contact with the conductive surface 601 of the lamp body. The input coupling-element 630 is conductively connected with RF amplifier output 212 . Input coupling-element 630 is closely received by the lamp body 600 through opening 611 , and as such is not in direct DC electrical contact with the conductive surface 601 of the lamp body. However, it is another key aspect of the invention that the top of the input coupling-element is grounded to the body 600 and its conductive surface 601 at plane 631 .
RF power is primarily inductively coupled strongly from the input coupling-element 630 to the bulb/output coupling-element assembly 100 through physical proximity, their relative lengths, and the relative arrangement of their ground planes. Surface 637 of bulb/output coupling-element assembly is covered with an electrically conductive veneer or an electrically conductive material and is connected to the body 600 and its conductive surface 601 . Alternatively it can integrated as part of the lamp body 600 . The other surfaces of the bulb/output coupling-element assembly including surfaces 638 , 639 , and 640 are not covered with a conductive layer. In addition surface 640 is optically transparent or translucent. The coupling between input coupling-element 630 and output coupling-element 120 and lamp assembly 100 is found through electromagnetic simulation, and through direct measurement, to be highly frequency selective and to be primarily inductive. This frequency selectivity provides for a resonant oscillator in the circuit comprising the input coupling-element 630 , the bulb/output coupling-element assembly 100 , the feedback coupling-element 635 , and the amplifier 210 .
One of ordinary skill in the art will recognize that the resonant oscillator is the equivalent of the RF source 111 depicted schematically in FIG. 1A and FIG. 1B . A significant advantage of the invention is that the input coupling-element 630 and the bulb/output coupling-element assembly 100 are respectively grounded at planes 631 and 101 , which are coincident with the outer surface of the body 600 . This eliminates the need to fine-tune their depth of insertion into the lamp body—as well as any sensitivity of the RF coupling between them to that depth—simplifying lamp manufacture, as well as improving consistency in lamp brightness yield.
FIG. 2B is a simplified perspective view of an electrodeless lamp that differs from that shown in FIG. 2A only in its RF source, which is not a distributed oscillator circuit, but rather a separate oscillator 205 conductively connected with RF amplifier input 211 of the RF amplifier 210 . RF amplifier output 212 is conductively connected with input coupling-element 630 , which delivers RF power to the lamp/output coupling-element assembly 100 . The resonant characteristics of the coupling between the input coupling-element 630 and the output coupling-element in the bulb/output coupling-element assembly 100 are frequency-matched to the RF source to optimize RF power transfer. Of course, there can be other variations, modifications, and alternatives.
FIG. 2C is a simplified perspective view of an electrode-less lamp that is similar to the electrode-less lamp shown in FIG. 2A except that it does not have a reflector 670 . The top coupling-element 125 in the bulb assembly is directly connected to the lamp body 600 using ground straps 715 . This diagram is merely an example, which should not unduly limit the scope of the claims herein. One of ordinary skill in the art would recognize other variations, modifications, and alternatives.
FIG. 3A is a simplified perspective view of an alternative design for an integrated bulb/output coupling-element assembly 100 . The assembly does not contain a top coupling-element. The assembly consists of two sections. The bottom section 110 contains the output coupling-element 120 which consists of a dielectric post 122 made from a material such as alumina with its outer surface coated with a conductive veneer such as silver. The top section consists of the bulb (gas-fill vessel) 130 which is made from a material that is transparent to visible light such as quartz or translucent alumina. It is a key aspect of the invention that dielectric post of the output coupling-element 120 is bored to closely receive bulb 130 , such that heat transfer through its dielectric center and RF coupling through its conductive outer coating take place simultaneously. The area of the dielectric post of the output coupling-element that come in contact with the bulb is not covered with a conductive veneer. Using this bulb assembly approach the high RF fields is kept away from the end of bulb resulting in a more reliable lamp. It is also a key aspect of this invention that output coupling-element 120 makes ground contact at plane 121 with the lamp body 600 depicted in FIGS. 2A , 2 B, and 2 C.
The portion of body 110 that is received by the lamp body 600 as depicted in FIGS. 2A , 2 B, and 2 C (and overlaps with the length of input coupling-element 630 ) and is shown in FIG. 3A as being below the dashed line 140 ; is not coated with a conductive layer. The portion of body 110 that is above the lamp body 600 but substantially below the bulb 130 is depicted schematically as the area between 140 and 141 ; this portion may be coated with a conductive veneer 117 . The purpose of the conductive coatings is to shield against unwanted electromagnetic radiation. An example embodiment of conductive veneer 117 is silver paint. Alternatively, instead of a conductive veneer, portion of the body 110 between 140 and 141 can be covered by a metal ring 650 as part of the extension of the lamp body 600 .
FIG. 3B is a simplified side-cut view of an integrated bulb/output coupling-element assembly 100 shown in FIG. 3A .
FIG. 3C is a perspective view of an alternative design for an integrated bulb/output coupling-element assembly 100 which is the same as the output support structure depicted in FIG. 7A . The assembly is made using a solid conductor (metal post) 120 and is recessed at the top to closely receive one end of the gas-filled vessel 130 . The other end of metal post 121 is grounded to the lamp body. A thin layer of dielectric material or refractory metal such as molybdenum can be used as interface between the bulb and the metal post. Alternatively the top part of the metal post or all of the metal post can be made from a refractory metal with its outer surface covered with a layer of metal with high electrical conductivity such as silver or copper. The metal post can also be hollow inside or filled with a different metal with higher thermal conductivity. The assembly has no top coupling element.
FIG. 3D is a side-cut view of an integrated bulb/output coupling-element assembly 100 shown in FIG. 3C . The bulb/output coupling-element is similar to FIG. 3B except the post is made from a solid conductor instead of a dielectric material covered with conductive layer. This diagram is merely an example, which should not unduly limit the scope of the claims herein. One of ordinary skill in the art would recognize other variations, modifications, and alternatives.
FIG. 4A is a simplified perspective view of an embodiment of the present invention including an RF output coupling-element that is helical in structure and encompasses air. The helical structure 507 can have anywhere from 2 to 30 windings. In other embodiments, the windings can be more than one winding, including portions, and may be greater than thirty windings. In still other embodiments, the windings can be a portion of one winding. The output coupling-element includes a conductive metal and is attached to the metal post structure 505 that holds the bulb 130 in place. The metal used in the output coupling-element can be but is not limited to aluminum, brass, copper, gold, or silver. the other end of the RF output coupling-element 506 is grounded to the outer conductive surface of the lamp body as illustrated in FIG. 5A . Thus the design serves as an effective means of coupling the RF energy to the gas filled vessel created by the RF source that flows into the resonating structure.
An advantage of the present embodiment is that the post and helical structure RF output-coupling element serve as a more effective means of dissipating heat from the bulb within the resonating structure thus creating improved device heat transfer characteristics. That is, the post structure draws a substantial portion of the thermal energy generated from the bulb away through the material or coatings of the post structure, while maintaining the helical structure at a desirable temperature. Such desirable temperature leads to desirable conductive characteristics of the helical structure to maintain the performance (e.g., efficiency) of the plasma apparatus according to a specific embodiment. During the creation of a plasma, a great amount of heat is generated. The particles in the plasmas generated by such devices typically are at a temperature on the order of one thousand degree or of several thousand degrees Celsius. In order to prevent damage to the lamp and for the overall safety of the device, an effective means of dissipating the heat generated by the bulb is necessary. As the helical RF output coupling-element is coupled directly to the metal base which holds the bulb, the generated heat is conducted into the RF output coupling-element. The use of a helical shaped RF output coupling-element creates a structure with a larger surface area in which the heat can dissipate into the air. By creating a larger surface area in which the surrounding air comes into contact with, a greater amount of heat is dissipated from the bulb and out through the RF output-coupling element. The improved heat transfer characteristics of the lamp, leads to improved reliability and safety.
Another advantage of the present embodiment is that the use of a helical RF output coupling-element lowers the resonant frequency of the device, thereby allowing the device to operate at lower RF frequencies. Specifically, in creating a helical shaped RF output coupling-element structure, creates a large amount of magnetic flux within the structure, in turn leading to increased inductance levels of between 50% to about 1000% of that of the resonator structure according to one or more embodiments. In one or more preferred embodiments, the inductance increases from about 1.1 to 10 6 and greater. That is, the operating resonating frequency may be 50 kHz and greater, e.g., 10 MHz. The resonance frequency of the device is inversely related to the inductance, therefore at higher inductance levels, the resonance frequency is decreased. In decreasing the resonance frequency in the range of 8 MHz to about 1000 MHz, the device is capable of operating at lower RF frequencies, in turn becoming more efficient. Of course, there can be other variations, modifications, and alternatives.
FIG. 4B is a simplified perspective view of an alternate embodiment of the present invention consisting of an RF output coupling-element that is helical in structure 907 and encompasses a dielectric material 908 with a metal insert 909 that allows for the tuning of the resonance frequency of the resonator. As with the previous embodiment, the RF output coupling-element of the present embodiment is connected to the metal post structure 905 that is used to support the bulb 130 . The other end of the output coupling-element 906 is grounded to the outer surface of the conductive lamp body as illustrated in FIG. 9 .
The present embodiment incorporates a dielectric material within the helical RF output coupling-element. Such dielectric material can be but is not limited to Alumina or any other suitable dielectric or ceramic material. The dielectric material does not conduct the current that is generated from the RF source and flows through the RF output-coupling element, however, the dielectric material does absorb the heat from the helical coils of the RF output coupling-element and the heat from the bulb through the top of the coupling element 905 . Since dielectric materials are capable of absorbing large amounts of heat while providing electrical isolation, the use of a dielectric within the RF output coupling-element further improves the heat transfer characteristics of the lamp. Using a helical output coupling-element increases the inductance of the resonator reducing the resonance frequency of the resonator, thereby allowing for operation the lamp at lower RF frequencies.
The present embodiment also incorporates a metal insert 909 between the dielectric material and the helical RF output coupling-element. The metal insert makes contact at one end with the helical RF output coupling element and at the other end makes contact with the base 906 of the output coupling-element. The length of the metal insert is less than the length of the entire helical RF output coupling-element. However, the length of the metal insert can be adjusted such that it can make contact at different positions along the length of the helical RF output coupling element. One method of adjusting the length of the metal insert is by using screw threads along the length of the metal insert and turning the metal insert into the base of the output coupling element to adjust its length. Of course other methods of adjusting the length of the metal insert are possible. As the length of the metal insert is adjusted such that it makes contact with the helical output coupling-element at different positions, the inductance of the output coupling-element changes resulting in changes in the resonant frequency of the resonator. The metal insert can be used to tune the resonant frequency of the resonator to optimize the performance of the lamp and improve manufacturing yield.
FIG. 5A illustrates the cross-section for a coil electrodeless plasma lamp according to an embodiment of the present invention. Energy from an RF source is directed to the input port 502 of the resonator enclosure 501 . RF Energy is coupled into the resonator enclosure 501 through a standard RF connector 503 . A straight resonator coupling element 504 that has one end connected to the RF connector and the other end grounded, directs the RF energy inside the resonator and couples the energy to the output support structure comprised of elements 505 , 506 , and 507 . The output support structure is comprised of three elements. The conductive grounded support base 506 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 507 on the other end. The coil element is an electrically conductive material configured into a helical structure to extend through the resonator enclosure to support and connect to the output support structure 505 . The output support structure 505 can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 504 into the gas-filled vessel 130 where light is produced.
FIG. 5B illustrates the cross-section for a coil electrodeless plasma lamp according to an embodiment of the present invention. Energy from an RF source is directed to the input port 502 of the resonator enclosure 501 . RF Energy is coupled into the resonator enclosure 501 through a standard RF connector 503 . A straight resonator coupling element 504 that has one end connected to the RF connector and the other end grounded, directs the RF energy inside the resonator and couples the energy to the output support structure comprised of elements 505 , 506 , 507 , and 508 . The output support structure is comprised of four elements. The conductive grounded support base 506 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 507 on the other end. The coil element is an electrically conductive material configured into a helical structure to extend through the resonator enclosure. A non-conductive (ceramic) support structure 508 is used to physically support the coil element 507 and output support structure 505 and facilitate heat transfer from the gas-filled vessel 130 to the rest of the resonator. It is directly attached to the output support structure 505 . The output support structure can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 504 into the gas-filled vessel 130 where light is produced.
FIG. 5C illustrates the cross-section for a coil electrodeless plasma lamp according to an embodiment of the present invention. Energy from an RF source is directed to the input port 502 of the resonator enclosure 501 . RF Energy is coupled into the resonator enclosure 501 through a standard RF connector 503 . A straight resonator coupling element 504 that has one end connected to the RF connector and the other end grounded, directs the RF energy inside the resonator and couples the energy to the output support structure comprised of elements 505 , 506 , 507 , and 509 . The output support structure is comprised of four elements. The conductive grounded support base 506 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 507 on the other end. The coil element is an electrically conductive material configured into a helical structure to extend through the resonator enclosure. A non-conductive (ceramic) support structure 509 is used to physically support the output support structure 505 and facilitate heat transfer from the gas-filled vessel 130 to the rest of the resonator. It is directly attached to the output support structure 505 . The output support structure can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 504 into the gas-filled vessel 130 where light is produced.
FIG. 5D illustrates the cross-section for a coil electrodeless plasma lamp according to an embodiment of the present invention. Energy from an RF source is directed to the input port 502 of the resonator enclosure 501 . RF Energy is coupled into the resonator enclosure 501 through a standard RF connector 503 . A straight resonator coupling element 504 that has one end connected to the RF connector and the other end grounded, directs the RF energy inside the resonator and couples the energy to the output support structure comprised of elements 505 , 506 , 508 , and 510 . The output support structure is comprised of four elements. The conductive grounded support base 506 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 510 on the other end. The coil element is an electrically conductive material configured in the shape of conductive stripes onto the non-conductive (ceramic) support structure 508 and provides an electrical connection to the output support structure 505 . The non-conductive support structure 508 is used to physically support the output support structure 505 and facilitate heat transfer from the gas-filled vessel 130 to the rest of the resonator. It is directly attached to the output support structure 505 . The output support structure can be made of any conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 504 into the gas-filled vessel 130 where light is produced.
FIG. 6A illustrates the cross-section for a coil electrodeless plasma lamp according to an embodiment of the present invention. Energy from an RF source is directed to the input port 602 of the resonator enclosure 601 . RF Energy is coupled into the resonator enclosure 601 through a standard RF connector 603 . A coil resonator coupling element 604 that has one end connected to the RF connector and the other end grounded surrounds the center support structure assembly and directs the RF energy inside the resonator to couple the energy to the output support structure comprised of elements 605 , 606 , and 607 . The output support structure is comprised of three elements. The conductive grounded support base 606 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 607 on the other end. The coil element is an electrically conductive material configured into a helical structure to extend through the resonator enclosure to support and connect to the output support structure 605 . The output support structure 605 can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 604 into the gas-filled vessel 130 where light is produced.
FIG. 6B illustrates the cross-section for a coil electrodeless plasma lamp according to an embodiment of the present invention. Energy from an RF source is directed to the input port 602 of the resonator enclosure 601 . RF Energy is coupled into the resonator enclosure 601 through a standard RF connector 603 . A coil resonator coupling element 604 that has one end connected to the RF connector and the other end grounded surrounds the center support structure assembly and directs the RF energy inside the resonator to couple the energy to the output support structure comprised of elements 605 , 606 , 607 , and 608 . The output support structure is comprised of four elements. The conductive grounded support base 606 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 607 on the other end. The coil element is an electrically conductive material configured into a helical structure to extend through the resonator enclosure. A non-conductive (ceramic) support structure 608 is used to physically support the coil element 607 and output support structure 605 and facilitate heat transfer from the gas-filled vessel 130 to the rest of the resonator. It is directly attached to the output support structure 605 . The output support structure can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 604 into the gas-filled vessel 130 where light is produced.
FIG. 6C illustrates the cross-section for a coil electrodeless plasma lamp according to an embodiment of the present invention. RF Energy is coupled into the resonator enclosure 601 through a standard RF connector 603 . A coil resonator coupling element 604 that has one end connected to the RF connector and the other end grounded surrounds the center support structure assembly and directs the RF energy inside the resonator to couple energy to the output support structure comprised of elements 605 , 606 , 607 , and 609 . The output support structure is comprised of four elements. The conductive grounded support base 606 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 607 on the other end. The coil element is an electrically conductive material configured into a helical structure to extend through the resonator enclosure. A non-conductive (ceramic) support structure 609 is used to physically support the output support structure 605 and facilitate heat transfer from the gas-filled vessel 130 to the rest of the resonator. It is directly attached to the output support structure 605 . The output support structure can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 604 into the gas-filled vessel 130 where light is produced.
FIG. 6D illustrates the cross-section for a coil electrodeless plasma lamp according to an embodiment of the present invention. RF Energy is coupled into the resonator enclosure 601 through a standard RF connector 603 . A coil resonator coupling element 604 that has one end connected to the RF connector and the other end grounded surrounds the center support structure assembly and directs the RF energy inside the resonator to couple energy to the output support structure comprised of elements 605 , 606 , 608 , and 610 . The output support structure is comprised of four elements. The conductive grounded support base 606 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 610 on the other end. The coil element is an electrically conductive material configured in the shape of conductive stripes onto the non-conductive (ceramic) support structure 608 and provides an electrical connection to the output support structure 605 . The non-conductive support structure 608 is used to physically support the output support structure 605 and facilitate heat transfer from the gas-filled vessel 130 to the rest of the resonator. It is directly attached to the output support structure 605 . The output support structure can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 604 into the gas-filled vessel 130 where light is produced.
FIG. 7A illustrates the cross-section for an electrodeless plasma lamp with a coil resonator coupling element according to an embodiment of the present invention. Energy is coupled into the resonator enclosure 701 through a standard RF connector 703 . A coil resonator coupling element 704 that has one end connected to the RF connector and the other end grounded is situated from the connector to the opposite end of the resonator without encircling the output support structure 705 . The output support structure is connected to the gas-filled vessel 130 at one end and connected to ground (resonator enclosure) at the other end. The output support structure 705 is used to physically support and facilitate heat transfer from the gas-filled vessel 130 to the rest of the resonator. The output support structure can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 704 into the gas-filled vessel 130 where light is produced.
FIG. 7B is a simplified cross section of a coil electrodeless plasma lamp with a coil resonator coupling element according to an embodiment of the present invention. Energy is coupled into the resonator enclosure 701 through a standard RF connector 703 . A coil resonator coupling element 704 that has one end connected to the RF connector and the other end grounded is situated from the connector to the opposite end of the resonator without encircling the output support structure that is also in the form of a coil similar to FIG. 5A . The output support structure is comprised of three elements, 705 , 706 , and 707 . The conductive grounded support base 706 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 707 on the other end. The coil element is an electrically conductive material configured into a helical structure to extend through the resonator enclosure to support and connect to the output support structure 705 . The output support structure 705 can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 704 into the gas-filled vessel 130 where light is produced.
FIG. 8 illustrates the cross-section for a coil electrodeless plasma lamp according to another embodiment of the present invention. Energy from an RF source is directed to the input port 802 of the resonator enclosure 801 . In this case, the input is situated on the side of the resonator. RF Energy is coupled into the resonator enclosure 801 through a standard RF connector 803 . A coil resonator coupling element 804 that has one end connected to the RF connector and the other end grounded surrounds the output support structure assembly and directs the RF energy inside the resonator to couple the energy to the output support structure comprised of elements 805 , 806 , 808 , and 810 . The output support structure is comprised of four elements. The electrically conductive grounded support base 806 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 810 on the other end. The coil element, made from an electrically conductive material, is configured into a helical structure to extend through the resonator enclosure. A non-conductive (ceramic) support structure 808 is used to physically support the coil element 810 and output support structure 805 and facilitate heat transfer from the gas-filled vessel 130 to the rest of the resonator. It is directly attached to the output support structure 805 . The output support structure can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 804 into the gas-filled vessel 130 where light is produced.
FIG. 9 illustrates the cross-section for a coil electrodeless plasma lamp according to an embodiment of the present invention. Energy from an RF source is directed to the input port 902 of the resonator enclosure 901 . Energy is coupled into the resonator enclosure 901 through a standard RF connector 903 . A straight resonator coupling element 904 that has one end connected to the RF connector and the other end grounded, directs the RF energy inside the resonator and couples the energy to the output support structure comprised of elements 905 , 906 , 907 , 908 , and 909 . The output support structure is comprised of five elements and is similar to the structure illustrated in FIG. 4B . The conductive grounded support base 906 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 907 on the other end. The coil element, made from an electrically conductive material, is configured into a helical structure to extend through the resonator enclosure to support and connect to the output support structure 905 . The output support structure 905 is connected to gas-filled vessel 130 at one end and to the coil element 907 and a support post 908 made from a non-conductive material (ceramic) at the other end. The output support structure 905 can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. An electrically conductive adjustable element 909 is used to tune the resonant frequency by traveling up and down the coil element. The adjustable element must be in electrical contact with the coil element 907 . The output support structure directs the RF energy that is coupled to it from the resonator coupling element 904 into the gas-filled vessel 130 where light is produced.
FIG. 10 illustrates the cross-section for a coil electrodeless plasma lamp according to an embodiment of the present invention. Energy from an RF source is directed to the input port 1002 of the resonator enclosure 1001 . Energy is coupled into the resonator enclosure 1001 through a standard RF connector 1003 . A coil resonator coupling element 1004 that has one end connected to the RF connector and the other end grounded surrounds the center support structure assembly and directs the RF energy inside the resonator to couple energy to the output support structure comprised of elements 1005 , 1006 , 1007 , and 1009 . The output support structure is comprised of four elements. The conductive grounded support base 1006 provides a physical and electrical connection to the resonator on one end and a connection to the coil element 1007 and a non-conductive (ceramic) support structure 1009 on the other end. The coil element is an electrically conductive material configured into a helical structure to extend through the resonator enclosure and is connected at the other end to the top portion of the output support structure 1005 . The non-conductive (ceramic) support structure 1009 is used to physically support the output support structure 1005 , which in this case has an extended post to the lower portion of the resonator, and to facilitate heat transfer from the gas-filled vessel 130 to the rest of the resonator while providing a DC block. The output support structure can be made of any electrically conductive or non-conductive material (ceramic) but must have its surface covered with an electrically conductive layer. The output support structure directs the RF energy that is coupled to it from the resonator coupling element 1004 into the gas-filled vessel 130 where light is produced.
FIG. 11 illustrates the cross-section for a coil electrodeless plasma lamp according to an embodiment of the present invention. This embodiment is similar to the one shown in FIG. 5A except that around the output support structure 505 , at the top section of the resonator enclosure 501 , is filled with a dielectric material 511 (for example quartz or alumina) to further lower the resonant frequency of the resonator. It is also possible to partially or completely fill the bottom portion of enclosure 501 with a dielectric material as well.
While the above is a full description of the specific embodiments, various modifications, alternative constructions and equivalents may be used. As used herein, the term “coil” may include regularly spaced windings or irregularly spaced windings, as well as spiral, rectangular, helical, annular, polygon, or any combination of these, and others that would be understood by one of ordinary skill in the art. Additionally, the terms “input coupling” and “output coupling” have been used in the above embodiments, but such terms can be described more generally as a resonator coupling element, an RF coupling element, or such terms as support structure(s) and combinations, as well as other well known ordinary meanings. Therefore, the above description and illustrations should not be taken as limiting the scope of the present invention which is defined by the appended claims.
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A plasma lamp apparatus includes a post structure with a material overlying a surface region of the post structure, which has a first end and a second end. The apparatus also has a helical coil structure configured along the post structure. The apparatus includes a bulb with a fill material capable of emitting electromagnetic radiation. A resonator coupling element configured to feed radio frequency energy to at least the helical coil causes the bulb device to emit electromagnetic radiation.
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TECHNICAL FIELD
[0001] The present invention relates to an eye tracking method that determines the location a subject's eye in a video image by correlation, and more particularly to a method of periodically updating the determined eye location based on detected characteristic eye movement.
BACKGROUND OF THE INVENTION
[0002] Vision systems frequently entail locating and tracking a subject's eye in an image generated by a video camera. In the motor vehicle environment, for example, a camera can be used to generate an image of the driver's face, and portions of the image corresponding to the driver's eyes can be analyzed to assess drive gaze or drowsiness. See, for example, the U.S. Pat. Nos. 5,795,306; 5,878,156; 5,926,251; 6,097,295; 6,130,617; 6,243,015; 6,304,187; and 6,571,002, incorporated herein by reference. While eye location and tracking algorithms can work reasonably well in a controlled environment, they tend to perform poorly under real world imaging conditions, particularly in systems having only one camera. For example, the ambient illumination can change dramatically, the subject may be wearing eyeglasses or sunglasses, and the subject's head can be rotated in a way that partially or fully obscures the eye.
[0003] Tracking eye movement from one video frame to the next is generally achieved using a correlation technique in which the eye template (i.e., a cluster of pixels corresponding to the subject's eye) of the previous frame is compared to different portions of a search window within the current frame. Correlation values are computed for each comparison, and the peak correlation value is used to identify the eye template in the current frame. While this technique is useful, the accuracy of the eye template tends to degenerate over time due to drift and conditions such as out-of-plane rotation of the subject's head, noise and changes in the eye appearance (due to glasses, for example). At some point, the eye template will be sufficiently degenerated that the system must enter a recovery mode in which the entire image is analyzed to re-locate the subject's eye.
SUMMARY OF THE INVENTION
[0004] The present invention is directed to an improved eye tracking method that tracks a subject's eye template by correlation between successive video frames, where the eye template is periodically updated based on detected characteristic eye or eyelid movement such as blinking, eyelash movement and iris movement. In the absence of eyelid motion detection, a state vector corresponding to the center of the subject's eye is determined by an improved correlation method, when eyelid motion is detected, the state vector is determined based on the location of the motion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
[0006] FIG. 1 is a block diagram of a motor vehicle vision system including a video camera and a microprocessor-based image processor for monitoring driver alertness.
[0007] FIG. 2 is a flow diagram depicting a software routine executed by the image processor of FIG. 1 for carrying out the eye tracking method of this invention.
[0008] FIGS. 3A-3B together depict a flow diagram detailing a portion of the flow diagram of FIG. 2 pertaining to eyelid motion detection.
[0009] FIG. 4 is a diagram illustrating a portion of the flow diagram of FIG. 2 pertaining to a correlation technique for tracking eye movement in successive video frames.
[0010] FIGS. 5A-5B together depict a flow diagram detailing a portion of the flow diagram of FIG. 2 pertaining to a correlation method of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0011] The eye tracking method of the present invention is disclosed in the context of a system that monitors a driver of a motor vehicle. However, it will be recognized that the method of this invention is equally applicable to other vision systems, whether vehicular or non-vehicular.
[0012] Referring to the drawings, and particularly to FIG. 1 , the reference numeral 10 generally designates a motor vehicle vision system for monitoring driver alertness. The system 10 includes a CCD camera 12 , a microprocessor-based image processor 14 , a driver monitor 16 , and an alarm 18 . The camera 12 is mounted in a convenient location within the vehicle passenger compartment, such as in a center console or instrument panel, and is configured to produce an unobstructed image of the driver's head, taking into account differences in driver height and orientation. The image processor 14 captures a stream of video frames or images (IMAGE t-1 , IMAGE t , etc.) produced by camera 12 , and executes software routines for identifying a state vector (S t-1 , S t , etc.) corresponding to center of the driver's eye in each image, and tracking eye movement between successive video images. The driver monitor 16 receives the driver eye information from image processor 14 , detects eye movement characteristic of driver drowsiness and/or distraction, and activates the alarm 18 or other safety alert when it is determined that the driver's lack of alertness or attention may possibly compromise vehicle safety.
[0013] The flow diagram of FIG. 2 depicts a software routine executed by the image processor 14 according to this invention. Inputs 20 a, 20 b and 20 c to the routine include the current video image (IMAGE t ), and the state vector S t-1 and search window SW t-1 , for the previous video image (IMAGE 1-1 ). The block 22 designates a set of instructions for defining a portion of the current image (referred to herein as a search window SW) that should include the driver's eye, even with driver movement between IMAGE t-1 and IMAGE t . This is achieved by defining the coordinates of an eye template (eyeT)—that is, a small set of pixels that encompass primarily just the driver's eye—based on the state vector S t-1 , for IMAGE t-1 , applying the coordinates of eyeT to IMAGE t , and defining the search window SW as a larger portion of IMAGE, that includes both eyeT and a set of pixels surrounding eyeT.
[0014] The block 24 then carries out a sum-of-absolute-differences (SAD) computation on the search window SW for the current image IMAGE t and the search window SW t-1 for the previous image IMAGE t-1 . The SAD computation is essentially a pixel-by-pixel comparison of SW and SW t-1 , and provides a fast and reliable measure of the driver movement between the successive images IMAGE t-1 , and IMAGE t . The block 26 compares the computed SAD value to a predefined threshold THR_SAD. If SAD<=THR_SAD, there is inconsequential driver movement between the images IMAGE t-1 and IMAGE t , and the block 28 sets the state vector S t for the current image IMAGE t equal to the state vector S t-1 for the previous image IMAGE t-1 . If SAD>THR_SAD, there is significant driver movement between the images IMAGE t-1 and IMAGE t , and the block 30 is executed to detect if the differences between SW and SW t-1 include driver eyelid motion. As described below in reference to the flow diagram of FIGS. 3A-3B , the eyelid motion detection technique identifies various candidate regions of the difference image, and sets the state of an EYELID MOTION flag to TRUE if at least one of the candidate regions is validated as eye motion. If the EYELID MOTION flag is TRUE, as determined at block 32 , the block 34 sets the state vector S t for the current image IMAGE t equal to the eye center-of-movement EYE_COM (i.e., the centroid) of the validated candidate region. If the EYELID MOTION flag is not TRUE, the block 36 updates the state vector St using a correlation technique described below in reference to the flow diagram of FIGS. 5A-5B .
[0015] As indicated above, the flow diagram of FIGS. 3A-3B details block 30 of FIG. 2 . Referring to FIGS. 3A-3B , eyelid motion detection is initiated at block 50 by creating an absolute-difference image (AD IMAGE) based on pixel-by-pixel magnitude differences between the search window SW of the current image IMAGE t and the search window SW t-1 of the previous image IMAGE t-1 . The block 52 then binarizes the AD IMAGE using a calibrated or adaptive threshold, essentially converting the grey-scale AD IMAGE to a binary image. The blocks 54 and 56 then process the binarized image to fuse neighboring like-value pixels, and identify regions or pixel blobs that potentially correspond to facial features of interest. The block 58 employs window thresholding to select the identified regions that are size-wise consistent with facial features, such regions being referred to herein as candidate regions.
[0016] The blocks 60 - 76 are then executed for each of the candidate regions identified at block 58 to determine which, if any, of them corresponds to the driver's eye. In general, this is achieved by comparing each candidate region with a stored database or model that defines two categories of possible shapes: eye or non-eye. If the candidate region is more like the eye category than the non-eye category, it is accepted for purposes of eyelid movement detection; otherwise, it is rejected.
[0017] First, the block 60 selects a candidate region. The block 62 identifies the eye center-of-movement, or EYE_COM, according to the centroid of the selected candidate region, and the block 64 extracts a patch or block of pixels from the search window SW surrounding EYE_COM. The block 66 enhances the contrast of the extracted patch using a known contrast-enhancing transfer function, and the block 68 applies the contrast-enhanced patch to the eye and non-eye models. This involves computing an effective distance or deviation DST_EYE between the respective patch and the eye model, and an effective distance or deviation DST_NON-EYE between the respective patch and the non-eye model. If DST_NON-EYE is greater than DST_EYE, as determined at block 70 , the candidate region is accepted for purposes of eyelid movement detection; in this case, the block 72 sets the EYELID MOTION flag to TRUE, completing the eyelid motion detection routine. If DST_NON-EYE is less than or equal to DST_EYE, the candidate region is rejected for purposes of eyelid movement detection and the block 74 is executed to determine if the selected candidate region was the last of the identified regions. If not, the block 60 selects the next candidate region, and the blocks 62 - 70 are repeated for the selected region. If none of the candidate regions are accepted for purposes of eyelid motion detection, the block 74 will eventually be answered in the affirmative, whereafter block 76 sets the EYELID MOTION flag to FALSE, completing the eyelid motion detection routine.
[0018] As indicated above, the flow diagram of FIGS. 5A-5B details block 36 of FIG. 2 . In general, the block 36 carries out two different correlation techniques to identify the location of the driver's eye in the current video frame, and updates the state vector S t based on the correlation result that is deemed to be most reliable.
[0019] The first correlation technique is generally known in the art as normalized cross-correlation (NCC), and involves comparing the eye template eyeT defined at block 22 of FIG. 2 with various pixel combinations of the search window SW. A normalized cross-correlation is illustrated in FIG. 4 , where the letters A, B and C respectively designate the eye template eyeT, the search window SW and the resulting correlation matrix. The numerical values within the eyeT and SW arrays represent illumination magnitudes for individual respective pixels of the image IMAGE t . In the example of FIG. 4 , the pixels of eyeT are compared to three different sets of pixels within SW, producing the three correlation values designated by the letter C. In this case, the set of pixels in the upper left portion of SW correspond exactly to the pixels of eyeT, resulting in a maximum correlation value of one.
[0020] Referring to FIG. 5A , the block 80 computes NCC values for various search window patches, and the block 82 identifies the patch having the highest correlation value, or MAX(NCC), as the candidate eye template CAND_eyeT. The block 82 also stores the center of the patch CAND_eyeT as the NCC-based state vector variable St_NCC.
[0021] The second correlation technique utilizes the eye and non-eye models described above in reference to block 68 of FIG. 3B . Referring to FIG. 5A , the block 84 compares various patches of the search window SW to the eye model and computes an effective distance or deviation DST_EYE for each. The block 86 identifies the patch having the smallest distance, or MIN(DST_EYE), as the candidate eye template CAND_eyeT and stores the center of the patch CAND_eyeT as the model-based state vector variable St_MODEL. Finally, the block 88 compares the candidate eye template CAND_eyeT to the non-eye model and computes an effective distance or deviation DST_NON-EYE.
[0022] Referring to FIG. 5B , the blocks 90 - 112 are then executed to assess the correlation results and to update the state vector S t accordingly. If both correlation techniques fail to reliably identify the driver's eye, as determined at block 90 , the block 92 is executed to enter a recovery mode in which IMAGE, is re-analyzed to locate the driver's eye. The model-based correlation technique is considered to be unsuccessful if DST_NON-EYE<MIN(DST_EYE); and the NCC-based correlation technique is considered to be unsuccessful if MAX(NCC) is less than a threshold correlation THR_CORR. If the model-based correlation technique is deemed unsuccessful (i.e., DST_NON-EYE<MIN(DST_EYE)) but the NCC-based correlation technique is successful (i.e., MAX(NCC)>=THR_CORR), the block 94 is answered in the affirmative and block 96 sets the state vector S t equal to the NCC-based state vector variable St_NCC. If the NCC-based correlation technique is deemed unsuccessful (i.e., MAX(NCC)<THR_CORR), but the model-based correlation technique is successful (i.e., DST_NON-EYE>=MIN(DST_EYE)), the block 98 is answered in the affirmative and block 100 sets the state vector S t equal to the model-based state vector variable St_MODEL.
[0023] If blocks 90 , 94 and 98 are all answered in the negative, both the model-based correlation technique and the NCC-based correlation technique are deemed successful, and the blocks 102 - 112 are executed to update the state vector S t based on the more reliable of St_NCC and St_MODEL. The block 102 computes the Euclidian distance D between St_NCC and St_MODEL. If the distance D is less than a threshold THR_DIST as determined at block 104 , the state vector S t may be set equal to either St_NCC or St_MODEL, whichever is most convenient (in the illustrated embodiment, S t is set equal to St_NCC). If D>=THR_DIST, the block 106 computes the variance of search window patches surrounding the state vector variables St_NCC and St_MODEL. The variance VAR_NCC corresponds to the state vector variable St_NCC, and the variance VAR_MODEL corresponds to the state vector variable St_MODEL. If VAR_MODEL>VAR_NCC, the model-based correlation technique is considered to be more reliable, and the blocks 108 and 110 set the state vector S t equal to St_MODEL. Otherwise, the NCC-based correlation technique is considered to be more reliable, and block 1 12 sets the state vector S t equal to St_NCC.
[0024] In summary, the method of the present invention uses eyelid motion detection to overcome the inherent disadvantages of conventional correlation-based eye tracking, resulting in a method that is robust, even in the presence of out-of-plane rotation of the driver's head, varying distances between the driver and the camera, different orientations of the driver's head, and changes in ambient illumination. While the method of the present invention has been described in reference to the illustrated embodiment, it will be recognized that various modifications in addition to those mentioned above will occur to those skilled in the art. For example, correlation calculations other than a normalized cross-correlation may be utilized, and so on. Accordingly, it will be understood that methods incorporating these and other modifications may fall within the scope of this invention, which is defined by the appended claims.
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An eye tracking method tracks a subject's eye template by correlation between successive video frames, and periodically updates the eye template based on detected characteristic eye or eyelid movement such as blinking, eyelash movement and iris movement. In the absence of eyelid motion detection, a state vector corresponding to the center of the subject's eye is determined by a correlation technique, and when eyelid motion is detected, the state vector is determined based on the location of the detected motion.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to gas turbine engines, and more particularly to means for confining cooling air to a flowpath extending about the interior of the outer case of such an engine.
2. Description of the Prior Art
A gas turbine engine has a compression section, a combustion section and a turbine section. The turbine section has a rotor assembly and a stator assembly. An annular flowpath for working medium gases extends axially through the engine. The annular flowpath passes in alternating succession between components of the stator assembly and components of the rotor assembly. The rotor assembly includes a plurality of outwardly extending rotor blades. The rotor blades extend into the working medium flowpath and into proximity with components of the stator assembly. To confine the working medium gases to the working medium flowpath a plurality of outer air seal segments radially oppose the tips of the rotor blade. The outer air seals are part of the stator assembly. An outer case and support structure extending inwardly from the outer case support and position the outer air seals about the tips of the rotor blades.
Because the outer air seals, the outer case, and the rotor blades expand and contract at different rates in response to changes in temperatures of the hot working medium gases, the clearance between the tips of the rotor blades and the outer air seal varies. To minimize the clearance during steady-state conditions such as at cruise, cooling air is discharged against the outer case from cooling tubes circumscribing the case to cause the case to contract. The contracting case displaces the outer air seals inwardly to a smaller diameter. The inward movement of the outer air seals decreases the clearance between the rotor tips and the outer air seals with a concomitant beneficial effect on engine efficiency. One such construction directed to such a structure is shown in U.S. Pat. No. 4,069,320 to Redinger et al. entitled, "Clearance Control For Gas Turbine Engine".
In modern engines, cooling air is also flowed through passages on the interior of the case. The cooling air removes heat from the case and from the outer air seals which are in intimate contact with the hot working medium gases to increase the service life of such components. Along the cooling air flowpath, the cooling air is at a higher pressure than the surrounding gases. The case forms the outer boundary of the cooling air flowpath and seal means extend between the cooling air flowpath and the hot gases to form an inner boundary of the flowpath. Holes through the seal means face a corresponding cavity in the outer air seal and precisely meter the flow of cooling air into the cavity. Cooling air leakage around the edges of such seal means degrades engine performance. One example of a design directed to a construction which meters cooling air to outer air seal cavities and which blocks the leakage of cooling air around the ends of the seal means is shown in U.S. Pat. No. 3,583,824 to Smuland entitled, "Temperature Controlled Shroud and Shroud Support". The seal means of Smuland is welded or brazed to the outer air seal. U.S. Pat. No. 3,836,279 to Lee entitled, "Seal Means for Blade and Shroud" discloses a circumferentially extending sheet metal shroud seal. The seal has a plurality of openings each of which faces a corresponding cavity in an outer air seal. A raised portion extends around each opening and is resiliently deformed to provide an annular seal around the opening.
Notwithstanding the above art, scientists and engineers are still seeking to increase the sealing effectiveness of a seal means extending about the interior of an engine case between an outer case and the hot working medium gases and, in particular, between the outer case and an array of outer air seals.
SUMMARY OF THE INVENTION
A primary object of the present invention is to increase the sealing effectiveness of a seal means defining a cooling air flowpath between a working medium flowpath and the outer case. Another object is to set the diameter of the ring in operative response to changes in diameter of the outer case. A further object is to ensure an effective fatigue life of the seal structure. In one embodiment, an object is to increase the sealing effectiveness of a seal means defining a cooling air flowpath between an array of outer air seals and the outer case.
According to the present invention, a segmented means for sealing having dual walls is positioned radially by an outer case between the case and a working medium flowpath to define a cooling air flowpath between the means for sealing and the outer case.
A primary feature of the present invention is the segmented seal means having dual walls. The segmented seal means has a segmented inner wall and a segmented outer wall. Another feature is the ring-like shape of the seal means. The segments of the outer wall radially face the segments of the inner wall. The inner wall segments are circumferentially spaced one from another leaving an expansion gap therebetween. The outer wall segments are similarly spaced. In one embodiment the expansion gaps of the inner wall are offset with respect to the expansion gaps of the outer wall. Other features are an upstream support hoop and a downstream support hoop extending inwardly from the outer case to engage the outer air seal and the segmented seal means. In one embodiment, the inner wall of each segment is trapped between the support hoops and an outer air seal. A pin extends through each segment of the segmented seal means and the support hoop.
A principal advantage of the present invention is the effective seal which results from the engagement between the support hoops and the dual walls of the segmented seal means. Circumferential gaps between adjacent wall segments are decreased in operative response to decreases in the diameter of the case. An adequate fatigue life is ensured by the sliding engagement between adjacent segments of the segmented ring and between the segmented ring and the support hoops. Differential rates of thermal expansion are accommodated by providing an expansion gap to the segments of the dual wall structure. In one embodiment, radial leakage of the cooling air is further decreased by offsetting the gaps.
The foregoing and other objects, features and advantages of the present invention will become more apparent in the light of the following detailed description of preferred embodiments thereof as discussed and illustrated in the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a simplified, side elevation view of a turbofan engine with a portion of an outer case broken away to reveal internal structures positioned by the case and a seal means extending therebetween.
FIG. 2 is an enlarged sectional view of a portion of the outer case, the internal structures positioned by the outer case and a seal means extending therebetween.
FIG. 3 is a sectional view of the seal means taken along the lines 3--3 as shown in FIG. 2.
FIG. 4 is a sectional view taken along the lines 4--4 as shown in FIG. 2.
DETAILED DESCRIPTION
A gas turbine engine embodiment of the invention is illustrated in FIG. 1. The principal sections of the engine include a compression section 10, a combustion section 12 and a turbine section 14. An annular flowpath 16 for working medium gases extends axially through the engine. An outer case 18 circumscribes the flowpath for hot working medium gases. In the turbine section, a flowpath 22 for cooling air extends between the outer case and the hot working medium gases.
FIG. 2 is an enlarged sectional view of a portion of the turbine section 14. A first element, such as upstream support hoop 24, and a second element spaced axially from the first element, such as downstream support hoop 26, extending inwardly from the outer case. The outer case is adapted by a downstream groove 28 to receive the downstream support hoop and by an upstream groove 30 to receive the upstream support hoop. As those skilled in the art will realize the upstream and downstream support hoops may be continuous rings or segmented rings. The upstream support hoop has an outer flange 32 and an inner flange 34. The inner flange is radially spaced from the outer flange leaving a rearwardly facing groove 36 therebetween. The outer flange has an inner surface 38 and an outer surface 40. Similarly, the downstream support hoop has an outer flange 42 and an inner flange 44. The inner flange is radially spaced from the outer flange leaving a forwardly facing groove 46 therebetween. The outer flange has an inner surface 48 and an outer surface 50.
Means for sealing and metering cooling air, such as a segmented ring 52, extends between the outer flange 32 on the upstream support hoop 24 and the outer flange 42 on the downstream support hoop 26. The segmented ring has a segmented inner wall 54 and a segmented outer wall 56. Each segment of the outer wall has an upstream end 58, a center section 60 and a downstream end 62. Each segment of the inner wall has a downstream end 64, a center section 66 and an upstream end 68. The center section of each segment of the outer wall is attached, for example by welding or other suitable means, to the center section of a single segment of the inner wall. A pin 70 penetrates the downstream support hoop and the inner wall. The inner wall is adapted by a slot 72 extending axially to receive the pin at a spline-type connection 74.
The free position of the outer wall and the inner wall at the upstream end and at the downstream end are shown by the dotted lines. At the upstream support hoop 24 in the installed position, the inner wall presses against the inner surface 38 to exert a sealing force along a line of sealing contact A, the line having a radius R a about the axis of the engine and a radius R b in the free state. The outer wall presses against the outer surface 40 to exert a sealing force along a line of sealing contact C, the line having a radius R c about the axis of the engine and a radius R d in the free state. The difference between R c and R a is greater than the difference between R d and R b causing an interference fit between the flange and the inner and outer walls, i.e. [R c -R a ]>[R d -R b ]. Similarly at the downstream support hoop 26, the inner wall presses against the inner surface 48 to exert a sealing force along the line of sealing contact A', the line having a radius R a ' about the axis of the engine and a radius R b ' in the free state. The outer wall presses against the outer surface 50 of the outer flange 42 to exert a sealing force along a line of sealing contact C', the line having a radius R c ' about the axis of the engine and a radius R d ' in the free state. The difference between R c ' and R a ' is greater than the difference between R d ' and R b ' causing an interference fit between the flange and the inner and outer walls, i.e. [R c '-R a ']>[R d '-R b '].
An array of vanes, as represented by the single vane 76, extends inwardly from the outer case into the working medium flowpath 16. An array of rotor blades, as represented by the single rotor blade 78, extends outwardly into the working medium flowpath into proximity with the outer case 18. A plurality of outer air seals, as represented by the single outer air seal 80, radially oppose the rotor blades. Each outer air seal has an upstream tongue 82 and a downstream tongue 84. The upstream tongue projects into the groove 36 and traps the inner wall between the outer air seal and the upstream support hoop. Similarly the downstream tongue 84 projects into the groove 46 and traps the inner wall between the seal and the downstream support hoop.
Each outer air seal 80 has a cooling air cavity 86 and a cooling air exit hole 88. A plurality of holes 90 in the center section 60 of each segment of the ring 52 are in gas communication with the cooling air cavity and the cooling air flowpath 22.
A plurality of external cooling air tubes 92 circumscribes the outer case 18. A source of cooling air at an upstream location, such as compression section 10, is in flow communication with the tubes.
FIG. 3 is a sectional view of the segmented ring 52. Each outer wall circumferentially overlaps an inner wall of an adjacent segment. Each segment is circumferentially spaced from the adjacent segment leaving an expansion gap E therebetween.
FIG. 4 is a directional view along the line 4--4 of FIG. 2. Each outer air seal is spaced circumferentially and overlaps the adjacent outer air seal leaving an expansion gap E' therebetween. In the absence of a pin 70, a pin 94 penetrates the inner flange 44 of downstream support hoop 26 and the tongue 84 of a corresponding outer air seal 80.
During operation of a gas turbine engine, the hot working medium gases and cooling air enter the turbine section 14 of the engine. The hot working medium gases follow the flowpath 16 into the turbine section. Components of the turbine section, including the outer air seal 80, the segmented ring 52, the outer case 18 and structure positioned by the case, such as upstream support hoop 24 and downstream support hoop 26 are heated by the working medium gases. High pressure cooling air following the flowpath 22 is flowed through the holes 90 in the segmented ring to enter the plurality of cooling air cavities 86 in each outer air seal. The cooling air is flowed out of the cooling air cavity through the exit holes 88 and provides film cooling to the outer air seal.
The components of the engine respond thermally at different rates to heating by the working medium gases and cooling by the cooling air. The outer air seal 80 and the segmented ring 52 have a thermal capacitance that is much smaller than the thermal capacitance of the outer case 18. The outer air seal and the segmented ring are also in closer proximity to the hot working medium gases 16 than is the outer case. Accordingly the outer air seal and the segmented ring respond more quickly to changes in gas path temperature than does the outer case. An increase in the temperature of the hot working medium gases, such as occurs during accelerations and startup, causes the array of outer air seals and the segmented ring to expand circumferentially decreasing the circumferential gaps between adjacent outer air seals and adjacent ring segments. The outer air seal and the segmented ring are maintained at a radius dependent on the position of the turbine case which determines the position of the pins 70 and 94. Locating these pins at the circumferential midpoint of each outer air seal causes the circumferential ends of each of these components to move equally. As those skilled in the art will appreciate these pins may be located away from the circumferential midpoint of the sections causing the circumferential ends to move unequally in response to thermal growth.
The inner wall 54 of each seal segment presses the outer air seal 80 tightly against the inner flange 34 of the upstream support hoop 24 and the inner flange 44 of the downstream support hoop 26. Correspondingly, the upstream tongue 82 and the downstream tongue 84 of the outer air seal press against the inner wall to exert a spring-type sealing force along sealing contact line A and sealing contact line A'.
Each outer air seal 80 and each segment of the sealing ring also expands axially during startup and accelerations. As the seal means expands axially the sealing contact line A and A' slide axially along the inner surface 38 of the outer flange 32 and along the inner surface 48 of the outer flange 42. In addition to the spring-type contact force supplied by the outer wall along the sealing contact lines C and C' on the outer surface 40 of the outer flange 32 and the outer surface 50 of the outer flange 42, the high pressure cooling air 22 urges the outer wall inwardly causing the outer wall to press tightly against the outer flanges.
The outer case 18 and adjacent structure such as the upstream support hoop 24 and the downstream support hoop 26 responds more slowly than does the array of outer air seals 80 and the segmented ring 52. The case reaches a steady-state position after these components. Before the case reaches a steady-state condition, the case grows outwardly with respect to the centerline of the engine and causes the array of outer air seal segments and the segmented ring 52 to move to a larger diameter. The outer air seal segments and the segments of the segmented rings slide circumferentially with respect to each other causing the expansion gaps E and E' to increase.
At cruise, the clearance between the ends of the rotor blades 78 and the outer air seal 80 is excessive and decreases the operating efficiency of the engine. Cooling air from an upstream location such as the compression section 10 is flowed through the cooling air tubes 92 and caused to impinge the outer cases. The outer case contracts causing the case to decrease in diameter. The outer air seals and the segmented rings slide circumferentially with respect to each other. The expansion gaps grow smaller, and the diameter of the outer air seal decreases until the steady-state operating clearance at cruise between the blade tips and the outer air seal is reached.
Although this invention has been shown and described with respect to a preferred embodiment thereof, it should be understood by those skilled in the art that various changes and omissions in the form and detail thereof may be made therein without departing from the spirit and scope of the invention.
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Apparatus for confining cooling air to a flowpath between an outer case and adjacent structure is disclosed. Various construction details which enable the means to sealingly engage the adjacent structure to block the leakage of cooling air and to accommodate changes in diameter are discussed. The means has dual walls which are segmented.
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BACKGROUND OF THE INVENTION
This invention relates to burners and particularly to those which utilize a catalyst for flameless combustion. Such burners can operate with a large number of fuels and under a wide variety of environmental conditions to provide a very high heating intensity. The combustion products of these devices contain lesser amounts of substances such as carbon monoxide than open flame burners and hence are less toxic and more pollution free.
STATEMENT OF THE INVENTION
According to our invention we have divised a catalytic burner and a method of operating it. The burner that we have invented includes at least two zones and a plenum. One zone contains the catalyst and the other, an ignition zone, contains a starter means. The ignition zone is disposed downstream from the catalyst zone and is arranged in fluid flow relation with the plenum that receives mixes and distributes the materials for combustion. The catalyst zone, the ignition zone and the plenum are each separated from the other by foraminous members. Means are provided in conjunction with the plenum to interrupt the flow of the fuel or the combustion supporting gas, or both, into the ignition zone.
To operate the burner according to our invention, the fuel and combustion supporting gases are introduced into the plenum and in turn, passed into the ignition zone through a foraminous member. Flame combustion is initiated in the ignition zone and maintained for a sufficient time for the hot combustion gases to pass through another foraminous member and heat the catalyst to a temperature which will support flameless combustion. Then the flow of either the fuel or the combustion supporting gas or both is interrupted momentarily and the flame is extinguished. The flow is then resumed and flameless combustion will begin on the hot catalyst. The products of combustion flow out of the catalyst zone and provide the heat that is required.
We have found that it is important to separate the catalyst zone from the ignition zone by a foraminous member, preferably a screen with openings between about 0.075 and 0.028 inches. Likewise, it is important to separate the plenum and the ignition zone with another foraminous member, again preferably a screen with openings between about 0.075 and 0.028 inches. In the former case, the foraminous member provides for efficient distribution of the gas and prevents the catalyst from entering the ignition zone and in the latter case, the member prevents the flame from entering the plenum which might cause preignition and possible explosion.
Flame combustion in the ignition zone can be initiated in a number of ways. One of the more reliable approaches is to connect an incandescible source to a power supply. The source reaches a red heat quickly and a flame will be produces when combustible materials are passed over it. When the flow of such materials is interrupted, the current to the source can be stopped and, as the gas is introduced again, flameless combustion on the catalyst will start and be sustained. Another approach can be the use of a spark igniter which is attached to a high voltage source. Most preferably we use the discharge of a piezoelectric spark between a pair of electrodes for the ignition. Such discharges do not require auxiliary power supplies which can be highly advantageous when the burner is used as a camp stove.
DRAWINGS
FIG. 1 is a cross sectional view of one embodiment of the invention in which the catalyst can be maintained in a static or fluidized bed.
FIG. 2 is a cross sectional view of another embodiment of the invention which can be used for a stove burner and the gasses pass from the periphery of the catalyst zone into the center.
FIG. 3 is a cross sectional view of another embodiment of the invention. The flow path of the gasses is from the axis to the periphery of the catalyst bed.
DESCRIPTION
Referring now to the burner shown in FIG. 1, a bed of pellets is disposed in a cylindrical container 2 and is supported upon a metallic screen 3. The portion of the burner which confines the pellets constitutes the catalyst zone and combustible materials and combustion supporting gasses enter the zone through the distribution screen 3. In the preferred embodiment of this construction, the gasses and materials flow upwardly through the pellets in an even stream throughout the horizontal cross section of the bed 1. When the gasses are injected into the bed with sufficient pressure and flow rate, individual pellets are disengaged from each other and become suspended to form a fluidized bed which takes on many of the characteristics and appearances of a boiling liquid. When the entire bed 1 is in the fluidized state, the injected gases spread uniformly throughout the volume of the bed 1 with relatively uniform distribution and by maintaining the bed temperature above the ignition temperature of the fuel, the catalytic reaction of the fuel and combustion supporting gases will occur uniformly and complete combustion will be produced, leaving substantially no carbon monoxide.
An ignition screen 4 is disposed a short distance beneath the distribution screen 3 and the two screens 3 and 4 cooperate to define the ignition zone 11. A piezoelectric spark generator 5 is connected to two electrodes 6 and 6' which are disposed in the ignition zone 11. When the piezoelectric generator is activated, a spark jumps between the electrodes 6 and 6'.
Ignition screen 4 separates the ignition zone 11 from a plenum 14 that is disposed therebeneath. Fuel is admitted to the plenum 14 through conduit 7 and the flow rate is controlled by a valve or pressure regulator (not shown). The fuel conduit 7 communicates with orifices 9 and entrains air which enters there through orifices 9. The mixture of fuel and combustion supporting gas then flows through the throat of an aspirator 12, into the plenum 14 and thence into ignition zone 11 to the catalyst zone. Preferably the flow of combustion supporting gas is controlled by a sleeve 13 which is slidably disposed about tube 7 and is movable to cover and uncover the air intake orifices 9.
In operation of the burner, a two stage series is used. To start the burner, a fuel is introduced through conduit 7 at a fairly low rate, with sufficient air to completely burn the fuel in the ignition space without the production of carbon monoxide, or other products of incomplete combustion. In general, in order to keep the space of the ignition zone relatively small, the flow rate is less during the starting cycle than during the combustion cycle. The fuel entrains air which enters through orifices 9 and the gases pass through aspirator 12 which insures mixing. From the aspirator 12, the mixture enters the plenum 14 and passes through ignition screen 4 into ignition zone 11. A spark is initiated between electrodes 6 and 6' and a flame will form. The combustion products of the flame flow into the catalyst zone and heat at least a portion of the catalyst bed 1 to a temperature above about 350° F. in a few seconds. Such temperature will support spontaneous flameless combustion within the catalyst bed. The flame in ignition zone 11 is then extinguished by momentarily stopping the flow of fuel through conduit 7 or combustion supporting gas through orifices 9. The bed will be sufficiently hot to start the flameless combustion cycle in the catalyst bed 1 when the flow is reintroduced. When the flameless combustion starts, the flow rate is adjusted to a rate which completely burns the fuel and which is sufficient to fluidize the bed but insufficient to entrain the particles and blow them from the burner. Of course if the fluidized bed operation is not desired, the flow rate can be maintained at a level which will not produce this condition. We have found that a preferred rate is one which produces a heating intensity in the catalyst bed of at least approximately 1.6×10 6 BTU per hour per cubic foot of catalyst in the unfluidized state.
The flame that is produced during the first stage of operating our burner is confined to the ignition zone 14 by screens 3 and 4. They prevent the flame from entering the aspirator 12 or the mouth of the conduit 7. The size of the ignition zone 11 is not critical so long as it is large enough to allow for spark generation and to provide for a sufficient volume of flame to heat the catalyst. The quantity of catalyst disposed in the catalyst zone also is not critical so long as there are sufficient quantities to promote complete combustion of the fuel that is introduced.
As a further example of operating the burner of FIG. 1, the catalyst 1 was in the form of spheres of highly porous gamma alumina approximately 1/8" in diameter containing on their surfaces an average of approximately 0.1% by weight of catalytic platinum black. The catalyst zone had an inside diameter 15/8" and the depth of the catalyst bed 1 was 11/2". The screens 3 and 4 were stainless steel rectilinear wire mesh with wire diameter of 0.025" and wire spacing center-to-center of 0.050". The fuel orifice had a diameter of 0.007". Flame combustion in the ignition zone 11 was initiated by a commercial piezoelectric igniter, with propane entering conduit 7 at a pressure of 10 psig. After a few seconds of flaming, the combustion in the ignition zone 11 was extinguished by sliding sleeve 13 over orifices 9, thereby closing them.
Sleeve 13 was slipped back and orifices 9 were opened. The air reentered and the fuel-air mixture burned flamelessly on the surface of the catalyst pellets. The hot products of combustion left from the top of the catalyst bed to provide heat.
The ignition method described above can be applied to advantage in the design of a stove burner as illustrated in FIG. 2. The catalyst zone 21 is in the form of an annular body which has a screen 22 covering the opening through which the fuel-air mixture enters, and an exit screen 23 through which the combustion products leave. The bottom surface 24 of a cooking utensil can be located above the upper surface 26 of the catalyst zone 21 or alternatively, a plate (not shown) can be disposed therebetween. The combustion products move radially outward through the space 25 between the upper surface 26 of the catalyst zone and the surface 24. This configuration provides for effective heat transfer between the upper surface 26 of the catalyst zone and the surface 24 both by radiation from the hot combustion products passing through the space 25. A mixture of air and fuel enters through tube 27 into plenum 28 which can be formed of insulation material. The gases then flow into an annularly disposed ring 29 bounded by the ignition screen 22, distribution screen 30, the upper surface 26, and side surface 31, which together define the ignition zone 29. A piezo electrode 32 produces a spark in the ignition zone 29 to ignite the air-fuel mixture when a low flow of fuel is provided. By momentarily interrupting the flow of combustion air and/or fuel, the combustion is extinguished and thereafter flamelessly occurs in the catalyst bed when the flow is reintroduced.
Optionally an annular ring of non-catalytic material such as inert pellets or steel wool can be disposed about the catalyst bed 21 immediately inside of ignition screen 22 to prevent overheating of screen 22 and accidental backfiring into ignition zone 29 or plenum 28.
FIG. 3 illustrates another catalytic stove configuration which can use our method of ignition. The catalyst bed 41 is annular in shape and is enclosed on the entrance side by ignition screen 42 and on the exit side by another screen or perforated metal band 43 to retain the catalyst pellets.
The fuel enters under pressure through conduit 8 and then issues through a high velocity jet from orifice 45. As the fuel passes through the throat of an aspirator 47, air enters through orifices 54 and becomes entrained in the stream. The combustible mixture passes from a plenum 56 through distribution screen 48 into ignition zone 49. A piezoelectric igniter 50 is disposed within ignition zone 49 and is sparked from the tip to a nearby grounded metallic element. In operation, when fuel and air flows into ignition zone 49 and the spark is formed, a flame will be produced and confined within the ignition zone 49 by distribution screen 48. The products of the flame combustion will flow through ignition screen 42 and into the catalyst bed. The heat will be transferred to the catalyst pellets 41 and heat them to about 350° F. or above at which point they will support flameless combustion. The flame is then extinguished by momentarily sliding sleeve 55 over orifices 54. When the sleeve is slipped back, the air will reenter the orifices 54 and in turn will flow into the catalyst bed 41. At that time, flameless combustion will begin on the surfaces of the catalyst pellets. The products of combustion will leave the burner through the screen 43 at the periphery of the burner.
The top surface 51 of the burner may be formed of a metallic plate of good thermal conductivity, and of sufficient thickness to distribute the heat fairly uniformly throughout the top, thus preventing distortion which could result from large temperature gradients. The combination of a flat burner top and a cooking utensil with a flat bottom minimizes the thickness of the air film between the stove top and the utensil, and enhances the conduction of heat into the utensil promoting efficient use of fuel.
The lower surface 53 which retains the catalyst bed can be formed of metal and thermal insulation. In this embodiment, thermal insulation 52 is shown in contact with the catalyst pellets, and a metal support 53 provides the outer construction. A suitable insulation is a felt formed from refractory fibers. Such felt provides a resilient cushion for the pellets and protects them from cracking as a result of forces generated by thermal expansion during heating.
A wide variety of gaseous and liquid fuels can be used in the present invention. Liquid fuels such as gasoline, kerosene and Number 1 fuel oil along with liquid hydrocarbon mixtures or individual hydrocarbons such as benzene have applicability. Gaseous fuels such as city gas, natural gas, methane, propane, and butane may be used. Also applicable are liquids such as the lower alcohols, for example methanol, ethanol, propanol, butanol and their isomers. In the case of the heavier hydrocarbons such as kerosene and the Number 1 fuel oil, the liquids are atomized upon their entrance into the plenum, and it is sometimes necessary to initially entrain a supplementary starting gas or liquid to aid in the formation of a flame in the ignition zone. Also an evaporator may be provided downstream to heat the fuels in the fuel conduit or the liquid can be atomized from a nozzle. Means for mixing the fuel and air such as turbulence vanes may be provided in the plenum in addition to or in substitution for the aspirator. The fuel can also be introduced tangentially into the plenum, whereby turbulence can be inherently provided.
The catalyst which we prefer to use in the burner constitutes at least a substantial portion of discrete material in the bed and in sufficient quantities to effect complete oxidation of the fuel therein without the production of a flame. Examples of oxidation catalysts for use with the invention include activated forms of metal oxides impregnated with a minor amount of a metal in finely divided form. In particular, activated forms of alumina, beryllia, thoria, zirconia or magnesia or mixtures of these oxides impregnated with minor amounts of finely divided metals such as platinum, palladium, rhodium, ruthenium, silver, copper, chromium, manganese, nickel, cobalt or combinations of these metals are especially suitable.
As is known in the art of catalysts, the so-called activated forms of these metal oxides, such as activated alumina, are those forms which are characterized by a porous structure which possesses a large internal pore volume and surface area. The activated form is prepared by controlled dehydration of a hydrated form of the oxide, control of temperature during the dehydration being essential to prevent destruction of the pore structure. Activated alumina, for example, may be prepared by precipitating a hydrous alumina gel from a solution of an aluminum salt, drying gel, and thereafter heating carefully at a temperature not higher than about 2000° F. to expel the hydrated water and produce a partially anhydrous or substantially anhydrous oxide often referred to as gamma alumina. Catalytically active alumina may also be prepared from the naturally occurring bauxite, which contains, hydrated alumina, by removal of the impurities which it contains, such as iron and silicates, following by heating at a temperature below about 2000° F. to drive off the hydrated water.
The amount of metal impregnating the activated oxide may vary considerably and the optimum amount depends to some extent upon the particular metal chosen. In the case of platinum or palladium, for example, very small amounts are required to produce an oxidation catalyst of excellent activity, such as from 0.01% to 1.0% by weight based on the weight of the activated metal oxide. In the case of other materials, such as a silverchromium combination, a somewhat higher percentage of the metal such as from 0.2% to 5.0% may be more desirable.
Impregnation of the active oxide may be accomplished by any desirable method which will result in the depositing of the metal upon the surface of the oxide in finely divided form. Impregnation is most conveniently accomplished by dipping the metal oxide, such as activated alumina, into a solution of a salt of the desired metal and then decomposing the salt. Thus for example, activated alumina may be dipped into a 1.0% by weight aqueous solution of chloroplatinic acid, dried, and then the platinum salt decomposed into metallic platinum by heat. As a result of this type of impregnation, the platinum is distributed over the surface of the alumina in extremely divided form.
While oxidation catalysts of the type described above are particularly suitable for use with the invention, it is to be understood that other types having similar activity and similar properties with respect to deactivation temperature may also be employed. In general, it may be stated that suitable oxidation catalysts for use in accordance with the invention should have the following characteristics: good activity, that is the ability to promote the oxidation of fuels at high rates per unit catalyst surface area; wide range of effective operating temperatures, that is, the ability to promote the oxidation of fuels at significant rates at relatively low operating temperatures, such as temperatures from 350° F. to 1000° F. coupled with the ability to operate at high temperatures, such as up to 1300° F. or 1800° F. without undergoing deactivation; and fairly good physical stability such as resistance to erosion, attrition or other types of disintegration.
It is apparent that modification and changes can be made within the spirit and scope of the present invention. It is our intention, however, only to be limited by the scope of appended claims.
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A flameless combustion burner and method for operating the device. The burner includes an ignition zone with a starting device, a catalyst zone, and a plenum. To obtain flameless combustion, a fuel and a combustion supporting gas is introducted into the ignition zone from the plenum and a flame is initiated by means of the starting device. The products of combustion flow over the catalyst to heat it to a temperature where it can initiate flameless combustion. Then the flow of either the fuel or the combustion supporting gas or both is momentarily stopped and the flame is extinguished. The flow is then resumed while the catalyst is still hot and flameless combustion will start in the catalyst zone. The products of combustion are withdrawn from the catalyst zone and the heat is utilized in the burner.
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FIELD OF THE INVENTION
This invention relates to automatic fluid mixing devices. More particularly, this invention relates to enclosed devices designed to mix fluids passing therethrough safely. Specifically, this invention relates to automatic fluid mixing devices in which the component fluids passing through the device are intimately mixed in a way that facilitates the homogeneity of the components being mixed following their mixing.
BACKGROUND OF THE INVENTION
Industrial activities frequently involve a need to chemically interact liquids with each other. For example, it is oftentimes necessary to combine a liquid stream with another liquid, either to synthesize a new chemical product by chemical reaction, or in some instances, to render noxious liquids substantially harmless. In still other cases, liquids are combined to achieve a physical effect, as in the case where polymeric flocculents are added to, for example, sewage wastes in the process of their treatment.
In the case of the mining industry, for instance, it is commonly necessary to chemically treat mine seepage to control pH and precipitate dissolved metals prior to discharge. In such cases, sulfur-bearing rock formations are frequently associated with the mine geology, and these are subject to leaching by acidic water seeping into the mine through the overlying strata. As a consequence, such seepage often becomes contaminated with sulfur-containing acids as it passes through sulfidebearing strata, for example, geological formations containing pyritic sulfur, making it undesirable, if not illegal to discharge the seepage wastes into the environment without first neutralizing the contaminating sulfurous materials. As indicated, these are typically acidic in nature, creating a hazard to plant and animal life with which such seepage comes in contact, either directly or indirectly.
As a consequence, and in order to comply with state and federal environmental and mining regulations, it has been become commonplace to introduce a neutralizing material, such as for instance, liquid caustic soda to such wastes to facilitate the precipitation of metals before before releasing the wastes to the environment.
One method for treating mine seepage wastes involves collecting the wastes in an intermediate storage tank prior to treatment. Thereafter, following filling of the tank to a predetermined level, a portion of the tank's contents are automatically syphoned from the tank, activating a caustic-dispensing, spring-loaded valve by impact of the syphoning stream against the valve actuating mechanism. Caustic soda introduced through the actuated valve mixes with the wastes, which then travel through an open mixing trough during a reaction process between the waste and the caustic, the neutralized stream ultimately being deposited, for instance, in a waste water storage and settling pond. While the system described can be successfully employed to treat the wastes, it has the distinct disadvantage of risking inadvertent contact of those in the vicinity of the treatment equipment with hazardous materials during the treatment process.
Another method of neutralization involves passing the acid wastes over sodium carbonate briquettes; however, this process suffers from the fact that the briquettes are somewhat hazardous materials, in addition to which, the reaction rate and the amount of treatment are difficult to control, and the operation is relatively labor intensive.
BRIEF SUMMARY OF THE INVENTION
In view of the foregoing, therefore, it is a first aspect of this invention to provide a device for combining liquid materials.
It is a second aspect of this invention to provide a totally enclosed mixing device for chemically reactive liquid materials.
An additional aspect of this invention is to provide a device and an associated process for rendering hazardous and toxic liquid materials safe for discharge to the environment.
A further aspect of this invention is to provide an adjustable mixing device for combining liquids in appropriate stoichiometric amounts.
Another aspect of this invention is to provide a mixing device for automatically combining liquid streams of reactive materials as they pass through the device.
A still further aspect of this invention is to provide a device for the non-hazardous mixing of mine seepage liquids with materials whose combination with such liquids results in their neutralization and/or settling.
Yet an additional aspect of this invention is to provide a mixing device for liquids that facilitates their mixing in ratios that result in their neutralization.
The preceding and still further aspects of the invention are provided by a device for mixing fluids. The device comprises a housing wherein mixing of the fluids takes place and which has a fluid entry port for a first fluid, and a fluid exit port. A first valve is also included that extends into the housing, providing an entry point into a mixing chamber within the housing for admitting a second fluid, the first and second fluids being mixed in the chamber before being discharged through the fluid exit port. The device also includes first valve actuating means, activated by the flow of fluids through the mixing chamber, as well as a second valve for controlling the flow of fluid to the first valve.
The preceding and still other aspects of the invention are provided by a process for neutralizing acidic fluids in an enclosed fluid mixing device. The device includes a housing enclosing a mixing chamber that is provided with a port for the entry of acidic fluids and/or fluids containing highly suspended solids, and an exit port for the discharge of neutralized or treated fluids.
A first valve extends into the housing, providing an entry point for introduction of basic fluid materials and/or flocculating agents into the mixing chamber, the acidic materials being mixed with the basic fluid materials and/or agents and neutralized in the chamber. The device also includes first valve actuating means activated by the flow of fluids through the chamber, and a second valve for manually controlling the flow of basic fluids and/or agents to the first valve.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood when reference is had to the drawing, which shows a semi-schematic representation of the liquid mixing device of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The FIGURE represents a semi-schematic drawing of the liquid mixing device of the invention, generally 10. The device comprises a housing 12 which serves as a mixing chamber, advantageously provided with baffles 13 at an entry point 15 of the housing 12, and additional baffles 13a at an exit port 17 of the housing.
An entry point 19 is also provided in the housing 12 through which a valve arrangement, generally 26, extends. The valve arrangement 26 comprises a body portion 21 of a needle valve, or its equivalent, at the lower end of which is located in series a toggle valve, generally 14, through which neutralizing fluids enter the housing 12 through a series of orifices 18. The toggle valve 14 also includes a toggle mechanism 16 which actuates the valve and allows fluids (not shown) to entry the housing 12.
A toggle valve mechanism actuating rod 20 is attached to the toggle mechanism 16 preferably by a flexible coupling 22. An actuating rod augmentation attachment 24 can also be fastened to the lower end of the mixing device actuating rod 20, if desired. A drain port 28 is advantageously located at the lower portion of the housing to provide relief for potentially valve-damaging increases in pressure within the mixing device.
As previously indicated, the mixing device is particularly useful in the neutralization of acidic mine wastes. In such uses, mine wastes enter the mixing device in the direction of the arrow "A", being mixed in the interior 25 of the housing 12, which serves as a mixing chamber, with a neutralizing fluid and/or flocculating agents entering the mixing device in the direction "C", the neutralized mixture exiting the mixing device in the direction "B", following neutralization of the acidic material.
While the application of the liquid mixing device 10 has been described in connection with the neutralization of acidic materials, for example, acidic mine wastes, it can also be used for the commingling of any fluids reactive with each other, and it can also be successfully employed in connection with the mixing of fluids in which the reaction is not chemical but rather physical, as for instance, in the case of introducing flocculating agents, for example, polymeric floculents in order to assist the settling of suspended material in the introduced fluids.
In the case of the neutralization of acidic fluids such as mine wastes, the neutralizing agent added through valve 26 can be any basic liquid such as solutions of caustic soda, potassium hydroxide, or others. Since such materials are corrosive, and in view of the fact that the wastes being treated are acidic in nature, an advantage of the liquid mixing device of the invention is that the mixing of the potentially hazardous materials occurs in an enclosed apparatus, eliminating the danger of inadvertent contact with the materials.
The shape of the housing within which mixing takes place is relatively unimportant; however, it has been found to be particularly advantageous to employ a housing having a "Tee" configuration since such a configuration lends itself well to the introduction of the neutralizing fluids, as well as the materials being treated. In the case of such a mixing device, the neutralizing fluid advantageously enters the branch portion 19 of the Tee.
If desired, and in the preferred embodiment of the invention, the housing can be provided with baffles 13 and 13a to enhance the mixing action of the fluids being combined, therefore assuring intimate commingling and substantially complete reaction in those cases where a chemical reaction is occurring between the introduced components. While baffles may take a variety of forms, it has been found that a simple grid pattern, as illustrated in the FIGURE is satisfactory since it provides superior mixing results, and since such baffles are relatively inexpensive; consequently, their use provides a preferred embodiment of the invention.
In the case of mine wastes, as well as in other chemical reactions, it is desirable to assure that relatively stoichiometric amounts of the materials being mixed enter the mixing device 12. As a consequence, and although other valves can be used for introducing the neutralizing agent at C, employment of a needle valve, particularly one manually adjusted, has been found to be especially useful since it can be accurately adjusted to introduce relatively exact amounts of the materials needed to neutralize the amount of acidic wastes entering at A. In conjunction with such needle valves, the invention comprehends the use of a further valve in series, in effect providing a compound valve arrangement, in the form of a toggle valve 14 which is actuated by the lateral displacement of a toggle mechanism 16, allowing fluids passing through the needle valve 26 to exit the toggle valve through orifices 18. Although other equivalent valves can be used, an example of a suitable toggle valve is that manufactured by Mono Flo International Inc. of McClean, Va., and marketed as a "Nipple Drinker" valve, Model No. 10094.
Actuation of the toggle operated valve 14 in the mixing device of the invention is accomplished by flow of the waste being treated, entering at A, impacting actuating rod 20, connected to the toggle mechanism 16 by a flexible coupling 22. The flexible coupling 22 can advantageously be a piece of elastomeric tubing of suitable length.
Since the flow of the liquid waste being treated varies with conditions, an advantage of the mixing device of the invention is that the valve 26 can be manually adjusted from time-to-time to correspond to changes in the operating conditions. Furthermore, and in cases where lower volumes of wastes are being treated, the effective impact area of the actuating rod 20 may be increased by addition of an augmentation device such as 24 which increases the area of the actuating rod 20 being impacted by the fluid entering at A. Such an augmentation device can simply be a ball screwed on the end of the actuating rod 20 or an equivalent device. Conversely, during periods of high flow of wastes entering the mixing device, the toggle valve 14 is protected by the fact that the flexible coupling 22 allows the actuating rod 20 to move further laterally without causing a corresponding movement in the toggle mechanism 16.
In a preferred embodiment of the invention, a drain port 28 is provided in order to accommodate increased pressure within the liquid device, for instance, in the event the liquids within the device were to freeze.
Any of a variety of materials can be used for fabricating the mixing device described in the preceding, for example, the housing can be made of plastic including polyolefins, polyvinyl chloride, or others. Similarly, plastics are also useful in fabricating the actuating rod 20 and the area augmentation devices 24. However, corrosion-resistant metals may also be used if desired.
In the case of the valves, metals resistant to corrosion, such as stainless steel and similar materials have been found to be particularly useful.
The dimensions of the components of the liquid measuring device will naturally depend on the flows being accommodated; however, commonly Tees having ratios of 4×4×4, 6×6×4, as well as other ratios are suitable. Where the preceding ratios define inches, a 11/2" long by 1/4" diameter flexible connecting tubing is suitable, while the actuating rod in such cases will be about 1/4" in diameter and extend to near the bottom of the housing.
While in accordance with the patent statutes, a preferred embodiment and best mode has been presented, the scope of the invention is not limited thereto, but rather is measured by the scope of the attached claims.
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A fluid mixing device comprises a housing provided with fluid entry ports for fluids being treated, and for treatment fluids, as well as a fluid discharge port for the discharge of treated fluids. A compound valve arrangement is positioned in the entry port, comprising one valve for adjusting the amount of treatment fluids entering the mixing device, and in series therewith a toggle valve actuated by a rod attached to the toggle valve which extends into the housing and which is actuated by the impact of fluids passing through the device. The mixing device is particularly suited to the neutralization of mine waste waters with caustic soda and for the introduction of polymer flocculents to induce the settling of solids in liquid suspension.
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FIELD OF THE INVENTION
The present invention relates to an apparatus for routering a surface and a cutting head and tool piece therefore. More specifically, the present invention relates to an apparatus for routering surfaces such as concrete and asphalt with reasonable accuracy of positioning and depth and an improved cutting head and tool piece therefore.
BACKGROUND OF THE INVENTION
Apparatus for routering surface art well known and include systems for routering cracks in asphalt or concrete as a step in the process of repairing those cracks. Such system may also be used to remove paint from the asphalt or concrete surfaces, by setting the routering action to a depth substantially equivalent to the paint thickness, and for a variety of other purposes.
As used herein, the terms cut and/or router a surface and cut or router a groove in a surface are intended to comprise the removal of undesired material from a surface. Such undesired material can be a portion of the material making up the surface, such as the cutting of a groove in an asphalt surface to repair a crack therein, or the removal of material which has been previously applied to a surface, such as removing paint from a concrete surface substantially without damaging the surface.
Prior art routers include those described in U.S. Pat. No. 4,175,788 and 4,204,714 to Crafco Inc. Generally, these routers comprise a two wheeled device with a cutting head located between the wheels and motor mounted above the wheels. The cutting head includes a horizontal shaft, which is substantially in line with the axis of the wheels, and a pair of large diameter steel discs spaced about five inches apart the center of the shaft Six cutting blades are mounted between these discs via six pins which extend between the discs and through the center of the respective blade. Each of these cutting blades includes eight cutting blades which extend radically from the center of the blades in a star-like manner.
The shaft and the assembly of the discs and blades is rotated by the motor, via a belt drive, and the blades are free to rotate on the pins and also have some free play between their centers and the pins. As the discs are rotated by the motor, the cutting blades pound a cut into the surface being worked.
A set of handles extend from the device and are held by the operator working the device who uses the handles to propel the device and to steer the cutting head onto the crack or other surface area to be routered. An electric switch is provided on the handles to operate a motorized screw actuator which is used to alter the routering depth of the cutting head by moving the cutting head vertically, relative to the two wheels and the surface.
Problem exist with the prior art router devices in that it is difficult for the operator to accurately control the positioning of the cutting head. It is also difficult, if not impossible, for the operator to control the routering depth of the device in that the actuator is not susceptible to accurate operation and the inevitable vertical movement of the handles by the operator while controlling the device also results in changes to the routering depth. Further, as the operator must exert great care when maneuvering and propelling the device with the handles, the amount of surface which is routed in a given time is reduced from that which would be routed if accurate operation and movement of the devices was easier. Also, and perhaps most importantly, with conventional cutting heads such as those disclosed in the above-mentioned U.S. patents to Crafco, due to the pounding action whereby the cutting blade effects its cut, micro cracks may be formed in the surface being worked adjacent the cut, resulting in new damage be introduced to the surface.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a novel apparatus for routering a surface which obviates or mitigates at least one of the above-described disadvantages of the prior art. It is a further object to provide a novel cutting head and tool piece therefore for routering a surface.
According to a first aspect of the present invention, there is provided a self propelled device for cutting groove in a surface, comprising:
a frame;
prime mover means;
at least on pair of drive wheels rotatably mounted to said frame and each wheel independently driven by said prime mover means and rotating about a substantially common axis;
at least one balance wheel rotatably mounted to said frame and operable with said at least one pair of drive wheels to support said device on said surface, said balance wheel being substantially freely pivotable about a vertical axis to allow said device to be steered by said driven wheels;
a cutting head assembly vertically moveable between a desired working position wherein at least one cutting tool piece in said cutting head assembly contacts said surface and a free position wherein said at least one cutting tool piece is above said surface, said cutting head assembly being driven by said prime mover to cut said surface with said cutting tool piece;
a steering means to operate each of said drive wheels to move and steer said device; an
a cutting bead control means to move said cutting head assembly between said desired working position and said free position.
According to yet another aspect of the present invention, there is provided a cutting head assembly for routering a surface, comprising:
a tool collar;
a shaft rotatably mounted to said collar;
means to rotate said shaft;
a cutting head mounted to one end of said shaft and rotating therewith, said head being operable to receive at least one cutting tool piece:
a pivotal mount to connect said tool collar to a cutting device and to allow the height of the tool piece relative to a surface to be altered.
According to yet another apect of the present invention, there is provided a tool piece for routering a surface, comprising;
a cylindrical steel body;
a filler material comprising a mixture of micron-sized tungsten carbide particles and a diamond setting binder, said mixture forming a plurality of finger depending from said steel body and forming a layer over at least a portio of said steel body;
a plurality of industrial bonded to outer and lower faces of said fingers to form a cutting surface thereon; and
a carrier attached to said steel body, said carrier include means to attach said tool piece to a cutting head.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
FIG. 1 shows a perspective new of a router in accordance with an embodiment of the present invention;
FIG. 2 shows a view of the router of FIG. 1 from the operator's chair;
FIG. 3 shows a partial cut away view of a cutting head assembly of the router of FIG. 1 in a raised position;
FIG. 4 shows the cutting head assembly of FIG. 3 is a lowered position;
FIG. 5 shows another embodiment of a cutting head assembly:
FIG. 6 shows a side view of a tool piece for use with the cutting head assembly of FIG. 5; and
FIG. 7 shows a bottom view of the tool piece of FIG. 6.
DETAILED DESCRIPTION OF THE INVENTION
A router device in accordance with an embodiment of the present invention is indicated generally at 10 in FIGS. 1 and 2. Device 10 includes a frame 12, a prime mover means 14, which in this embodiment is a forty-seven HP diesel engine, operatively coupled to a hydraulic pump 18 which is in turn coupled to a variety of devices, described below. A diesel fuel tank 20 is provided at one end of device 10, as is a radiator 21 and a supply of hydraulic oil for pump 18 is maintained in tank 19.
Device 10 is propelled by a pair of hydraulic motors 22 and 26, mounted to frame 12, each of which rotates a respective one of a pair of drive wheels 30 and 34 via chain drives 38 and 42. Drive wheels 30 and 34 are mounted to frame 12 via axles and suitable bearings, not shown. Motors 22 and 26 are controlled by joysticks 46 and 48, respectively, which operate an appropriate set of valves to supply hydraulic pressure from pump 18 to motors 22 and 26 such that pushing joysticks 46 and 48 forward moves device 10 forward, pulling joysticks 46 and 48 backward moves device 10 backward and moving one of joysticks 46 and 48 forward and the other backward causes device 10 to rotate either clockwise or counter-clockwise, depending upon the relative joystick positions, about a point midway between the axles of drive wheels 30 and 34.
A balance wheel 50 is to frame 12 adjacent one end of device 10 and acts' as a third support point, in addition to drive wheels 30 and 34, for device 10. In this embodiment of the present invention, the center of gravity of device 10 is located between the of the axles of drive wheels 30 and 34 and balance wheel 50 and thus device 10 is stable on these three contact points. Balance wheel 50 is mounted to frame 12 such that it may freely turn about a vertical axis and thus, as drive wheels 30 and 34 are driven by motors 22 and 26 to steer a desired path for device 10, balance wheel 50 is free to turn to allow device 10 to follow that path. It is contemplated that an additional balance wheel (not shown) may be provided at the end of device 10 opposite balance wheel 50 to stabilize the device when the center of gravity is not otherwise favorably located. If this additional balance wheel is provided, it can be similarly mounted to frame 12 to operate to allow device 10 to be steered by drive wheels 30 and 34.
While hydraulic motors 22 and 26 and chain drives 38 and 42 are employed in this embodiment of the present invention, it is contemplated that a hydrostatic drive may be preferred in some circumstances and the selection, use and configuration of such a drive will be readily apparent to those of skill in the art.
In addition to suppling hydraulic pressure to motors 22 and 26, pump 18 also supplies hydraulic pressure to cutting head motor 100. Specifically, as best shown in FIGS. 3 and 4, a cutting head assembly 108 includes cutting head motor 100 and a cutting head 104 which is rotatably mounted to cutting head assembly 108. Cutting head motor 100 drives cutting head 104 via a dual belt drive 112 as shown. Cutting head 104 is similar to the conventional cutting heads, as described above, with a pair of spaced discs with a plurality of cutting tools (not shown) mounted therebetween.
Cutting head assembly 108 is mold pivotal to the frame of device 10 via a pivot pin 116 and a hydraulic ram 120 extends between a vertical member of frame 12 and cutting head assembly 108 such that the working portion of cutting wheel 104 is lowered or raised as ram 120 is extended or retracted. In the raised position, shown in FIG. 3, cutting wheel 104 is disengaged from surface 124 allowing device 10 to be moved to a desired position. In the lowered position, shown in FIG. 4, cutting wheel 104 engages surface 124 and a groove 128 can be routered to a selected depth. As will be apparent, cutting head assembly 108 is located within a perimeter defined by balance wheel 50 and drive wheels 30 and 34.
Ram 120 is controlled by moving joystick 46 from side to side which, via appropriate valving, provides for accurate control of the position (depth) of cutting wheel 104 relative to surface 124. It is contemplated that, if required, joystick 46 and its associated valving may provide for changes to cutting wheel 104 to an accuracy of about 1 mm.
FIG. 2 shows the view an operator has when seated in the operator's chair 134. As will be noted, the operator has a clear view of the area which is to be worked, in this example a crack 136 in an asphalt surface, as well as cutting wheel 104 and cutting head assembly 108 in general. It is contemplated that, the combination of the accuracy of movement provided by drive wheels 30 and 34 via joysticks 46 and 48 and he relatively clear view of the working area provided will result in an operator being able to router surface 124 more quickly than with prior art devices and with greater accuracy, both in terms of positioning of groove 128 and of its depth.
In FIG. 5 another cutting head assembly for use with device 10 is indicated generally at 200. In this embodiment, cutting head assembly 200 includes a shaft 220 which is rotatably mounted in a tool collar 224 via a pair of bearings 228. Shaft 220 includes a cutting head 204 at one end and a drive pulley 232 is fixed to the other end of shaft 220. Drive pulley 232 receives a double belt drive 236 from a drive pulley 240 rotated by a hydraulic motor 244 which is also mounted to tool collar 224. Hydraulic motor 244 is operated by hydraulic pressure supplied from pump 18, as in the embodiment of FIGS. 1 through 4 discussed above. Cutting head 204 includes a male threaded portion (not shown) to receive tool piece 208, described below.
Tool piece 208, which is best seen in FIGS. 6 and 7, includes a body 300 which in the presently preferred embodiment is formed of hardened steel. Carrier body 300 includes a female threaded portion 304 to engage the complementary threaded portion of cutting head 204 and tapers through a transition zone 308 to cutting portion 312. Cutting portion 312 includes nine depending fingers 316 which are arranged in a circular pattern. Fingers 316 include tungsten carbide outer and bottom surfaces to which several industrial diamonds 320 have been mounted as shown in the FIGS. Diamonds 320 are mounted to fingers 316 through any suitable process, such as by silver soldering into recesses formed in fingers 316, as will occur to those of skill in the art. In the presently preferred configurations of tool piece 208, the height of fingers 316, and thus cutting portion 312, can be 20 mm or 40 mm depending upon the maximum desired depth of the grove to be routered with tool piece 208. The diameter of cutting portion 312 is presently preferably about 40 mm, other diameters or heights can be constructed as desired and larger diameter tool pieces 208 may favorably include more than nine fingers 316 while smaller diameter tool pieces 208 may include less than nine fingers 316.
The presently employed method of fabricating tool piece 208 is to insert a steel body into an appropriately shaped mold along with filler material of micron-size tungsten carbide mixed with a diamond sewing binder to promote eventual bonding of diamonds 320. The slots between fingers 316 are formed by inserting graphite spacers in the filler material and the mold is then inserted into a furnace for firing. After being appropriately fired, the graphite spacers are removed and diamonds 320 are bonded to fingers 316 by silver soldering. Carrier body 300 is then attached, after having been appropriately threaded. While this fabrication method is presently employed, it is believed that other suitable methods will occur to those of skill in the art.
As was the case with cutting had assembly 108, cutting head assembly 200 is pivotally mounted to device 10 via a pivot pin 116 and hydraulic ram 120 connects to tool collar 224 as shown in FIG. 5 such that cutting head 204 may be raised or lowered in to and out of engagement with surface 216.
In operation, cutting head 204, and thus tool piece 208, is rotated at an appropriate speed by hydraulic motor 244 and ram 120 lowers cutting head 204 until cutting portion 312 of tool piece 208 engages the surface 216 to be routered to the desired depth of a groove 212. An adjustable foot plate (not shown) attached to tool collar 224 extends toward surface 216 to ensure that cutting head 204 is not lowered too far, to prevent portions of tool piece 208 other than cutting portion 312 from contacting surface 216. Ram 120 maintains tool piece 208 at the desired work depth, as set with joystick 46, and provides sufficient downward pressure to keep the lower surfaces of fingers 316 in cutting engagement with surface 216 as tool piece 208 is moved along surface 216 with device 10. Depending upon the diameter and configuration of tool piece 208 and de composition of surface 216, the rotational speed of shaft 220 can be set to speeds of from about 3000 RPM to about 12000 RPM.
It is contemplated that the diamond tipped tool piece 208 will provide cleaner and more accurate cuts than conventional knife-based cutting heads and will be less expensive to maintain than such prior art devices, requiring only normal replacement of tool pieces 208. Further, it is contemplated that use of tool piece 208 will avoid the formation of micro crack damage to the working surface. It is also contemplated that replacement of tool pieces 208 can be accomplished in a relatively simple and quick manner compared to the replacement of the cutting tools in conventional cutting heads such as cutting head 104 describe above. Specifically, a spent tool piece 208 can simply be, unscrewed from cutting head 204 and a new tool piece 208 screwed on. It is further contemplated that spent tool piece 208 may be refurbished, with diamonds 320 being replaced as necessary and tungsten carbide surface being repaired as necessary.
While the embodiment of cutting head assembly 200 shown in FIG. 5 is presently preferred, one of the advantages of device 10 is that it may use either cutting head assembly interchangeably. Thus, device 10 can be sold with either or both of cutting head assembly 108 and cutting head assembly 200, or retro fitted with either as desired. It is further contemplated that cutting head assembly 200 can be modified, as will be apparent to those of skill in the art, to allow retrofitting to prior art routering devices if such should be desired.
It is further contemplated that device 10 may be equipped with a vacuum system (not sown) which is operable to capture the detritus and debris produced by the cutting operations. It is contemplated that such as vacuum system can be employed with either embodiment of cutting head assembly disclosed above, although it is presently believed that better capture results art obtain from cutting head assembly 200.
The above-described embodiment of the invention are intended to be examples of the present invention and alterations and modifications may be effected thereto, by those of skill in art, without departing from the scope of the invention which is defined solely by the claims appended hereto.
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Apparatus for routering a surface comprises a pair of independently driven drive wheels and a balance wheel which is freely pivotal to follow a path steered by the drive wheels. A cutting head is pivotally mounted between the drive wheels and its height relative to the surface may be adjusted to alter the depth of the router action. An operator's seat is located such that the operator has a relatively unobstucted view of the surface to be routed and the cutting head. A control for adjusting the height of the cutting head is provided adjacent the operator's seat, as are controls for the drive wheels. An improved cutting head assembly and cutting tool place are also disclosed, the cutting head assembly including a rotating shaft with a cutting head at one end, the shaft being orientated perpendicularly to the surface to be routered. The cutting head retains a diamond tipped cutting tool piece which rotates with the shaft to router the surface.
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BACKGROUND OF THE INVENTION
The invention relates to a precision high frequency integrated circuit attenuator, which can be used in various integrated circuits, such as a window comparator circuit of the type which indicates whether an input voltage is within or outside of a predefined range or an analog-to-digital converter.
FIG. 1 shows a typical window comparator circuit including a comparator 1 having a non-inverting (+) input connected by conductor 4 to a first reference voltage V REF1 , its inverting (-) input connected to conductor 3 to an input signal V IN , and its output connected by conductor 6 to produce an output signal V 01 . A second comparator has its non-inverting input connected to conductor 3, its inverting input connected by conductor 5 to a second reference voltage V REF2 , and its output connected by conductor 7 to produce an output voltage V 02 . If V IN is between V REF1 and V REF2 , comparator 1 will not invert, so V 01 will be high. Comparator 2 will not invert, so V 02 will be high. If V IN is less than V REF2 , comparator 2 inverts, so V 02 will be low. If V IN is greater than V REF1 , comparator 1 will invert, so V 01 will be low.
Several difficult problems arise if a high speed window comparator of the general type shown in FIG. 1 is to be integrated onto a single monolithic integrated circuit chip. For typical standard integrated circuit manufacturing processes, the permissible range for the input signal V IN which can be applied directly to electrodes of integrated circuit transistors without causing undesired forward biasing of PN junctions and/or undesired PN junction breakdown is quite limited, typically between ground and -3 to +3 volts for present high speed IC comparators. If resistive voltage dividers are used to attenuate the input signal and reference signal before they are applied to the inputs of the integrated circuit comparators, the frequency response of the circuit is very poor because parasitic capacitors of integrated circuit resistors such as 25 and 26 in FIG. 2 usually are proportional to the resistor values and respond much differently to rapidly rising and rapidly falling edges of V IN than do the resistors 13 and 14. The result of this is unacceptable inaccuracies in the attenuation of V IN . For example, if resistors 13 and 14 are ordinary nichrome resistors and if the resistance of resistor 13 is five times that of resistor 14, the parasitic capacitance associated with resistor 13 is likely to be much larger than the parasitic capacitance 26 associated with resistor 14. Therefore, capacitive voltage division of V IN across parasitic capacitances 25 and 26 occurs in the opposite sense to voltage division of V IN across resistors 13 and 14, causing substantial errors in the attenuation of V IN from conductor 3 to conductor 15 for high frequency components. This, of course, causes inaccuracy in the results produced by the window comparator circuit 100.
Thus, there is an unmet need for an improved integrated circuit attenuator that can be used in an integrated circuit wherein accurate attenuation of both low frequency and high frequency input signals is needed, and especially where the amplitude of the input signals exceed the voltage tolerance capabilities of the internal integrated circuit which receives the attenuated signal.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide an integrated circuit attenuator circuit which avoids errors due to unequal dividing of low frequency and high frequency components of an input signal.
It is another object of the invention to provide an accurate, integrated circuit attenuator capable of accurately attenuating high frequency input signals, especially input signals having such large amplitudes that would normally cause undesired reverse biasing and/or forward biasing of certain PN junctions in the integrated circuit in which the attenuator included.
It is another object of the invention to provide an accurate, high speed integrated circuit attenuator which operates accurately in response to high frequency signals having a voltage range substantially beyond levels at which certain PN junctions of the integrated circuit undergo undesired reverse junction breakdown and/or undesired forward biasing of certain PN junctions.
It is another object of the invention to provide a window comparator circuit capable of producing accurate results for input signals with high frequency components and having voltages within a range that greatly exceeds certain maximum PN junction breakdown voltages of the integrated circuit and causes undesired forward biasing of certain PN junctions therein.
Briefly described and in accordance with one embodiment thereof, the invention provides an integrated circuit attenuator, which can be used as an input attenuator for an integrated circuit window comparator, analog-to-digital converter, or the like, including a divider circuit for dividing an external input voltage, the divider circuit including a thin film first resistor having a first terminal receiving the input voltage, a thin film second resistor having a first terminal connected to a reference voltage conductor and a second terminal connected to a second terminal of the first resistor to produce an attenuated input signal. A buffer applies the attenuated input signal to an integrated circuit window comparator, analog-to-digital converter or the like on the same chip. The first resistor includes a plurality of separate identical segments connected in series between its first and second terminals, and the second resistor includes a plurality of separate identical segments connected in series-parallel arrangement so that the ratio of the resistance of the first resistor to the resistance of the second resistor is precisely equal to the ratio of the parasitic capacitance of the second resistor to the parasitic capacitance of the first resistor. All of the identical segments of the first resistor are formed over an isolated region of a first integrated circuit structure, and all of the isolated segments of the second resistor are formed over a second isolated region of the integrated circuit structure. In the described embodiment, the first and second isolated regions are P-type regions each formed in an N-type region, and the first isolated region is connected to receive the input signal and the second isolated region is connected to the reference voltage conductor. The second resistor includes a plurality of series-connected groups of the identical segments, each of the groups including a plurality of the identical segments connected in parallel. In one embodiment, the attenuator is connected to an input of window comparator on the same chip wherein first and second voltage dividers are provided which divide first and second reference voltages, respectively, in the same ratio that the divider circuit divides the input voltage. In another embodiment, the attenuator is connected to an analog input of an analog-to-digital converter on the same chip.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a prior art window comparator circuit.
FIG. 2 is a schematic diagram of an integrated circuit window comparator useful in describing the problems of the prior art and also in describing the present invention.
FIG. 3A is a circuit diagram useful in describing the attenuator of the present invention.
FIG. 3B is a diagram illustrating an embodiment of the attenuator of the present invention.
FIG. 3C is a partial section view diagram useful in describing the attenuator of the present invention.
FIG. 4 is a schematic diagram useful in describing a preferred embodiment of the present invention.
FIG. 4A illustrates the structure in detail 4A in FIG. 4.
FIG. 4B illustrates the structure in detail 4B in FIG. 4.
FIG. 4C is a diagram of one of the resistors in FIG. 4B.
FIG. 5 indicates the topography of an integrated circuit including the attenuator of the present invention and a window comparator circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 2, numeral 100 designates an integrated circuit window comparator including the high frequency attenuator 50 of the present invention. However, FIG. 2 does not show an implementation of voltage division resistors 13 and 14 in which the parasitic capacitances 25 and 26 are precisely inversely proportional to the resistances of resistors 13 and 14, respectively, as is required in accordance with the present invention.
In FIG. 2, external reference voltage V REF1 applied to conductor 4 is divided down by resistors 8 and 9 to produce an internal reference voltage on conductor 10 which is applied by non-inverting buffer 16 to the inverting input of comparator 1. Attenuator 50, subsequently described in detail, divides the V IN signal applied to conductor 3 by means of resistors 13 and 14 to produce an attenuated input signal on conductor 15. The attenuated input signal on conductor 15 is applied by non-inverting buffer 17 to the non-inverting input of comparator 1. The attenuated signal on conductor 15 also is applied by non-inverting buffer 23 to the non-inverting input of comparator 2. An external reference voltage V REF2 applied to conductor 5 is divided down by resistors 18 and 19 to produce an attenuated internal reference voltage on conductor 20, which is applied by non-inverting buffer 24 to the inverting input of comparator 2. The divider consisting of resistors 8 and 9, the divider consisting of resistors 18 and 19, and the divider consisting of resistors 13 and 14 divide V REF1 , V REF2 .sub., and V IN , respectively, in the same ratio.
FIG. 3A illustrates an example of how parasitic capacitances 25 and 26 should correspond to the resistances of resistors 13 and 14 to provide an accurate 6-to-1 attenuation of V IN to produce V IN '. If the resistance of resistor 13 is R, then the resistance of resistor 13 should be R÷5. If the parasitic capacitance of resistor 13 is C, then the parasitic capacitance of resistor 14 should be 5C.
In FIG. 3A, dotted line 51 designates an integrated circuit chip containing both high frequency attenuator 50 and another integrated circuit 52 which receives an accurately attenuated signal V IN ' generated by attenuator circuit 50. Circuit 52 can be the window comparator circuitry in FIG. 2, a low voltage analog-to-digital converter, or the like, with an applied power supply voltage substantially less than the maximum value of V IN . It should be appreciated that as integrated circuits are developed which provide increased performances at lower power supply voltages, the need for high frequency, high precision integrated analog attenuators will increase, because the external analog input signals applied thereto may have amplitudes so great as to cause undesired reverse biasing and/or forward biasing of certain PN junctions.
FIG. 3B illustrates an integrated circuit implementation of the circuit shown in FIG. 3A. FIG. 3C shows a cross section of a bipolar integrated circuit implementation of the circuit of FIG. 3B or FIG. 4. The integrated circuit structure in FIG. 3C includes a P+ substrate 29. An N-type epitaxial layer 30 on the upper surface of substrate 29 includes an N-type island 30A or 30B isolated by a P+ isolation diffusion 35. A P-type diffused base region 27,28 (which can be either region 27 or 28 of FIGS. 3B and 4), is formed on the upper surface of N-type region 30A or 30B, respectively. An oxide layer 38 is disposed on the upper surface of N-type layer 30. An N+ buried layer diffused region 31 is formed beneath base type region 27 or 28. N+ collector contact regions 36 allow low resistance electrical contact to be made to N+ buried layer 31. A plurality of rectangular elongated nichrome 5 kilohm resistors 33 are disposed on oxide layer 38 over P-type region 27, 28.
Referring to FIG. 3B, resistor 13 is a nichrome resistor having a resistance R. The parasitic capacitance between resistor 13 and the underlying P-type region 27 is proportional to the area of resistor 13, and hence to its resistance. P-type region 27 is disposed in N-type region 30B, and is connected to V IN conductor 3. Diode 27A designates the PN junction between P-type region 27 and isolated N-type region 30B, and diode 27B designates the PN junction between N-type region 30B and P+ substrate 29.
Resistor 14 is a nichrome resistor having a resistance R/5. The parasitic capacitance between resistor 14 and the underlying P-type region 28 is proportional to the area of resistor 14. P-type region 28 is disposed in N-type epitaxial region 30A. Both N-type regions 30A and 30B are electrically floating. P-type region 28 is connected to ground. P+ substrate 29 is connected to -V s . Diode 28A designates the PN junction between P-type region 28 and N-type region 30B. Diode 28B designates the PN junction between N-type region 30B and P+ substrate 29.
These back-to-back diode structures prevent clamping of V IN to the substrate and allow V IN to operate over a larger voltage range than otherwise would be permitted, and avoids undesirable reverse breakdown of certain PN junctions and/or undesirable forward biasing of certain PN junctions in the integrated circuit.
In FIG. 3B, resistor 14 is formed of five parallel resistors 14-1, 14-2...14-5 each having resistance R, and each having the same width as resistor 13. Each of the resistors 14-1, 14-2, etc. is composed of nichrome material having the same resistivity as resistor 13. Resistors 14-1, 14-2, etc., are formed over P-type region 28.
FIG. 4 shows a schematic representation of a practical, accurate implementation of the attenuator circuit shown in FIG. 3B. Resistor 13 is designed to have a resistance of, for example, 100 kilohms, and is implemented by four 25 kilohm resistors 13A-13D connected in series. Each of resistors 13A-13D is formed of five 5 kilohm nichrome resistors 33 (see FIG. 3C) connected in series. Numeral 25A indicates the parasitic capacitance between each 5 kilohm nichrome resistor 33 and the underlying P-type region 27. These parasitic capacitances all therefore are, in effect, connected in parallel, even though the nichrome resistors are electrically connected in series.
Thus, voltage division resistor 13 consists of twenty 5 kilohm nichrome resistors 33 connected in series to provide the desired 100 kilohms. However, the total parasitic capacitance between resistor 13 and P-type region 27 is the sum of the 20 equal parasitic capacitances 25A between the individual 5 kilohm resistors 33 and P-type region 27.
It should be appreciated that the foregoing explanation of the capacitive voltage division is somewhat oversimplified. Actually, the parasitic capacitances associated with the individual resistor segments (33) are not in parallel, but rather, have one terminal in common, and their respective second terminals distributed along the resistor strings. Referring to FIG. 4, the result of having the capacitances connected in this fashion is that any change in V IN causes unequal voltage changes across parasitic capacitances 13A, 13B, 13C, and 13D. Similarly, as V IN ' changes in accordance with changes in V IN , the voltage changes across parasitic capacitances 14A, 14B, 14C, and 14D also will be unequal. These voltage changes will cause capacitive displacement currents that also will be unequal. It is important to note, however, that in the described embodiment the capacitive displacement current in parasitic capacitance 13D will equal that in the parasitic capacitance 14A because the voltage change across parasitic capacitance 13D is five times greater than that across parasitic capacitance 14A. But, since parasitic capacitance 14A is five times greater than parasitic capacitance 13D, the corresponding displacement currents will be equal.
Similarly, the displacement currents of parasitic capacitances 13C and 14B will be equal, the displacement currents of parasitic capacitances 13B and 14C will be equal, and the displacement currents of parasitic capacitances 13A and 14D will be equal. Thus, all of the capacitive displacement currents will sum to zero, thereby allowing accurate attenuation of the high frequency components of V IN .
Voltage division resistor 14 is designed to have a total resistance of, for example, 20 kilohms, and includes four series-connected 5 kilohm nichrome resistors 14A-14D. The parasitic capacitance between each of the nichrome resistors 14A-14D and the underlying P-type region 28 adds in parallel with the corresponding parasitic capacitance of all of the others. Each of the 5 kilohm resistors such as 14A includes five one kilohm nichrome resistors 41 connected in series, as shown in FIG. 4B, formed over P-type region 28. Each of the one kilohm resistors 41 includes five of the 5 kilohm nichrome resistors 33 connected in parallel, as shown in FIG. 4C, formed over P-type region 28.
Thus, the total parasitic capacitance between region 28 and nichrome resistor 14 is equal to the sum of the 100 individual capacitances between each of the 100 resistors 33 and P-type region 28, even though the electrical resistance of resistor 14 is only 20 kilohms.
Thus, the resistance of resistor 13 is precisely five times that of resistor 14, producing a 6-to-1 DC voltage ratio between V IN and V IN '. The parasitic capacitance of nichrome resistor 13 is precisely one-fifth that of resistor 14 producing a 6-to-1 high frequency AC voltage division ratio between V and V IN '. Therefore, no error is produced in V IN ' as a result of unequal attenuating of high frequency input signal and low frequency input signal components of V IN by nichrome resistors 13 and 14 and their respective parasitic capacitances.
The resistances of resistors 8 and 9 and the resistances of resistors 18 and 19 can correspond precisely to the resistances of resistors 13 and 14, in which case the integrated voltage comparator 100 will produce an output that indicates when V IN is between the voltage window defined by V REF1 and V REF2 . The very high accuracy, high frequency and low frequency attenuation of high analog amplitude input signals needed by various low voltage integrated circuit comparators, analog-to-digital converters, and the like, is achieved.
In FIG. 5, the chip topography is shown for the integrated circuit window comparator 100 of FIG. 2, The chip measures 124 mils in the horizontal direction and 90 mils in the vertical direction. To avoid circuit operating inaccuracies due to differentials in the silicon temperature resulting from variations in power dissipation in comparators 1 and 2, in buffers 16, 17, 23, and 24, especially in comparator output transistor areas 55A and 55B and comparator output transistor areas 56A and 56B, the layout was arranged so that, to the extent possible, the topography of the right half of the chip is a mirror image of the topography of the left half of the chip, with center line 57 dividing the two halves.
The greatest thermal differentials are created by the four comparator output transistors, so they were located in the upper left and right corners of the chip, as far as possible from the precision attenuator resistors 13 and 14. As indicated above, the resistors 13 and 14 are formed over N-type epitaxial regions. In FIG. 5, the locations of the epitaxial regions are shown. To further minimize thermal effects, resistor 13 was broken up into two sections symmetrically positioned about center line 57. More specifically, N-type region 30A was broken into two equal sections 30A-1 and 30A-2, positioned as shown, and N-type region 30B was broken into two sections 30B-1 and 30B-2 symmetrically positioned about center line 57 as shown. Block 62 contains additional input circuitry that is not important to the present invention.
The V IN bonding pad conductor 3 and an analog ground conductor pad 60 are positioned in the middle of the lower edge of the chip to enable them to be wire bonded to the lowest inductance leads of a DIP lead frame, and the power supply common conductor bonding pads are located similarly along the upper edge of the chip for the same reason. The bias circuitry required for operation of comparators 1 and 2 is located in areas 58A and 58B positioned symmetrically about center line 57. The buffer circuitry containing the above-mentioned buffers are laid out in mirror image fashion in block 16, 17, 23, and 24, as shown. Comparators 1 and 2, including their respective output transistors, are generally located in the upper half of the chip. This layout gives maximum isolation of the nichrome resistors forming the attenuator and therefore results in minimum inaccuracy caused by thermal differences generated in the silicon during chip operation.
While the invention has been described with reference to a particular embodiment thereof, those skilled in the art will be able to make variations from the described embodiments without departing from the true spirit and scope of the invention. For example, the nichrome resistor 33 could be formed directly over N-type region 30A instead of P-type region 27,28 in FIG. 3C if the protective effect of diodes 27A and 28A in FIGS. 3B and 4 is not needed.
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An attenuator for use in an integrated circuit window comparator circuit provides voltage division across an input voltage divider including a large number of identical thin film resistor segments combined in various series and parallel arrangements so that resistive voltage division of the input signal is in the same ratio as capacitive voltage division of the input signal by parasitic capacitances of the resistors.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to micro-spray cooling, and in particular to a micro-spray cooling system with piezoelectric actuators to vibrate and spray refrigerant.
2. Description of the Related Art
The speed of a computer depends on processing speed of a central processing unit, which generates heat, which must in turn be dissipated by various methods.
A conventional method for heat dissipation employs fins for heat conduction and fans for heat convection. Fans and fins cannot, however, satisfy the requirements for heat dissipation of many current high speed desktop computers. Nor are they able to satisfy the requirement of heat dissipation over 100 W for a compact laptop. As heat can be absorbed by a refrigerant as latent heat during phase change, the phase change method is preferred.
As heat dissipation modules for a laptop must be as flat as possible to conserve height and space, a heat pipe is applicable therein. The heat pipe, however, is a passive cooling device which depends on heat convection by phase change and is not capable of actively controlling heat dissipation.
BRIEF SUMMARY OF INVENTION
An embodiment of a micro-spray cooling system for a plurality of heat sources comprises an evaporator contacting the heat sources and comprising a plurality of actuators corresponding to the heat sources, a condenser connected to the evaporator, and at least one driving circuit connected to the actuators to drive some or all of the actuators sequentially according to a predetermined timing to cool the heat sources. The refrigerant in the evaporator, sprayed by the actuators to thermally contact the heat sources, is evaporated by heat from the heat sources, condensed in the condenser and re-enters the evaporator.
The evaporator comprises at least one chamber storing the refrigerant and at least one evaporation chamber thermally contacting the heat sources, and the refrigerant is sprayed by the actuators disposed above the storage chamber to the evaporation chamber to thermally contact the heat sources.
The evaporator further comprises a main body and a plurality of spray sheets disposed within the main body. Each spray sheet has at least one hole and divides the main body into the storage chamber and the evaporation chamber. The actuators are disposed on the spray sheets and vibrate the spray sheets to spray the refrigerant to the evaporation chamber via the holes. The actuators are piezoelectric elements. The actuators are annular and encircle the hole.
The driving circuit controls the vibration amplitude and frequency of the actuators. A negative pressure generated in the storage chamber by the vibration of the actuators enables the refrigerant to flow from the condenser into the storage chamber.
A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
FIG. 1 is a schematic view of an embodiment of a micro-spray cooling system of the invention;
FIG. 2 is a schematic view of detailed structure of a micro-spray cooling system of the invention;
FIG. 3 is a schematic view showing an actuator assembled to a spray sheet;
FIG. 4 a depict the structure of an embodiment of the spray sheet of the invention;
FIG. 4 b is a cross section along line A-A of FIG. 4 a;
FIG. 4 c depicts another embodiment of the spray sheet of the invention;
FIG. 5 is a schematic view of another embodiment of a micro-spray cooling system of the invention;
FIGS. 6 a ˜ 6 d depict the micro-spray cooling system of the invention applied to a dual core processor; and
FIGS. 7 a ˜ 7 d depict the micro-spray cooling system of the invention applied to a multiple core processor.
DETAILED DESCRIPTION OF INVENTION
Referring to FIG. 1 , a micro-spray cooling system 1000 comprises an evaporator 100 , a condenser 200 and ducts 300 and 400 connecting the evaporator 100 and condenser 200 .
Referring to FIG. 2 , the evaporator 100 comprises a main body 110 , a spray sheet 120 and an actuator 140 . A chamber is formed in the main body 110 . The spray sheet 120 is disposed in the main body 110 and divides the chamber into a storage chamber 160 and an evaporation chamber 180 . Refrigerant R is stored in the storage chamber 160 . The evaporation chamber 180 contacts a heat source 5 . A plurality of holes 122 is formed on the central portion of the spray sheet 120 . The actuator 140 comprises piezoelectric elements connected to a driving circuit 500 . The driving circuit 500 controls the actuator 140 to vibrate the spray sheet 120 . The vibration pushes the liquid refrigerant R stored in the storage chamber 160 . The pressured liquid refrigerant R passes through the holes 122 and is sprayed into the evaporation chamber 180 . As the evaporation chamber 180 contacts the heat source 5 , heat is absorbed by the liquid refrigerant R as latent heat. The latent heat causes phase change of the liquid refrigerant R to refrigerant vapor. To increase heat dissipation area, a plurality of slots 182 is formed on the walls or the bottom of the evaporation chamber 180 . An exit 165 is formed on the storage chamber 160 to purge unnecessary refrigerant vapor.
The refrigerant vapor flows through the duct 400 to the condenser 200 with fins 220 on the top thereof. Refrigerant vapor is condensed by conducting latent heat to the fins 220 . The heat conducted to the fins 220 is dissipated by force convection caused by a fan unit 600 .
When the spray sheet 120 vibrates to push the liquid refrigerant R in the storage chamber 160 , a part of the liquid refrigerant R passes through the holes 122 to spray into the evaporation chamber 180 . As the liquid refrigerant R decreases, the refrigerant pressure in the storage chamber 160 is less than that in the condenser 200 , whereby the liquid refrigerant R flows from the condenser 200 to the storage chamber 160 via the duct 300 due to pressure difference.
The liquid refrigerant R is sprayed into the evaporation chamber 180 by vibration of the spray sheet 120 , absorbs heat of the heat source 5 , and evaporates. The refrigerant vapor flows through the duct 400 to the condenser 200 and condenses therein. The pressure difference causes the liquid refrigerant to flow into the storage chamber 160 . Completing the cycle of refrigerant for heat dissipation.
FIG. 3 depicts the spray sheet 120 assembled to the actuator 140 . In this embodiment, the actuator 140 is annular and bonded to the spray sheet 120 by thermal pressing.
In the embodiment, only one spray sheet 120 and one actuator 140 are used. The size of the actuator 140 is limited by power supply, for example, when the power supply is under 3 W, the size of the annular actuator 140 is limited to an outer diameter of 14 mm and inner diameter of 8 mm. In such a structure, the spray area is limited to a diameter of 8 mm. A heat sink of the Intel CPU is 31 min×31 mm, exceeding the spray area. The small spray area causes poor heat dissipation efficiency, non-uniform temperature in heat sink, and accumulation of liquid refrigerant due to local fast cooling. If the liquid refrigerant is accumulated near the hole 122 , the liquid refrigerant may jam. The structure of the spray sheet 120 is described as follows.
The spray sheet 120 , shown in FIG. 4 a , comprises a nozzle layer 121 having a wetting angle, a hole 122 formed on the nozzle layer 121 , and a trench 124 formed on the nozzle layer 121 . The trench 124 is around the hole 122 and separated from the hole 122 by an appropriate distance shown in FIG. 4 b . The trench 144 is formed as ring-shaped and continuous. In another embodiment, the trench 124 is ring-shaped, but discontinuous as shown in FIG. 4 c . A filler 126 having a wetting angle is filled in the trench 124 . The wetting angle of the surface of the filler 126 is different from the wetting angle of the surface of the nozzle layer 121 . The difference of the wetting angle causes the accumulation of the liquid refrigerant around the hole 122 and prevents the liquid refrigerant from flowing randomly to other regions of the nozzle layer 121 .
Accordingly, the micro-spray cooling system comprises a plurality of actuators arranged in an array for a larger heat source. The storage chamber 160 and the evaporation chamber 180 can be shared by several actuators, or each actuator can correspond to individual storage chamber and evaporation chamber.
FIG. 5 depicts another embodiment of the micro-spray cooling system. The evaporator 100 ′ further comprises a fixture 800 having four positioning structures 820 which are arranged in an array of 2×2. Each positioning structure 820 receives a spray sheet 120 and an actuator 140 . The driving circuit 500 drives a part or all of the actuators 140 sequentially according to a predetermined timing. FIGS. 6 a ˜ 6 d depict a cooling method for a CPU with dual cores. In FIGS. 6 a and 6 b , the CPU with dual cores is arranged diagonally. FIG. 6 a shows the spray sheet 120 and the actuator 140 driven sequentially. The number in the spray sheet 120 represents the actuating order. FIG. 6 b shows the actuators 140 and the spray sheets 120 are driven simultaneously. In FIGS. 6 c and 6 d , the CPU with dual cores is arranged on the same side. FIG. 6 c shows the spray sheet 120 and the actuator 140 driven sequentially. The number in the spray sheet 120 represents the actuating order. FIG. 6 d shows the actuators 140 and the spray sheets 120 driven simultaneously.
FIGS. 7 a ˜ 7 d depict a cooling method for a CPU with multiple cores. For the CPU with multiple cores, a clockwise sequence of driving the spray sheet 120 and the actuator 140 is used as shown in FIG. 7 a . The number in the spray sheet 120 represents the actuating order. A counterclockwise sequence of driving the spray sheet 120 and the actuator 140 is used as shown in FIG. 7 b . A diagonal sequence ( FIG. 7 c ) or side-by-side sequence ( FIG. 7 d ) can also be applicable.
While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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A micro-spray cooling system for a plurality of heat sources includes an evaporator contacting the heat sources and comprising a plurality of actuators corresponding to the heat sources, a condenser connected to the evaporator, and at least one driving circuit connected to the actuators to drive some or all of the actuators sequentially according to a predetermined timing to cool the heat sources. The refrigerant in the evaporator is sprayed by the actuators to thermally contact the heat sources, evaporated by heat from the heat sources, condensed in the condenser and re-enters the evaporator.
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FIELD OF THE INVENTION
present invention relates to an improved automatic warehouse.
BACKGROUND OF THE INVENTION
In a typical automatic warehouse, a pair of racks are disposed on a floor surface in a parallel at an interval, a rail is laid on the floor surface in the space between the racks, and a travelling body including a loading apparatus travels on the rail. In this configuration, however, when the racks are high, the height of a mast on the loading apparatus must be increased, resulting in unstable loading. In addition, the floor surface in the space between the racks is occupied by the rail and travelling body, preventing easy maintenance.
It is an object of the present invention to allow the space between the racks to be used easily for maintenance and to enable an article to be transferred and loaded appropriately between the travelling body and racks.
It is an additional object of the present invention to further stabilize the elevation and lowering by means of the elevating rail.
It is an additional object of the present invention to enable an article to be loaded on both racks appropriately even if the space between the racks is narrower than in a conventional type.
It is an additional object of the present invention to provide a structure of an automatic warehouse with an increased capacity.
SUMMARY OF THE INVENTION
The present invention provides an automatic warehouse in which a pair of opposed racks are disposed in parallel at an interval, characterized in that elevation drive sections provided near opposite ends of one of the racks support, elevate and lower an elevating rail, and in that a travelling body is provided that travels along the elevating rail to load an article on each of the racks.
Preferably, a guide member for guiding the elevation and lowering of the elevating rail is provided near the center of the rack on which the elevation drive sections are provided.
Preferably, a turntable is provided on the travelling body that has a first arm, that oscillates relative to the turntable, a second arm that oscillates in a direction opposite the oscillating direction of the first arm, and a hand member borne on the second arm by an oscillating shaft to support an article, to transfer and load an article between the travelling body and the racks.
To increase the capacity, the racks are extended at their respective end and the elevating rail protrudes from the elevation drive section toward the end of the rack.
According to the present invention, the elevation drive sections are provided near the opposite ends of one of the racks to elevate and lower the elevating rail. He travelling body travels along the elevating rail to load an article onto each of the racks. As a result, the need for the rail to be laid on the floor in the space between the racks is eliminated to allow the travelling body to pause at the upside of the elevation rail, thereby enabling the automatic warehouse to be maintained easily. Since the elevating rail is supported near both its opposite ends by the elevation drive sections, the elevating rail is supported stably and articles can be transferred and loaded appropriately compared to the transfer and loading of articles between the travelling body supported on the floor surface and on the racks via a high mast. Since the elevation drive sections in the present invention are provided on only one of the racks, the automatic warehouse can be installed easily and the space occupied by the elevation drive sections can be reduced, compared to an installation on both racks.
According to the present invention, the guide member for guiding the elevation and lowering of the elevating rail is provided near the center of the rack on which the elevation drive sections are provided. Thus, the elevating rail is supported at three points, that is, by the elevation drive sections near the opposite ends and the guide member near the center, thereby further stabilizing the elevation and lowering of the elevating rail.
According to the present invention, a turntable is provided on the travelling body and a first arm that oscillates relative to the turntable; a second arm that oscillates in a direction opposite to the oscillating direction of the first arm; ;and the hand member borne on the second arm by the oscillating shaft to support an article are provided. When the first arm is oscillated, the second arm oscillates in the opposite direction and the oscillation of the first arm causes the oscillating arm bearing the hand member to linearly move back and forth to enable an article to be transferred and loaded smoothly. In addition, since the oscillating shaft bearing the hand member can oscillate relative to the second arm, the direction of the hand member is fixed despite the oscillation of the second arm, thereby preventing the hand member from colliding against the racks.
The present invention has a structure where the capacity of the warehouse can be increased by extending the racks. The racks are preferably extended from both ends, or at least from their respective end, and the elevating rail protrudes from the elevation drive section toward the end of the rack. The extension of the racks increases the capacity, and the elevating rail can be elevated and lowered stably despite its protrusion from the elevation drive sections because it is supported at at least two points near the respective ends of the original rack. dr
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic top view of an automatic warehouse according to one embodiment of the present invention.
FIG. 2 is a schematic top view of an automatic warehouse according to a variation.
FIG. 3 is a schematic side view of the automatic warehouse according to the one embodiment.
FIG. 4 is a top view of a loading apparatus in the automatic warehouse according to the one embodiment.
FIG. 5 is a top view of the loading apparatus in the automatic warehouse according to another embodiment.
FIG. 6 is a side view of the automatic warehouse according to the one embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 to 6 shows an embodiment and its variations. FIGS. 1 to 3 show an integral part of an automatic warehouse according to one embodiment.
In FIGS. 1, 1 and 2 are a pair of racks disposed opposite each other and in parallel. An elevating rail 3 , that has rail supporting members 12 , 12 near the opposite ends, is supported, elevated and lowered by elevation drive sections provided near the opposite ends of the rack 2 . Another rail supporting member 13 (FIG. 1) is provided near the center of the elevating rail 3 and supported by a guide rail 26 provided near the center of the rack 2 . A travelling cart 4 , has a turntable 5 that can rotate through 360 degrees (°) relative to the travelling cart 4 . A first arm 6 , and a second arm 7 are provided. The first arm 6 is installed so as to rotate around a rotating shaft 8 relative to the turntable 5 and the second arm 7 is installed so as to rotate around a rotating shaft 9 relative to the first arm 6 . A rotating shaft 10 enables a hand member 11 to rotate relative to the second arm 7 . Although the rotating shafts 8 , 9 and 10 can rotate through 360°, they must only oscillate through a predetermined angle.
In FIG. 3, the structure of the traveling cart 4 is described. The rail 3 is, for example, a monorail, 36 is a rack provided along the rail 3 and 37 is a pinion engaging the rack 36 and rotated by a motor (not shown in the drawing) for the travelling cart 4 . The pinion 37 is rotated to move the travelling cart 4 forward. A travelling mechanism for the travelling cart 4 and a mechanism for the rail 3 can be configured arbitrarily.
In FIG. 3, 14 is a turntable motor, 15 is a shaft used to rotate the turntable 5 and 16 is an arm drive motor. The turntable motor 14 rotates a belt 17 to cause the shaft 15 to rotate the turntable 5 . Likewise, the arm drive motor 16 rotates the rotating shaft 8 via a belt 18 , thereby rotating the first arm 6 . The rotation of the rotating shaft 8 is transmitted to the rotating shaft 9 via a belt 19 to rotate the second arm 8 relative to the first arm 6 . In addition, the rotation of the rotating shaft 9 is transmitted to the rotating shaft 10 of the hand member 11 through the belt 20 to rotate the hand member 11 . In addition, the rotation of the turntable 5 is independent of the rotation of the arms 6 and 7 and hand member 11 , and the arm 7 rotates in the direction opposite the rotational direction of the arm 6 , whereas the hand member 11 rotates in the same direction as the arm 6 . These operations can be implemented by the belts 18 , 19 and 20 .
A hanging member 30 , FIG. 3, such as a rope or a belt, is attached to the rail supporting members 12 , 12 and is wound around a winding drum 22 (FIG. 6) via supporting rollers 40 , shown in FIG. 6. A pair of rollers 25 a and 27 a or 25 b and 27 b are provided at the end of the rail supporting member 12 in such a way that the rail 3 is elevated and lowered along guide rails 28 a and 28 b. A counterweight 24 is connected at the other end of the hanging member 30 . A guide member such as a guide rail 26 is provided near the center of the rack 2 to guide rollers provided at the end of the rail supporting member 13 . The rail supporting member 13 and guide rail 26 can be omitted as shown in FIG. 2 . An individual storage position 31 is provided in the rack 1 , and an individual storage position 32 is provided in the rack 2 , while 33 is an article.
FIG. 4 shows a mechanism for transferring and loading the article 33 using the turntable 5 and hand member 11 . In this figure, the rail 3 and the travelling cart 4 are omitted. For example, the removal of the article 33 from the rack 1 is explained. The continuous line in FIG. 4 shows that the hand member 11 supports the article 33 . The rotating shaft 8 is rotated, for example, clockwise to rotate the rotating shaft 9 , for example, counterclockwise. The rotating shaft 10 bearing the hand member 11 thus rotates clockwise, as does the rotating shaft 8 . Then, the rotating shaft 10 for the hand member 11 linearly moves backward from the state shown by the continuous line to the state shown by the chain line in FIG. 4 and the hand member 11 rotates in the direction opposite the rotating direction of the arm 7 , so the direction of the hand member 11 remains unchanged, as seen from the racks 1 and 2 . Thus, the hand member 11 linearly moves back and forth in the same direction without colliding against the rack 1 . The movement is the reverse of the foregoing when the article 33 is housed in the rack 1 . As is apparent from the chain line in FIG. 4, the hand member 11 can transfer and load the article 33 on only the rack 1 unless the turntable 5 is rotated. If the article is loaded on the rack 2 , the turntable 5 is rotated through 180° to transfer and load the article in the same manner.
FIG. 5 shows a variation of the loading apparatus. According to this variation, the first and second arms are provided on the right and left sides, respectively, and the rotating shafts for the hand member 11 are also provided on the right and left sides. That is, first arms 6 R and 6 L, second arms 7 R and 7 L, and rotating shafts 8 R, 8 L, 9 R, 9 L, l 0 R, and l 0 L are provided.
In contrast to the embodiments in FIGS. 1 to 4 , the rotating shafts 9 R and 9 L, as well as 10 R and 10 L, are slave shafts, and rotate in response to the oscillation of the arms 6 R and 6 L. According to this variation, the rotating shafts 8 R and 8 L connected to an arm driving motor 16 rotate in opposite directions, and since the tips of the second arms 7 R and 7 L are connected to the hand member 11 through the rotating shafts 10 R and 10 L, the hand member 11 linearly moves backward in the same direction from the state shown by the continuous line as the rotating shafts 8 R and 8 L rotate, and is housed on the turntable 5 . According to this variation, the hand member 11 can also transfer and load the article on only the rack 1 unless the turntable 5 is rotated. The turntable 5 is rotated through 180° to transfer and load the article onto the rack 2 .
FIG. 6 shows the overall structure of an automatic warehouse according to the present invention. Although not limited to such applications, the automatic warehouse may be used, for example, to store devices in a clean room.
The rail 3 is supported by the rail supporting members 12 , 12 and 13 and is elevated and lowered along the rack 2 as the winding drum 22 rotates. The travelling cart 4 travels on the elevating rail 3 . Thus, there is no rail on the floor between the racks 1 and 2 , and elevating the elevating rail 3 enables a large space to be provided between the racks 1 and 2 , thereby allowing easy maintenance for the winding drum 22 , winding motor 23 , or other mechanisms.
The elevating rail 3 is elevated and lowered stably because the neighborhood of both of its opposite ends are supported by the supporting member 12 , 12 and because the neighborhood of its center (FIG. 1) is supported by the supporting member 13 . Thus, the travelling cart 4 can be stably supported by the rail 3 to enable the article to be transferred and loaded appropriately. Furthermore, the elevating rail 3 is elevated and lowered, so even if the racks 1 and 2 are high, loading can be executed stably by correspondingly raising the elevating rail 3 . In addition, the pair of arms 6 and 7 , that rotate in opposite directions, are provided on the turntable 5 , and the rotating shaft 10 at the end of the arm 7 bears the hand member 11 . Consequently, the hand member 11 linearly moves in the same direction relative to the racks 1 and 2 , so the interferential range is narrow and the article 33 can be transferred and loaded simply.
If the number of the racks 1 and 2 is increased to increase the capacity of the automatic warehouse after installation, the elevating rail 3 may be extended on both ends of existing racks 1 and 2 , for example, as shown by the chain line in FIG. 1 . In this case, since the elevating rail 3 is supported near the opposite ends of the existing racks 1 and 2 , the elevating rail can be elevated and lowered stably even if it is extended. Thus, the capacity of the existing automatic warehouse can be increased easily without changing the layout of facilities in the clean room. Not only can the capacity be simply increased after installation, but an automatic warehouse of a desired capacity can also be obtained by extending the racks 1 and 2 and elevating rail 3 as required, using as the standard the racks 1 and 2 shown by the continuous line in FIGS. 1 and 2.
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To provide an automatic warehouse that can elevate and lower an elevating rail stably even if racks are high, and that allows effective use of the space between the racks for maintenance. Elevation drive sections for an elevating rail 3 are provided near the respective ends of one of racks 1 and 2, a rope 40 attached to a rail-supporting member 12 is wound around a drum 22, and a counterweight 24 is used to balance the effect of gravity in order to elevate and lower a rail 3. A travelling cart 4 travels on the rail 3, and the rotation of a turntable 5 and the rotation of arms 6 and 7 and a hand 11 are used to load and unload an article on and from the rack 1 or 2.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This is a continuation of U.S. application Ser. No. 12/265,120, filed on Nov. 5, 2008, which is a continuation of U.S. application Ser. No. 11/027,271, now U.S. Pat. No. 7,534,157, filed on Dec. 30, 2004, which claims the benefit of provisional applications Ser. Nos. 60/533,591 and 60/533,634, both filed on Dec. 31, 2003, all of which are incorporated herein by reference in their entirety.
REFERENCE TO COMPUTER PROGRAM LISTING
A Computer Program Listing Appendix filed on CD ROM in application Ser. No. 11/027,880, filed on Dec. 30, 2004 is incorporated by reference in its entirety.
FIELD OF THE INVENTION
This application relates generally to a system and method for toy adoption and marketing.
More specifically, this application relates to an Entertainment System including a website, in combination with a commercially purchased toy, wherein the system allows a toy user to register the toy online using a registration code, allowing the user access to various activities and scenarios in a “virtual world” including a virtual representation of the toy, via a computer connected to the Internet.
BACKGROUND OF THE INVENTION
Typically, a consumer purchases a toy (e.g., a stuffed plush animal or other creature, etc.) as a gift for a child, for example, and that child then uses the toy for imaginative activities. However, the toy manufacturer relationship with the toy does not typically continue until the next toy is purchased.
This lack of continuity represents a lost opportunity to take advantage of the fact that the child or other toy owner likely wants to create a whole imaginative world for the toy for play purposes.
A means of creating a such an imaginative world using modern computer tools, such as a personal computer connected to the internet, wherein the toy can be utilized in a computer generated “virtual world” for various games and activities, given a name and a history, and taken care of, would allow the owner a more varied and interactive means of playing with the toy.
Further, such a virtual world could be used to maintain the relationship between the toy owner and the toy manufacturer (or, alternatively a retailer or service provider), allowing new toys, accessories, and services of the manufacturer, retailer, or other provider to be offered to the toy owner, thereby increasing the potential market for the manufacturer and increasing the usage of the toy by the user. Such a virtual world could also provide many educational and gaming scenarios that would engage a child or adult with many hours of play.
Furthermore, such a virtual world could increase the attachment that the toy owner feels for the toy, and thus increase the likelihood that additional toy or accessory purchases would occur, and also increasing the satisfaction the owner feels with the toy, thus extending the relationship between the toy manufacture and the toy owner.
Finally, by engaging the toy owner in the virtual world, advertising and other marketing advantages would likely occur because of the additional satisfaction that the toy would provide, hence leading to potential word-of-mouth and other means of marketing the toy and the website.
Accordingly, a system for creating such a virtual world to take advantage of such marketing potential might provide some or all of the listed benefits.
SUMMARY OF THE INVENTION
Provided is a method for providing a virtual world presentation to a user for entertainment. The method comprises the steps of: storing data relating to a plurality of registration codes, each of the registration codes corresponding to one of a plurality of toys; serving content, via a communication network, to a user computer; receiving one of the registration codes transmitted from the user computer via one or both of the communication network and an additional communication network; verifying the one of the registration codes against the data relating to the plurality of registration codes; registering a toy corresponding to the one of the registration codes after the verifying; and providing virtual world data for including in the content.
The virtual world data of the above method is for use by the user computer to present a virtual world to the user, and the virtual world includes a virtual toy representing the toy.
Also provided is a method for providing a virtual world presentation to a user of a toy for entertainment, comprising the steps of: a user obtaining the toy including a corresponding registration code; serving content, via a communication network, to a user computer; receiving one or both of data and commands from the user computer; verifying the toy to determining a validity of the toy; registering the toy for allowing the user to access a restricted portion of an Entertainment System; and the system providing virtual world data for including in the content.
The virtual world data of the above method is for use by the user computer to present a virtual world to the user, and the virtual world includes a virtual toy representing the toy, and further the virtual world provides a plurality of activities for the user to participate in via interactions with the user computer.
Further provided is an entertainment system for providing a virtual world for entertainment of a user of a toy. The system comprises: a server subsystem for serving content, via a communication network, to a user computer, and for receiving one or both of data and commands from the user computer; a registration subsystem for verifying and then registering the toy, wherein the verifying includes determining a validity of the toy, and wherein the registering is for allowing the user to access a restricted portion of the Entertainment System; and a virtual world providing subsystem for providing virtual world data for including in the content.
The virtual world data of this system is for use by the user computer to present a virtual world to the user, and the virtual world includes a virtual toy representing the toy.
Also provided is an entertainment system for providing a virtual world for user entertainment, which comprises: a storage subsystem for storing data relating to a plurality of registration codes, each of the registration codes corresponding to one of a plurality of toys; a server subsystem for serving content, via a communication network, to a user computer, and for receiving one of the registration codes transmitted from the user computer via one or both of the communication network and an additional communication network; a registration subsystem for verifying the one of the registration codes against the data relating to the plurality of registration codes, and subsequently registering the toy in the system after the verifying; and a virtual world providing subsystem for providing virtual world data for including in the content.
The virtual world data of the above system is for use by the user computer to present a virtual world to the user, and the virtual world includes a virtual toy representing the toy.
Further provided is a toy for utilizing an entertainment system, such as the ones listed above, for providing a virtual world for entertainment of a user of the toy. The toy comprises a toy body and a registration code, and the entertainment system uses the registration code to register and verify the toy. The entertainment system presents a virtual world to the user via a user computer connected to a communication network, and the virtual world includes a virtual toy representing the toy.
Further provided is an Entertainment System as described above, including one or more of the following activities for a user:
providing a virtual medical checkup for the virtual toy; playing a game; virtually purchasing virtual furnishings for a virtual room in the virtual world using virtual cash; virtually furnishing the virtual room in the virtual world; virtually purchasing virtual food for the virtual toy using the virtual cash; virtually feeding the virtual toy; playing with the virtual toy; playing with the virtual toy along with an additional virtual toy representing an additional toy registered by an additional user via interactions by the additional user with an additional user computer; virtually adding an additional virtual room in the virtual world; and chatting with the additional user using the user computer and the additional user computer.
Still further provided is a computer readable medium for storing computer readable program code for performing the method disclosed herein by utilizing a computer system, as also disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic block diagram of a current embodiment of the system and its interactions with some external entities;
FIGS. 1A , 1 B and 1 C show additional implementation details about the embodiment of 1 A;
FIG. 2 shows a schematic diagram of a possible hardware implementation of an embodiment of the invention;
FIG. 3 shows a schematic diagram of a more complex hardware implementation of another embodiment of the invention;
FIG. 4 shows a block diagram of another embodiment of the system and its interactions with some external entities;
FIG. 5 shows a diagrammatic representation of some features of a virtual world according to the current embodiment;
FIG. 6 shows a manner of a user registering with the System of the current embodiment for utilizing the System features;
FIG. 7 shows an example of how a user might utilize the System of the current embodiment;
FIG. 8 shows a high-level map of the major features of the current embodiment;
FIG. 8A-8G show the features of FIG. 8 in more detail;
FIG. 9 shows a sketch of an example toy according to the current embodiment;
FIGS. 10A and 10B show the front and back of a tag listing the System website address and a registration code according to the current embodiment;
FIGS. 11A-11J show example screen shots of the website as possibly seen by a user of the system of the current embodiment; and
FIG. 12A-12I are a structure diagram of the program code of the current embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Provided is an Entertainment System including an online “virtual world” where the user of a toy can register the toy using a unique registration number provided with the toy at purchase, adopt the toy online, and play with a virtual representation of the toy (the “virtual toy) in the virtual world. In a current embodiment, mostly as implemented by the software of the Computer Program Listing Appendix, incorporated by reference, the “virtual world” is implemented using an interactive website via a user computer connected to the Internet. In this manner, a user can play with the virtual toy in a computer generated fantasy world (i.e., the virtual world).
Graphics, animation, sound, and even recorded images might be utilized to generate this virtual world. Even live images might be utilized, if desired. In addition, other sources of material can also be utilized. In essence, the virtual world creates an interactive playland for the toy owner to encourage imagination using the toy, and at the same time, provide an incentive to purchase additional toys or encourage additional individuals to also purchase toys in order to participate in the Entertainment System.
Throughout this disclosure, the term “virtual” is used, for example, to describe the user viewable/hearable material presented to the user on the user computer from data and/or computer programs and commands generated and/or provided by the Entertainment System, to the user computer running one or more computer applications (e.g., a web browser with the appropriate plug-ins, applets, and/or other support programs, etc.). The System provides the data and/or programs, via a communication network connected to the System and the user computer (e.g., the Internet).
The term “virtual” does not necessarily mean that the displayed item is not “real”, because the displayed item could, for example, be a video or picture of a real item, for example. Furthermore, the “virtual world” is presented using “real” physical phenomena (e.g., light and sound), and is impacted by “real” user interactions (e.g., mouse and keyboard manipulations). Rather, the term “virtual” is used to describe the computer generated and/or provided presentation to the user, including both visual and audible effects, via the user computer. It is a “virtual world” in the sense that it is primarily a computer presented fantasy world with which the user can interact via manipulations of the user computer. In this manner, the “virtual” items of the virtual world can be presented as interacting with each other and with the user. Furthermore, the user is provided access to games and trivia as well.
In the current embodiment, the virtual world provides a biography of the toy, a virtual representation of the toy (the virtual toy) using graphics and/or sound (such as an animated image, for example) to participate in games and activities. The system also provides a virtual means for maintaining the “health and well-being” of the character through various maintenance activities, such as virtual feeding and playing, virtual shopping, and virtual medical checkups, for example.
Furthermore, in the current embodiment, the Entertainment System can be utilized for marketing additional toys and/or accessories and/or services related to the toy to allow restricted access to additional online activities and features to those who purchase the toys.
The Entertainment System of the current embodiment may provide some general services and features open to the public, such as information about the toys and where to purchase them, a description of the features of the website, and other similar information. However, the primary purpose of the System in the current embodiment is to encourage the public to purchase a toy to obtain a registration code for access to the primary features and services. Accordingly, the primary features of the System are restricted to registered users. The existence of the System may encourage initial sales of the toy by new users (such as via word-of-mouth from current users), and the System will also encourage the purchase of additional toys by current users.
Online sales may be supported and encouraged in an alternate embodiment, but in the current embodiment the invention is intended to be utilized to sell toys in retail establishments. Thus, the invention becomes a marketing tool, utilizing word-of-mouth and the desire to increase participation in the virtual world, and thusly makes the toys more attractive to retail merchants and increases their sales.
In essence, the present invention in its current embodiment provides an Entertainment System including an online virtual world with a virtual toy representing a toy purchased at a retail store. The toys might be plush toy animals, for example. However, there is no limit to the type of toy that the system could support, as long as the toy can be represented by a virtual replica.
The current system functions basically as follows: A consumer purchases a toy (such as the plush toy animal representing a particular animal, for example, or some other toy). The toy includes a tag attached to the toy body or the toy packaging (or alternatively, another indicator and/or a storage device) indicating a web site address and a registration code. The user can load the System web site using the web address in a browser application running on the user's computer, and then enter the registration code to register the toy, thereby obtaining access to restricted portions of the System website.
In an alternative embodiment, the code can be automatically entered via the storage device, for example, for automatically loading, and/or downloading, and/or registering the user with the System.
Registration allows the user to participate in a virtual adoption process utilizing a virtual online replica of the toy (the “virtual toy”) to provide an analogous online representation of the toy. The virtual toy should look somewhat like the real toy (e.g., same type of toy, similar shapes, color patterns, etc.), but could be more “cartoonized”, for example, and can be animated, which may or may not be the case for the real toy.
The registered user can then participate in various activities both for enjoyment, and to virtually “maintain” the virtual toy in a happy, healthy, contented state.
The System of the current embodiment utilizes a server subsystem including a web server subsystem for generating both dynamic and static web pages as is known in the art, and for receiving data and/or commands from the user computer. One or more databases support the functioning of this server subsystem. The web server utilizes various scripting or other executable programs for providing dynamic content to the user's computer, which is attached to the web server via some computer network, such as the Internet, for example. The web server can also utilize various animated motion programs, such as a Flash program, java scripts, etc., to provide dynamic content to the user.
FIG. 1 shows a top-level block diagram of the Entertainment System 1 , interacting with various users 10 . The users 10 should have previously purchased and registered one or more toys from a Retail Merchant 9 , who obtained the toys from a manufacturer 8 , or via a distributor.
If the user has not yet purchased a toy, he can still access the System 10 to obtain information about the System and/or the toys, but will not, in the current embodiment, have access to much of the site until a toy is purchased and registered.
The Entertainment System 1 is comprised of a server subsystem 2 for interacting with the users 10 via a user computer being operated by the user. The server subsystem can utilize a server 3 , for serving content, including web pages, data, commands, and/or programs, for example, to the user computer. In addition, the server subsystem can include a reception subsystem 4 , for receiving information and commands from the users 10 . Alternatively, the server 3 and reception subsystem 4 might be combined into a single computer application, such as a commercially available web server, for example, running on one or more computers. The current system will utilize commercially available applications to implement much of the server subsystem.
The Entertainment System 1 also comprises a Storage Subsystem 5 , for storing system data, user IDs and passwords, toy registration codes, personalized user information, etc. utilized by the various subsystems. The Storage Subsystem 5 of the current system will utilize a commercially available database application running on commercially available hardware, for example.
A Registration Subsystem 6 is used for registering the user and the user's toy into the system, so that the user has access to restricted portions of the system. The Registration Subsystem 6 may utilize its own dedicated application and hardware, or could be combined with or share the Server Subsystem 2 applications and/or hardware. The registration subsystem examines the registration code against stored data relating to a plurality of registration codes each representing a toy for sale.
A Virtual World Providing Subsystem 7 generates and/or provides the virtual world data to be served by the server 3 to the users 10 for use in displaying a virtual world on the users computers. Portions of this data may be generated on the fly in response to user interactions, and portions are likely to be obtained and/or derived from data stored in the Storage Subsystem 5 . (For example, in the current embodiment, items owned by the user (the items in the dock for example), the virtual room state [virtual furniture in the room for example], virtual cash, health, happiness, hunger parameters are all examples of “stored data”, whereas data generated on the fly include position in the room [which also gets stored], and Arcade Game scores, all of which are described in more detail below).
Again, the Subsystem 7 may utilize unique applications and/or hardware, or may be combined with one or more of the Registration Subsystem 6 and/or the Server Subsystem 2 applications and hardware.
FIG. 2 shows an example implementation 1 A of the Evaluation System 1 , in one of its simplest forms. The system 1 A comprises a server 12 , a database 14 , and a router/modem 16 to connect to a public communications network 20 . A user 10 A, utilizing a workstation 18 , is also connected to the communications network via a router and/or modem 19 , for example. In this implementation, the server 12 , along with the database 14 and router/modem 16 and the appropriate software, implement all of the subsystem functions of the System 1 shown in FIG. 1 by executing various application programs on the server 12 hardware, for example. Of course, the system 1 A may also support many additional users in a manner similar to that shown for user 10 A, for example.
The current embodiment can utilize the Internet as the public communications network. However, other communications networks could be utilized, such as telephone networks, cellular networks, dedicated networks, cable TV networks, power lines, etc. Furthermore, combinations of these networks can be used for various functions. However, because of the ubiquitous nature of the Internet, a solution utilizing that diverse network (which can utilize many individual communications networks) is utilized in the current embodiment.
Furthermore, the System 1 might also utilize a private communication network for at least part of the system. For example, the Registration Subsystem 6 of FIG. 1 might be connected to a private computer network located at the retail store 8 , where the user might register the toy, for example, as discussed in more detail below. Alternatively, the toy might automatically be registered at the time of purchase (e.g., by scanning a code at the register, for example), and thus not require any user interaction at all beyond purchasing the toy. Or the user might send in a registration card to implement registration, as another example.
FIG. 3 shows a more complex implementation 1 B of the System 1 . In this example system 1 B, a plurality of servers 21 A- 21 n can be utilized to implement the server subsystem 2 functions of FIG. 1 . Furthermore, a plurality of CPUs 23 A- 23 n can be utilized to implement the Virtual World Providing Subsystem 7 functions of FIG. 1 . A plurality of database storage devices 25 A- 25 n may be used to implement the Storage Subsystem 5 functions of FIG. 1 . And a CPU 30 can be used to implement the Registration Subsystem 6 functions of FIG. 1 , for example. Finally, a router 29 can be used to connect to the Public Communications Network 20
Note that, although FIG. 3 shows multiple servers 21 A-n, multiple CPUs 23 A-n, and multiple databases 25 A-n, any of these might be implemented on one or more shared computers in various configurations, executing one or more computer program applications, as desired. As the number of users supported by the system 1 C grows, additional hardware can be added to increase the capacity of the system, as necessary, in a manner similar to that shown in the Figure.
Continuing with FIG. 3 showing the more complex implementation 1 B, a plurality of users can be supported in various configurations. For example, a plurality of users 10 B operating single workstations 18 A- 18 n , individually connected to the public communications network 35 , can be supported. Furthermore, complex user networks can also be supported. Retailers and or Toy Manufacturers might also have access to the system, as represented by the example shown in 8 A, should an online-ordering system be implemented for selling toys. Of course, alternate implementations are also possible, depending on the types and number of users and/or retailers being supported, and also depending on the state-of-the-art computer technology.
In the current embodiment, the System uses an Apache web server running in a Linux environment. For webserver hardware, an Intel 2 Ghz+CPUs with 2 GB RAM running Gentoo linux with the appropriate extensions (e.g., mod_php4 and mod_perl) can be utilized. The server will serve flash content to a web browser running a web browser application using PHP, Perl, and actionscript, and flash plugins. A MySQL database application will also be utilized for the storage subsystem.
The client (user) side Flash application make the calls to a number of PHP files. These PHP files then “interface” with the MySQL database to obtain the necessary data. All are served by the Apache web server, which can serve HTML, XML, along with the appropriate flash and other content. For multi-user environments (e.g., the multi user rooms discussed below) these are served by a socket server written in Perl.
This is effectively a 3 layer type of setup: Flash layer <-> PHP layer (this handles requests to the back end) <-> MySQL database, as shown in FIG. 1A . FIGS. 1B and 1 C show the interaction between the client (user) and server subsystem data flows in more detail. A dedicated database server running MySQL on a dedicated computer running the Gentoo linux OS can be used in the current system.
A secure Apache SSL server can be utilized for the registration subsystem, likely sharing the computer with the other Apache server.
FIG. 1A shows an implementation of the current system utilizing an Apache Secure Web server 240 for serving files over secure connection (HTTPS, SSL mode), and an Apache Web server 250 for serving files over regular HTTP. A custom Socket Server 260 , which is an XML socket server, written in PERL, is also utilized for providing independent environments for game sessions.
Items 242 , 244 , and 246 are parts of adoption center (discussed below), which is a flash application with PHP backend. Item 242 provides for user registration, using a form-driven flash application which validates the registration code and creates a user account within the system. A pet creation application 244 , is a form driven flash application designed for guiding the user through pet creation process, and validating the registration code.
Authentication/Login process 246 is a flash application validating user credentials on the server side and spawning an API core in case of validation. It also has module designed for password retrieval based on collected user information, and currently passes user data to a client side API, and may in the future pass user data and a generated encryption key for a current session to a client side API.
Items 252 & 254 are Different media (files) available on the server subsystem for user use. Item 254 represents Flash Movies and Games available for the user. Item 256 represents the server side API. Chat 262 and Multi-user games interactions API (MAPI) 264 are a part of Client side API and are used for setting up and maintaining connection to the socket server, authenticating the user, and work in a pass-through mode for multi-user games/environment to exchange messages.
FIGS. 1B and 1C show the API as a functional layer, serving end user applications (Flash games and such) with stored data (users statistics, virtual toys' properties, item parameters, etc.) retrieved from the database; it also is used to modify/enter certain data.
The scheme of the API is subdivided into Client part 280 (flash application) and Server part 270 (PHP script). Flash clip/movie Game 290 calls a function within the API client side [Core 283 ] passing a request to some arbitrary data. The Client side API [Generator 285 ] sends the request to [Parser 272 ] server side API. The Server side [Core 273 ] processes it and retrieves data from the database, wraps it in XML [Generator 274 ] and sends it back to the Client Side API [Parser 282 ], which calls specified a callback function within originator Flash clip/movie [Game 290 ] and passes received data to it.
To ensure users privacy, prevent cheating and preserve validity/authenticity of information, additional security layers can be designed which encrypts all data being passed back and forth in-between parts of the APIs (client/server).
The chosen Encryption technique of the current embodiment is a modification of TEA routines, using a Feistel cypher with 128 bit key. Keys are generated at the login stage and securely passed to client side via HTTPS, after which the adoption centre spawns the client side API and passes the encryption data specific for the session. Additional measures which can be taken to prevent cheating and maintain data coherency include using different permutations of the original key for every data transmission.
The software of the Computer Program Listing Appendix supports the above described current configuration of the system.
FIG. 4 shows an alternate embodiment of the Entertainment System where the toys are sold to user via an online merchant. In this alternate embodiment, the Entertainment System 1 B includes an online store 40 for a user 10 to purchase toys. The user 10 purchases the toys using the user computer 11 , making an online payment using a credit card or online payment service, for example. A Warehouse or Retailer 42 then delivers the purchased toys, via a delivery service 44 , for example, to the user 10 . Registration of the toys could be automated, or as described above and below for a store-purchased toy.
FIG. 5 shows a diagrammatic representation of some features of the virtual world. An interesting feature of the current embodiment is maintaining the virtual well-being of the virtual toy. The well-being parameters 100 include Happiness 101 , Hunger 102 , and Health 103 . In the current embodiment, numerical values for each of these parameters are tracked and displayed to the user, as described in more detail below.
Furthermore, each virtual toy can have a specific Temperament/Personality 104 which impacts how the Happiness 101 , Hunger 102 , and Health 103 parameters interact with each other, and with activities in the virtual world, and how quickly they change. For example, a virtual toy representing a toy sheep might be more easily be made happy, and have less of an appetite, than a virtual toy representing a toy lion, which may be more grumpy and have a greater appetite, for example. Thus, the virtual toy sheep may be easier to please and need less food than the virtual toy lion, for example. Alternative parameters could also be utilized. For example, a robot toy might have a “charge” or “energy” level, and an automobile might have a “fuel” parameter, rather than a hunger parameter, for example.
One of the features of the Entertainment System in the current embodiment is to provide online User Games and Activities 110 , which can be used to win more virtual cash 111 . Some of these Games/Activities 110 are described in more detail below.
The collection of virtual cash 111 is for use in making “virtual purchases” of various “virtual commodities”, for example. In the current embodiment, each registration of additional new toys adds an increasing amount of virtual cash, which is monitored and tracked by the System, the balance of which is shown to the user when the user is participating in the virtual world. Virtual cash can be earned by playing games, successfully answering trivia questions, and via other means as well.
Furthermore, Virtual Cash 111 can be used to shop for virtual furnishings and accessories 114 . These can be used to furnish one or more virtual rooms set up for the virtual toy. Furthermore, by furnishing the virtual room(s) and adding virtual accessories, the well-being parameters 100 of the virtual toy can be improved by the System, especially the happiness parameter 101 and the health parameter 103 . Thus, a user can improve these parameters by using virtual cash to accessorize and outfit the various virtual rooms.
Furthermore, in the current embodiment, the user can purchase virtual Food and virtually feed the virtual toy 112 , in order to satisfy the virtual toy's hunger parameter 102 . This will also improve the virtual toy's happiness 102 and health 103 parameters in a manner determined by the System (utilizing, for example, the temperament/personality 104 of the toy).
Finally, in the current embodiment, by playing 115 with the virtual toy, the virtual toy's happiness and health parameters are improved. Playing may, however, make the toy hungry, thus affecting the toy's hunger parameter 102 . The virtual cash virtual cash may also be used to provide a virtual medical checkup for the virtual toy to improve the virtual toy's health parameter 103 .
In this manner, the Entertainment System uses the well-being parameters and virtual cash to help balance a platform for providing fun and activities, with an incentive to purchase new additional toys, and to increase the user's attachment to the physical toy. The fun and enjoyment obtained through the use of the system provides free word-of-mouth advertising, which also helps sell additional physical toys. In this manner, the Entertainment System is a marketing tool that will increase the overall sales of the toys, and thus provide a benefit to retailers selling the toys.
FIG. 6 shows the preferred manner of a user registering with the System for utilizing the Entertainment System. The user typically makes his first purchase 120 from a retail store. However, in an alternate embodiment, online purchases might also be supported using an online store (as discussed above for FIG. 4 ), especially for subsequent purchases.
The toys might be, for example, plush toy animals, robots, action figures, figures based on cartoon characters, vehicles, aliens, inanimate objects, etc. FIG. 9 shows an example sketch of a plush toy horse that might be purchased at a retail store and used for the Entertainment System.
The toy will be paired with a hang tag or other device having the system website address and a registration code imprinted thereon or stored therein. For example, in the current embodiment, a simple paper or cardboard hang tag, as shown in FIGS. 10A (front) and 10 B (back), has the website ( FIG. 10A ) and the registration code ( FIG. 10B ) imprinted on the tag.
Alternatively, an electronic storage device, such as a USB key, or wireless RF tag or Bluetooth device, could be embedded within or provided with the toy and/or its packaging at purchase. The electronic device would then have the registration code stored in the device using electronic memory (RAM, ROM, EEPROM, etc.), for example. As electronic storage devices become cheaper, using such a device for storing the registration code may become the preferred approach.
For the current embodiment, after the user takes the toy home, the user begins the registration process by visiting the Entertainment System website using the address on the tag and a user computer via an Internet connection to load the home page (see screen shot FIG. 11A ) and logging on to the System website (see screen shot FIG. 11B ) to load the adoption center 122 . The System then displays an adoption center page (item 123 of FIG. 6 ), and example of which is shown in screen shot FIG. 11E .
In the current embodiment, the user then registers the toy, thus receiving access to the various online features of the invention, as discussed herein.
The registration process 124 of the current embodiment is performed by manually entering the registration code printed on the registration tag via the user computer connected to the Internet. The user also chooses a user ID and password. The System can ensure that at least the combination of ID and password is unique, or might also insure that each user ID is unique as well.
Personal information might also be requested in order to recover user ID and password information. Such personal information might be a favorite color, user's birthdate, etc.
In an alternative embodiment using an electronic storage device with the registration code stored therein, the electronic device will communication with the user computer via a corresponding device, and thus automatically or manually transfer the registration code to the user computer. For example, the System could request that the user plug in a USB key into the user computer at the appropriate time, or the user computer may wirelessly read an RF or Bluetooth device located in or on the toy.
In the current embodiment, after the user enters the registration code, and before or after the user enters the user ID and password, the System checks the registration code in any one of a number of ways. In essence, the system uses stored data relating to all of the registration codes associated with corresponding toys for sale.
The system might check the registration code against a list of valid registration codes stored in the system database, for example. In this case, the stored data are the actual registration codes themselves. If there is a match, the registration code has been validated, and the system then determines the type of toy that the user purchased based on information stored with the registration code in the database. For example, each code could be linked to information about the type of toy (e.g., a basset hound, a fish, a lion, a robot, a soldier, etc.), its coloration and appearance, its temperament, etc.
The System may display a user agreement at some point, providing the terms of usage and legal notices, for example. The System require an affirmative response from the user in order to complete registration.
In such an embodiment discussed above, it would be beneficial to make each registration code unique and complicated, in order to make it difficult for an imposter or unauthorized user to make up a code or use a previously registered number to obtain unauthorized access or unauthorized additional virtual toys.
As an alternative, after being entered, the registration code is used in a mathematical algorithm to determine its authenticity, and such an algorithm might also be used to determine the type of toy being registered. For example, all lion plush toy registration codes might start with the letter “L”, and might use a following number that can be factored into exactly 5 prime numbers, for example, or the number might fall into a particular range or format. Another example is the use of an algorithmic pass-code based on a central key value. In these examples, the stored data relating to the registration codes provides the proper information to perform the validation process (e.g., the proper letters, number ranges, acceptable factors, the central key, or the algorithm itself). Accordingly, by these methods, the actual registration numbers need not be stored, but could still be verified. Then, perhaps by storing the registered registration code, uniqueness could be guaranteed by never allowing that same code to be used again.
Of course, additional techniques can be used to determine a registration code authenticity as well, as long as the registration process ensures that it is likely the user has purchased a valid toy, and thus is an appropriate user of the system.
Referring again to FIG. 6 , after validation and registration has occurred, and the user name and password accepted, the user is prompted to provide a name for the virtual toy 126 (or in an alternative embodiment, one is suggested by the site). The system can then display a biography of the virtual toy 127 , and can also show the user what the appearance of the virtual toy will be. The biography may show such items as a virtual birth certificate, adoption certificate and/or information, likes and dislikes and favorite foods of the virtual toy, etc. The biography may be related to the personality/temperament of the virtual toy, the type of toy, etc. A virtual identity for the toy is thus created by the System, including the biographical information, the name provided by the user, etc.
The user might then be prompted to register any additional toys ( 128 & 130 ), if any. Finally, the System might provide the user with an initial virtual medical checkup 132 for the new virtual toy at a virtual clinic (see screen shot FIG. 11D for an example view of the clinic). The toy's wellness parameters can then be displayed to the user for the first time, and the registration process is thereby finished, and the user now has access to at least some of the restricted portions of the Entertainment System website.
Note that alternative means of registering the toy are also possible in alternative embodiments. For example, the user might phone in the registration code using a telephone, and be given a user ID and password, or choose one over the phone. Or the user may register the toy at the place of purchase using a dedicated or general purpose computer on a private network. Or, if the toy is purchased online, the registration might occur at the time of purchase, before the user has obtained the actual physical toy. Thus, different communication networks may be utilized for registration as are utilized for website access, for example.
The System website can present various interactive scenes into which the virtual toy is incorporated. In the current embodiment, the toy characters can be animals that reside in a virtual village, for example. New features can be opened based on the number of toy animals a user owns and registers. For example, there might be a special adventure that opens when the user purchases and registers his fifth toy, regardless of what those toys are.
In an alternative embodiment, the scenes might be customized based on the type of toy. For example, a basset hound plush animal could be shown in an urban landscape or setting. Likewise, a cow could be shown in the countryside, a monkey in the jungle, and a lobster under the sea, as additional examples.
Furthermore, in another embodiment, each type of toy might have different traits that can impact the way the toy reacts based on the type of toy. Thus, a toy lion might be a mean carnivore, while a toy monkey eats fruit and is playful, for example. Soldiers might be aggressive, while dancers are graceful, for example. Thus, any of the above concepts are not limited to animal toys, but could easily support other toys such as human dolls, robots, machines, soldiers, etc.
Having virtually adopted their toy by registering it with the System, the consumer can then participate in a variety of online games, some involving the virtual representation of the toy (i.e., the virtual toy). These games can include adventure games, trivia games, arcade-style games, and the like. Participants can collect “virtual cash”, which is virtual money which can be spent to purchase virtual items for their toys, as discussed above and below. This virtual cash may or may not be useable at other sites, and may or may not represent legal tender.
Furthermore, a participant may purchase additional toys, register them, adopt them, and thus add them their virtual world, creating additional virtual toys. These purchases are preferred to be actual toy purchases using legal tender where the user obtains a real toy. However, in an alternative embodiment, “virtual toys” represented only online might also be utilized, whether purchased with legal tender or merely online “money”.
Each of the new toys is, after registration, represented as a virtual toy which can interact with other virtual toys (including those created to represent other actual toys), including team game play, for example. Participants can also chat with other registered users using online chatting or posting features. The current embodiment utilizes a symbol chat with preset icons, rather than general text chat, to protect children from inappropriate language. However, generalized chatting features could also be added, such as provided by a commercially available chat program, for example.
FIG. 7 shows an example of how a user might utilize the Entertainment System for a session or two. First, the user purchases one or more toys 200 . Then, the user registers one of the toys 202 , as described above. The user then purchases virtual furnishings and virtual accessories 204 for the virtual toy, and uses the purchased items to furnish the toy's virtual rooms 206 . The user can virtually move the furnishings around the room by “point, click, & drag” operations, for example, thus testing various types of decorating schemes. The user can also paint/wallpaper the room, provide flooring, etc. all of which were purchased 204 .
The user might then play with the virtual toy 208 for a while, increasing the toy's health and happiness parameters. The user might then add a friend to the site, and interactively play 212 with the friend, who can be online using his own computer. The friend will have virtual toy's that can be seen and interacted with, even though the friend may be remotely located, and thus not seen by the user. The user and his friend may chat with each other using the chat icons, for example.
The user might want to perform a checkup 214 of his virtual toy, if the toy displays some low health parameters. The user might then play various online games 216 , including online arcades and trivia, in order to generate more virtual cash 218 . The user might then use the new virtual cash to purchase virtual food, and then virtually feed 222 the virtual toy.
If the user bought additional toys, he can register the additional toys 224 , which will also generate additional virtual cash 218 . The user can then use both the original virtual toy and the additional virtual toy to play together, increasing the happiness parameter of both virtual toys, and perhaps making the toys hungry. The user then might end his online activities, or continue with additional online activities in a similar manner.
Of course, actual user sessions can involve an infinite combination of the various features of the invention, and the process of FIG. 7 is merely an example. FIG. 8 shows a site mapping of the various features that are available in almost any order the user should desire. FIGS. 8A-8H show these features in more detail.
In the current embodiment, the virtual items in the virtual world can be made to interact with each other. For example, the virtual toy might sit in virtual chair, or climb on top of a virtual table. The virtual toy might walk around the virtual world, and play with its own virtual toys. Virtual toys may play and interact with each other. Virtual accessories might be placed on a table, and virtual pictures “hanged” on a virtual wall. Virtual chairs might be moved around, and slid up to a virtual table. The virtual toy might sit in a chair. Virtual food might be placed on a virtual plate, for example, and the virtual toy may simulate eating the virtual food. Thus the user is provided with an animated display of these interactions, including both video and/or audio components. In this manner, the virtual world simulates activity in the real world.
The user can also zoom in and out of various views, virtually move from room to room (i.e., display different rooms), etc. all by manipulating the mouse and keyboard of the user computer.
The virtual world and the games represented on the Entertainment System website may be changed and updated on a regular basis to maintain the interest of the user participants. For example, trivia game questions may be updated, and new games periodically added.
Further, new types of plush toy animals can be periodically introduced to encourage consumers to make additional purchases. Special or limited addition toys could be introduced, for example, on holidays. For example, an American bald eagle might be introduced to commemorate Independence Day, and a Santa Claus for Christmas. These new toys can be introduced to the user in a virtual manner, and the user encouraged to purchase the actual toy. Bonuses of virtual cash, or special activities might be provided to those who do purchase special toys.
Subsequent purchases of toys, when registered, may lead to increasingly greater deposits of virtual cash as a reward. For example, the first toy registration may lead to $1500 in virtual cash, a second purchase and registration may add $2000, and a third add $2500, for example. Furthermore, purchasing and registering a certain number of toys could lead to bonuses, such as additional virtual rooms, and/or access to additional games (e.g., an outdoor tennis court with game). These bonuses encourage subsequent purchases, and keep the user interested in both the System and the toys.
Additional features that can be included in additional embodiments, as discussed above, are incorporating a storage medium into the plush toy animal instead of, or as a complement to, the registration tags, for example. This might allow the online profile of the toy, including everything the toy has “learned”, to be stored in the device with the toy. The toy could then be connected to another computer at another location, for example at a friend's house, in order to participate in online activities, as long as that computer is connected to the Internet, for example. Furthermore, the storage medium could be used to store other information for its owner, such as homework assignments, photographs, music or shortcuts to favorite online websites.
The Entertainment System website for providing this virtual world is a site where children and other toy owners that own an appropriate toy can adopt and care for their virtual toy (e.g., “virtual pets”), play games, and go on adventures, as discussed above. After registration, the user can begin to enjoy the complete ‘game’ in the virtual world, which is a combination of caring for the toy, going on fun adventures, being surprised by rollovers and trivia, and generally having interesting and entertaining experiences. It is a multi-faceted world, rich in amusement and learning opportunities, including both audio and video (graphics, animation, photos, etc.) representations.
In the current embodiment, there are about 7 or more main sections to explore in this virtual world. FIG. 8 provides a top-level view of the various features, with more detail shown in FIGS. 8A-8H . FIG. 8A provides a mapping of the home page, public pages, adoption center, and registration functions 302 . FIG. 8B provides a mapping of the pet virtual room, status, dock, and biography functions 308 . FIG. 8C provides a mapping of the Trivia/Question Corner functions 304 . FIG. 8D provides a mapping of the shopping functions 312 . FIG. 8E provides a mapping of the newspaper functions 314 . FIG. 8F provides a mapping of the Arcade functions 306 , and FIG. 8G provides a mapping of the multi-user functions 310 .
Some of these functions and features of the current embodiment, all of which utilize parts of the software of the Computer Program Listing Appendix, and are described in more detail, below:
Home Page
This section is preferably open to the public, whether an animal has been purchased or not, and features one or more Splash movies, for example. The options presented on the home page include: a Site Tour, Collection(s) portraits—plush and virtual—of each toy animal in the collection(s), access to the Free Arcade, as well as User Log On, and Entrance to User Registration. This section can encourage a person to purchase a toy if he has not yet done so for access to other site locations. See FIG. 11A for the screen shot of the example Home Page, and FIG. 11B for the example logon page.
Adoption Center (AC)
In the AC, the user is guided through the registration process, with the help of the host, Miss Birdie, for example. A User Agreement is presented here. Each user fills in “adoption” forms here, including choosing his or her user name (or “special name”) and password (“secret word”). The user enters the multi-(e.g., nine) digit alphanumeric code found on the hang tag of the toy that will authenticate his or her toy, and provide them access to the final steps of registration/adoption. See FIG. 11E for the example adoption center page.
In the current embodiment, the user is given an initial amount of “virtual cash” in order to begin “virtual furnishing” the room, purchasing “virtual food” for the toy, etc., as described in more detail above and below.
In an alternative embodiment, the user chooses the color of the toy's room, and also might choose a number (e.g., five) of free items for the toy's room. Finally, the adoption is completed with the presentation of a unique biography for the toy, randomly generated using many variables. Users have the option of changing the name of the toy, and perhaps generating a new biography.
Clinic
After the successful registration of the toy, the user is brought to the clinic for a check-up/familiarization. The host for this page is a virtual doctor (e.g., Dr. Quack), who gives the virtual toy a quick check-up and gives it a clean bill of health. A user may return to the clinic at any time, for another check-up or when virtual toy's health parameter is low. If the toy requires medical attention, the user chooses and purchases medicine, for example. Other treatments may also be provided. See FIG. 11D for the Example clinic page screen shot.
Toy's Room
The virtual toy's room is made up of a series of animated (e.g., Flash based) screens that depict the virtual room or rooms where the toy “lives”, “eats” and “plays”. In the current embodiment, a single isometric view of the room is provided. The virtual room can, in time, be converted into a large virtual house or even multiple virtual houses, through the use of room expansions via spending the virtual cash, for example. In the current embodiment, the user can purchase virtual flooring and virtual wallpaper or paint, and virtual furnishings, to prepare the virtual room for the virtual toy. See FIG. 11C for the screen shot of an example virtual pet room already furnished, showing an animated pig as the virtual pet.
Virtual outdoor yards, that have their own virtual furniture and exclusive virtual objects (i.e. trees) that cannot be placed inside the house, for example, can also be provided for “purchase” using virtual cash.
In the current embodiment, a user interface section located at the bottom of the window known as the “dock”, or “Control Panel” is provided, as shown in the example virtual room screen shot of FIG. 11C , showing the dock at the bottom of the screen shot. The user may virtually store many or all virtual purchases, collectibles, and adventure objects in the dock, (some of which are functional, such as a virtual calculator for example) or place them throughout the room by dragging them from the dock. The dock displays a visual description of the virtual toy's well-being parameters (e.g., a numerical index), as the toys need food and attention to remain healthy and happy. Also in the dock are the user's points level, and available “virtual cash” earned in virtual games and adventures that can be used throughout the site.
In an alternative embodiment, there might be a number (e.g. 3) of views of the room, and each scene might be accompanied by the dock.
If the user has multiple registered virtual toys, the dock interface will allow the user to switch between toys and view them when not in use. Furthermore, a plurality of virtual toys might be moved into a room for interactive play, for example.
Further, the user can add friends to a friends list, and then the friends can virtually visit each other's rooms, each seeing the same room and playing with their virtual toys, both interacting with the room objects, and chatting using a chatting tool, for example. In the current embodiment, the chatting tool can use “chat symbols”, for example, rather than using typed words, so that pre-defined phrases can be chosen and transmitted to the other participant.
In an alternative embodiment, users would be encouraged to revisit be receiving daily rewards, such as an ‘allowance’ or pieces of a puzzle that can be put together, or one piece will be put in the puzzle box every day, thus encouraging users to revisit.
In the current embodiment, a user can go virtually “shopping” using the computer in a dedicated shopping location/room (e.g., at the “WShop”). This simulated virtual shopping experience allows the user to simulate the purchase of virtual online goods for their virtual toy(s). An example screen shot of the W shop is shown in FIG. 11F .
Furthermore, real-life shopping for additional physical toys and/or their accessories, such as via mail-order, might also be supported.
A Family Album, which may be available from the dock, for example, can be used to contain all the important documents including one or more of:
a·Birth Certificate an·Adoption Record a·Biography
If the user has multiple toys, all records can appear in the album.
Arcade
The arcade is a collection of online games for the user to play via the user computer. The user can “take” his or her toy to play some of the games games, which in turn provides them with happiness points for their happiness parameter, and allows the user to earn online virtual cash. In the current embodiment, registered users may have full access to all games, with full access requiring the purchase of a toy with the accompanying registration code and registration, although in an alternate embodiment, the arcade may be made open to the general public with limited access to some limited number of the games. FIG. 11G shows an example screen shot from the Arcade.
Examples of Arcade games in the current embodiment are: Bananza; Color Storm; Dashing Dolphin; Driving School; Tulip Trouble; Jazz Monsters; Leaf Leaf; Lily Padz; Icecap Adventure; Picnic; Hungry Hog; Pumpkin Patch Protector; Webkinz Wishing Well; and Wacky Zingoz, for example.
Clubhouse
In an alternative embodiment, a virtual clubhouse is provided which is a virtual location which houses important community information. The blackboard displays statistics, such as high scores ranking for games. The usernames, or a subset of the user names (such as the first three letters, for example), of the high scores can be listed. The System website may provide users with the opportunity to provide feedback through a suggestion card interface at the Clubhouse, for example. There may also be an online survey, or Poll, area that allows administrators to poll the community's members on various topics.
Webkinz Gazette
In the current embodiment, most of the features of the above Clubhouse are provided in a virtual Newspaper (e.g., Webkinz Gazette) providing news and information, including a “What's New” section that informs users of the latest additions to the site. The virtual paper might also list the usernames (or the subset of the usernames) of the users with the high scores in various arcade games and/or trivia, for example. FIG. 11I shows an example screen shot of a page of the Gazette, and FIG. 11J shows a summary of the virtual pet biography and well-being parameters displayed by a user selecting a call-up.
Adventures
In an alternate embodiment, each virtual toy belongs to one of a number of areas (e.g., Urban, Country, Undersea, Jungle), with a corresponding Adventure. Each adventure area can consist of a large isometric map in four quadrants, and detailed scenes for playing games. The map is constructed in a maze-like fashion that allows the user to explore the different areas of the environment. The map is embedded with rollovers, pop-ups, trivia questions, and various virtual collectible objects that the virtual toy can pick up along the way. Within the map, there may be five or more extended play areas (the “scenes”) that allow the user to play games that provide virtual prizes and clues to aid them in completing the adventure. Upon completion of the initial adventure, the user acquires a special virtual key. There are a number of virtual keys (e.g. four keys) in total, one from each adventure area in the series. As a bonus for recovering all of the keys, the user is granted access to a “Wonder World”, or “WW”. (See below.)
Adventures can be an important part of play at the website. The game could involve a number of separate environments (e.g. four). Initially, each adventure takes place only in the designated environment (e.g., Jungle, Undersea, Urban and Country). Every adventure involves points and/or virtual cash. The virtual cash is useful in the virtual World as the users can make virtual purchases for their toys. In an alternative embodiment, after the user buys a number of toys (one from each environment, for example) and registers them and successfully completes the adventures, he or she can go to another (e.g. fifth) environment called the Wonder World (WW).
Each additional registered toy can add new sections to the adventure areas of the virtual website for the individual user. The only way a user can experience these additions is to buy a new toy, an accessory, or perhaps a service (whether virtual or actual—both can be supported). This will give the toy owner added value and entertainment. If the user has more that one toy from the same environment, they will have the option to go on an “extreme adventure” that combines the use of all owned and registered toys.
Multi-User
Multiple product purchases will be encouraged through access to new features being opened to use once the purchaser has entered multiple registration codes into the system. For example, while the first pet code opens access for the basic features of the site, the third pet code entered on the same account may open access to a virtual pet adventure, and the fifth pet code entered may add a special room to the virtual toy's house, such as a home theatre or tennis court.
In an alternate embodiment, core functionality could also require multiple product purchases, such as multi-use play being only accessible from the magical land of a Wonderworld (WW) that is accessed through the purchase of a set of toys. One of the things the user could get in WW is access to the “Magic W”, represented by a giant statue of a ‘W’ in the middle of WW. When the user gets to the Magic W, they get a virtual ring version of the magic W in his or her dock. This will enable the user to initiate some multi-use activities on the website, among other things.
In WW, there may be a midway full of virtual games, a vast magical virtual land, a virtual puzzle center, and a virtual vector world. This world can be made growing all the time and thus be full of excitement. In the center of it all, is the magic “W”. Here, the user can play in a new world that allows them to participate in multi-user games, multi-user adventures, and a user chat interface developed to utilize pre-scripted phrases and symbols, for the safety of the users.
Quizzy's Question Corner”
This is an area for users to answer trivia questions and age-appropriate educational questions based on U.S. and Canadian educational standards. In the current embodiment, the questions can be sorted by age in a “Learn and Play” section and there is a daily Trivia question that is tracked so that a user at anytime can answer the historical daily trivia question. Both sections reward the user with virtual cash and virtual stickers that are stored and viewable in a virtual sticker album. The user can earn virtual cash by correctly answering the questions. FIG. 11H shows an example screen shot from the Question Corner.
The multi-use capabilities of the site are used in the current embodiment to increase user satisfaction. Users can “invite” their friends (other users) over to their room and interact with the room objects together, including playing games. This can occur even though the users may be remotely located from one-another using different user computers. These multiplayer concepts might be brought into the Question Corner and Arcade allowing for competitive play between multiple users.
Some of the features of the current embodiment include the option to offer various additional toys, accessories, and/or services to the user, whether real or virtual, and perhaps entwined with the activities being participated in the virtual world (such as via a game, for example, or a health checkup, etc.). Some of the characters found in the current embodiment are Ms Birdie—The adoption centre penguin; Dr. Quack—The clinic duck; and Quizzy—The Quizzy's Question Corner bear.
The site web pages should be quick to load so as to make it useful and fun. Finally, additional enhancements can be provided for additional benefits. For example, some information on the toy might be stored locally, such as on a USB key, which can be carried by the user and used to access the site from various locations.
The Computer Program Listing on CD ROM made a part of this application provides the preferred code at the time of its generation for implementing the above system on a web server as is known in the art. The features and functionality of this code are incorporated herein by reference.
The invention has been described hereinabove using specific examples; however, it will be understood by those skilled in the art that various alternatives may be used and equivalents may be substituted for elements or steps described herein, without deviating from the scope of the invention. Modifications may be provided to adapt the invention to a particular situation or to particular needs without departing from the scope of the invention. It is intended that the invention not be limited to the particular implementation described herein, but that the claims be given their broadest interpretation to cover all embodiments, literal or equivalent, covered thereby.
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A method and computer system for providing a virtual world are disclosed. First and second registration codes, which are different and are obtained from purchasing items are used to access different portions of a website. Subsequent to accessing the portions of the website using the registration codes, a first image and a second image are accessed to be viewed, each by using a user identification name and a password without reentering the first and second registration codes. A name is to be selected for each of the images after using the registration codes. After entering the user identification name, the first and second images are to be interacted with to bring about changes to the first and second images, and the changes are based on the interacting. An invitation is to be extended to at least one friend on the website, the at least one friend to view at least one of the first and second images in a virtual room owned by and customizable by the user.
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RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 10/755,812, filed Jan. 12, 2004, now U.S. Pat. No. 7,509,122, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to CDMA2000 mobile networks, and more particularly to the interaction between always-on mobile data devices and third generation CDMA2000 networks.
BACKGROUND
In CDMA2000 networks it is important for a wireless data device to acquire and stay in a network that provides third generation (3G) data services such as email, browser and short message service (SMS) text messaging to the device. An always-on device should always try to keep a valid point-to-point protocol (PPP) session in order to send or receive data packets in a timely manner. When a mobile data device loses its PPP session or the device moves to a new network where, for example, the SID/NID/packet zone ID (system identification/network identification/packet zone identification) changes, the device should try to negotiate for a new PPP session with the network.
The problem with this, however, is that in current CDMA2000 networks there is no information broadcast to a mobile device on whether the network supports data services. The mobile device is merely notified that is has acquired a second generation (2G) or a 3G system.
Third generation systems do not always support data services. In some cases such a network only supports 3G voice services. In other situations such 3G networks might not have a data roaming agreement with the mobile device's home network, and therefore not allow the mobile device to access data services.
A mobile data device moving into a system that does not support 3G data currently wastes battery power by trying to establish a data connection with the network. Further, such attempts to establish a data connection waste network resources.
SUMMARY OF THE INVENTION
The present invention seeks to overcome the above deficiencies by providing a mobile data device with information about the capabilities of networks the device can connect to. Each mobile device includes a preferred roaming list (PRL) built into it, which assists the device to perform system selection and acquisition. This PRL includes the SID/NID pair Preference and Roaming Indication to aid the device in deciding whether the system is a preferred system that the device should connect to. In the present invention, information about whether the network supports 3G data capability is added to the PRL to assist a device in deciding whether it should connect to the network.
Other information that can be added to the PRL in the present invention includes whether the network supports data roaming for the device's home network. This allows the mobile data device to know whether the network can be connected to for data roaming services.
Also, with the advent of Mobile IP (Internet Protocol), a device prefers to connect to a network that supports Mobile IP rather than simple IP. This allows the device to move between networks with less time and effort spent establishing an IP connection. Information about whether the network supports Mobile IP can also be added to the PRL.
Further, with CDMA2000 networks, a device will prefer a packet data serving node that supports the always-on feature. Information about whether the network supports this feature can also be added to the PRL.
The new information provided to an always-on data device allows the device to create its own system preferences based on the 3G data capability of the network. If the network does not provide data capability, the device should search for a different network and not try to establish a PPP session, thereby saving batteries and network resources. Further, an attempt to connect to preferred networks, such as those that support Mobile IP data services and data roaming, should be made before attempting to connect to networks that do not support these services. The mobile data device should also try to stay in these networks whenever possible.
In present wireless devices, the device does not know what data service capabilities it has. The network stores this information, and resources may be wasted in attempting to utilize services the device does not support. A further possibility is therefore to include a field in the PRL to indicate what services the device supports. This will save battery life and network capacity by preventing the device from attempting to utilize a service it does not support.
The present invention therefore includes a method of providing a mobile data device in a wireless system with information about preferred networks to connect to, said mobile data device having a preferred roaming list with a list of networks, said method comprising the steps of: adding information to the preferred roaming list about data capabilities of each network; and determining preferred networks based on information within said preferred roaming list including a geographic area and the data capabilities of said network.
The present invention further includes a method of providing a mobile data device in a wireless system with information about preferred networks to connect to, said mobile data device having a preferred roaming list with a list of networks, said method comprising the steps of: adding information to the preferred roaming list about whether each said network in said list of networks supports third generation data capabilities; and determining preferred networks based on information within said preferred roaming list including a geographic area and whether said network supports third generation data capabilities whereby, within said geographic area, said mobile data device prefers those of said networks which support third generation data capabilities over said networks which do not support third generation data capabilities.
The present invention still further includes a method of providing a mobile data device in a wireless system with information about preferred networks to connect to, said mobile data device having a preferred roaming list with a list of networks, said method comprising the steps of: adding to the preferred roaming list information about whether each said network in said list of networks supports third generation data capabilities; adding to the preferred roaming list information about whether each said network in said list of networks supports data roaming; adding to the preferred roaming list information about whether each said network in said list of networks supports Mobile IP service; adding to the preferred roaming list information about whether each said network in said list of networks supports an always-on feature; and determining preferred networks based on information within said preferred roaming list including a geographic area and whether said network supports third generation data capabilities, data roaming, Mobile IP service and always-on feature; whereby, within said geographic area, said mobile data device firstly prefers those of said networks which support said third generation data capabilities over networks which do not support said third generation data capabilities, secondly prefers those of said networks which support said data roaming over networks which do not support said data roaming, thirdly prefers those of said networks which support said Mobile IP service over networks which do not support said Mobile IP service, and fourthly prefers those of said networks which support said always-on feature over networks which do not support said always-on feature.
The present invention still further includes A system for providing a mobile data device in a wireless system with information about preferred networks to connect to from a list of networks, said system comprising: the mobile data device, said mobile data device being capable of connecting to some or all networks within said list of networks; and a preferred roaming list within said mobile data device, said preferred roaming list including: identification information for each network within said list of networks; geographic information for each network within said list of networks; and information about each network within said list of networks indicating whether each network supports data capability; whereby said mobile data device chooses a preferred network based on said geographic information and those of said networks within said list of networks that supports said data capability.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood with reference to the drawings, in which:
FIG. 1 is a schematic diagram of a wireless device of the present invention; and
FIG. 2 is a flow diagram of a method of acquiring a system according to the method of the present invention.
DETAILED DESCRIPTION
Referring to the drawings, mobile data device 100 is preferably a two-way wireless communication device. Where mobile data device 100 is enabled for two-way communication, it will incorporate a communication subsystem 111 , including both a receiver 112 and a transmitter 114 , as well as associated components such as one or more, preferably embedded or internal, antenna elements 118 , local oscillators (LOs) 113 , and a processing module such as a digital signal processor (DSP) 120 . As will be apparent to those skilled in the field of communications, the particular design of the communication subsystem 111 will be dependent upon the communication network in which the device is intended to operate.
When required network registration or activation procedures have been completed, mobile data device 100 may send and receive communication signals over the network 119 . Signals received by antenna 116 through communication network 119 are input to receiver 112 , which may perform such common receiver functions as signal amplification, frequency down conversion, filtering, channel selection and the like, and analog to digital (A/D) conversion.
Mobile data device 100 preferably includes a microprocessor 138 , which controls the overall operation of the device. Communication functions are performed through communication subsystem 111 . Microprocessor 138 also interacts with further device subsystems such as the display 122 , flash memory 124 , random access memory (RAM) 126 , auxiliary input/output (I/O) subsystems 128 , serial port 130 , keyboard 132 , speaker 134 , microphone 136 , a short-range communications subsystem 140 and any other device subsystems generally designated as 142 .
Preferred roaming lists used by the microprocessor 138 during network registration are preferably stored in a persistent store such as flash memory 124 , which may instead be a read-only memory (ROM) or similar storage element (not shown).
As shown, flash memory 124 can be segregated into different areas for both programs storage 150 and preferred roaming list 152 .
Mobile devices 100 use preferred roaming lists to determine with whom contact should attempt to be established. This is useful when the mobile device loses the signal from the base station and a new signal needs to be acquired.
Table 1 shows an example of a PRL table as currently used by wireless devices 100 . One skilled in the art will realize that the information may be arranged differently depending on the mobile device, and that Table 1 is merely an example of a PRL table.
TABLE 1
INDEX
SID
NID
N/PREF
GEO
PRI
ACQ
ROAM
0
253
65535
Pref
NEW
SAME
21
0
1
3682
65535
Pref
SAME
MORE
2
0
2
2157
65535
Pref
SAME
SAME
14
1
3
46
65535
Pref
NEW
SAME
6
0
4
257
65535
Pref
SAME
SAME
7
1
If a mobile device 100 loses its signal, the device will attempt to reestablish contact. This will be done based on the information in the PRL. This information includes whether the SID/NID pair is negative or banned, or preferred and desired, as indicated in the column labeled N/PREF.
The PRL further includes information about whether the SID/NID pair is in the same or different geographical area. In Table 1, most of the entries are marked SAME under the GEO column. This means that they are in the same geographical area as the previous index SID. When the column indicates NEW, this SID is in a different geographical area than the previous index SID. The mobile device will first attempt to establish contact with a system in the same geographical area as the signal it just lost.
The then current PRL list of preferred networks is considered together with the then available networks to derive a ranked list of available networks. The PRL then ranks the priority of each system. This is seen in the column labeled PRI in Table 1. SAME indicates that the SID has the same priority as the next indexed SID. MORE indicates that the SID has more priority than the next indexed SID.
In Table 1, if a mobile device loses the signal for SID 2157 , it first looks for a new network in the same geographical area, or within SIDS 253 , 3682 and 2157 . Within these areas the mobile device then looks for the highest priority networks, which in the example are SIDs 253 and 3682 . If these cannot be connected to, the mobile device moves to the next highest priority network, which in the example is SID 2157 .
ACQ is the acquisition index, which tells the mobile device which channels to look for signals on. Roam tells the mobile device what to do with the roam indicator.
As indicated above, the problem with current PRL system tables is that they do not tell the mobile device whether the SID/NID pair support third generation data capabilities. This could lead to a mobile data device attempting to make contact with a SID/NID pair that does not support data capability, thus wasting both battery power on the mobile device and network resources due to the attempt to establish contact.
Table 2 shows an example PRL system table using the method and system of the present invention. Table 2 includes a column that indicates whether the SID/NID pair supports third generation data communications. One skilled in the art will realize that there are other ways to amend a PRL table to indicate that the SID/NID pair supports data capability, and the table below is merely meant to be illustrative of one way to implement this.
TABLE 2
INDEX
SID
NID
N/PREF
GEO
PRI
ACQ
ROAM
3G Data
0
253
65535
Pref
NEW
SAME
21
0
0
1
3682
65535
Pref
SAME
MORE
2
0
1
2
2157
65535
Pref
SAME
SAME
14
1
1
3
46
65535
Pref
NEW
SAME
6
0
0
4
257
65535
Pref
SAME
SAME
7
1
1
Using the PRL system table of Table 2, a mobile device can determine whether to attempt to establish communications with an SID/NID pair. Using the above example, if the mobile device 100 loses contact with SID 2157 , it will attempt to establish contact based on the PRL table in Table 2. This is done by geography first in this case, but now also by 3G data capability. In the prior art model, the mobile device would have first attempted to establish contact with SID 253 . However, using the method of the present invention the mobile data device does not attempt to contact SID 253 since it does not support 3G data capability. This saves both battery power and system resources. The device instead attempts to communicate with SID 3682 first.
One skilled in the art will appreciate that the PRL table of Table 2 can also save resources by identifying to the mobile device that no SID/NID pair in the area supports data capability, and thus the system should not attempt to establish contact at all.
Table 2 overcomes many of the deficiencies of the prior art. However, an alternate preferred PRL table may also include information about whether the SID/NID pair allows data roaming. This is used, for example, if the mobile device is outside of its home system. Table 3 shows an example of a PRL that includes information about whether the SID/NID will allow data roaming.
TABLE 3
INDEX
SID
NID
N/PREF
GEO
PRI
ACQ
ROAM
3G Data
Data Roam
0
253
65535
Pref
NEW
SAME
21
0
0
0
1
3682
65535
Pref
SAME
MORE
2
0
1
0
2
2157
65535
Pref
SAME
SAME
14
1
1
1
3
46
65535
Pref
NEW
SAME
6
0
0
0
4
257
65535
Pref
SAME
SAME
7
1
1
1
Table 3 includes the additional column for data roaming, indicating whether the network will accept data roaming. If it does not, the mobile data device that is not within that system as its home system will not attempt to establish communications with this SID.
Continuing with the above example, if the mobile device 100 is not within its home system for SID 3682 , it will know that 3682 does not allow roaming, and thus not attempt to establish contact with this system. The device will instead move to SID 2157 , which allows 3G data services and also allows roaming.
One skilled in the art will realize that 3G data and roaming may be combined or may be represented differently from the PRL system table of Table 3.
A further benefit would be to know whether the SID supports Mobile IP. Mobile IP allows a mobile device to move between SID/NID pairs without having to establish a simple IP. This presents significant benefits for roaming with mobile data devices.
A further preference criterion for a PRL can thus be whether the system supports Mobile IP. An example is illustrated in Table 4 below.
TABLE 4
INDEX
SID
NID
N/PREF
GEO
PRI
ACQ
ROAM
3G Data
Data Roam
Mobile IP
0
253
65535
Pref
NEW
SAME
21
0
0
0
1
1
3682
65535
Pref
SAME
MORE
2
0
1
0
1
2
2157
65535
Pref
SAME
SAME
14
1
1
1
0
3
46
65535
Pref
NEW
SAME
6
0
0
0
1
4
257
65535
Pref
SAME
SAME
7
2
1
1
1
In Table 4, the preference is first given by geography, then by 3G data capability, then by roaming, and finally by whether the network supports Mobile IP services.
A further benefit would be to know whether the packet data serving node (PDSN) supports an always-on feature. If the device is an always-on device and the PDSN supports an always-on feature, the PDSN is informed that the device is an always-on device and the device is informed about the maximum PPP inactivity time. Based on this, an always-on device would prefer to select a network that supports the always-on feature.
A further preference criterion for a PRL can thus be whether the system supports the always-on feature. An example is illustrated in Table 5 below.
TABLE 5
INDEX
SID
NID
N/PREF
GEO
PRI
ACQ
ROAM
3G Data
Data Roam
Mobile IP
Always-On
0
253
65535
Pref
NEW
SAME
21
0
0
0
1
0
1
3682
65535
Pref
SAME
MORE
2
0
1
0
1
1
2
2157
65535
Pref
SAME
SAME
14
1
1
1
0
1
3
46
65535
Pref
NEW
SAME
6
0
0
0
1
0
4
257
65535
Pref
SAME
SAME
7
1
1
1
1
0
In Table 5, the preference is first given by geography, then by 3G data capability, then by roaming, then by whether network supports Mobile IP services, and finally by whether the network support an always-on feature. One skilled in the art will realize that preference can be given to networks using a different ordering of the PRL table data, and that in some cases various columns in the PRL table may be omitted altogether.
The implementation of the table can further be a single data capability field, in which, for example, an eight bit field could use various bits to signify whether the network supported always-on, mobile IP, 3G data and data roaming, or other data capability features. For example, the first bit in the field could signify that the network supported an always-on feature with a “1”, or that the network did not support the always-on feature with a “0”. The remaining bits could similarly be used for other data capability information.
In a wireless system where the mobile data device can connect to a plurality of networks, the above is implemented by amending the PRL table and the logic for establishing priority within the mobile device. The PRL table can be modified and loaded onto the mobile device through known methods within the art. Further, the mobile device can be programmed to select preferred networks based on the modified PRL table.
A further benefit would be to know whether the data device is able to support various services, such as voice, data, or SMS. The device is configured by the carrier for specific services based upon the service plan that the user selects. In the current CDMA2000 standard, the device is not aware of the service configuration file at the network. The device is aware of the service that the network supports only after it sends a service request that is granted or rejected by the network.
In operation, if the device wants to send an SMS message in a non-provisioned network, the device first sends an SMS origination request to set up a dedicated traffic channel. The device next sends an SMS message on the dedicated traffic channel. Finally the network checks whether the devices is entitled to the SMS service. If not, the network sends an SMS error code to the device.
By adding device service information to the PRL, the device has the ability to know its service capability at the time the network is acquired and without any service request being sent out. This saves battery life and system capacity by ensuring the device does not attempt to establish a service it does not have the capability for.
A further preference criterion for a PRL can thus be the device service capability. An example is illustrated in Table 6 below.
TABLE 6
INDEX
SID
NID
N/PREF
GEO
PRI
ACQ
Data Capability
Device Service Capability
0
253
65535
Pref
NEW
SAME
21
01100000
1010
1
3682
65535
Pref
SAME
MORE
2
00110000
1010
2
2157
65535
Pref
SAME
SAME
14
11010000
1010
3
46
65535
Pref
NEW
SAME
6
00010000
1010
4
257
65535
Pref
SAME
SAME
7
11110000
1010
In Table 6, the preference to the choice of network is made as above, with the data capability field using the first four bits to indicate 3G data, Mobile IP, Always-On PDSN and data roaming. The device further has information about what services it supports. In Table 6, the four bits can, for example, indicate whether the device supports data service (first bit), voice service (second bit), SMS (third bit) and browser (fourth bit). The device will thus know what types of service it can request.
In a preferred embodiment, the carrier could update the device by downloading a new PRL when the user changes their service plan. The device could further display the services it supports using an icon to indicate its service capability.
The above will be better understood with reference to FIG. 2 . In FIG. 2 , a mobile device 100 stays in step 200 until the device realizes that it needs to acquire a new system. If the device 100 does not need to acquire a new system, the device stays in step 200 .
Once mobile device 100 realizes it needs to acquire a new system, mobile data device 100 moves to step 202 in which it stats a search for a new system. In step 204 mobile device 100 determines whether it has acquired a new system.
In step 204 , if the device finds that it has not acquired a new system, the device moves back to step 202 in which a search for a new system is again started.
Conversely, if the device finds that a new system has been acquired, the device next moves to step 206 . In step 206 the device asks the PRL table whether the potential system supports third generation (3G) data capabilities. As indicated above, for a data device this is a key feature.
In step 206 if the device finds that the potential network does not support third generation data, the system next moves to step 208 . In step 208 the device asks whether any network that the device can access supports third generation data capability. If step 208 finds networks that support 3G data capability, the device will prefer to connect to those networks, and will thus move back to step 202 and start a search for a new system.
Conversely, if the network does not support third generation data capability, the device can either decide not to connect to a system (not shown) or can connect to the potential system acquired in step 204 .
If in step 206 the system that is found supports 3G data, the system next moves to step 210 . In step 210 the device asks whether this is the best system to connect to. The decision in step 210 is based on the PRL table and the information contained therein. Specifically, depending on the device, it may prefer systems that support mobile IP, data roaming or always-on capabilities. Based on the device and the PRL table, a decision is made in step 210 whether the potential system is the best system to acquire.
If step 210 finds that the best system is being acquired, the system next moves to step 212 and acquires the system. Conversely, if step 210 finds that a better system exists, the device moves back to step 202 and start a search for the new system.
The above-described embodiments of the present invention are meant to be illustrative of preferred embodiments and are not intended to limit the scope of the present invention. Also, various modifications, which would be readily apparent to one skilled in the art, are intended to be within the scope of the present invention. The only limitations to the scope of the present invention are set forth in the following claims appended hereto.
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A method and system of providing a mobile data device in a wireless system with information about preferred networks to connect to, the mobile data device having a preferred roaming list with a list of networks, the method comprising the steps of: adding to the preferred roaming list information about whether each network in the list of networks supports third generation data capabilities; and determining preferred networks based on information within the preferred roaming list including a geographic area and whether the network supports third generation data capabilities, whereby, within the geographic area, the mobile data device prefers networks which support third generation data capabilities over networks which do not support said third generation data capabilities. Other information that may be added to the preferred roaming list includes whether the network supports data roaming, Mobile IP services or always-on features. The preferred roaming list may also include information about the device service capabilities.
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RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Serial No. 60/014,884, filed Apr. 4, 1996.
FIELD OF INVENTION
This invention relates generally to covered rolls for industrial applications, and more particularly to rolls with relatively hard covers.
BACKGROUND OF THE INVENTION
Covered rolls are used in demanding industrial environments where they are subjected to high dynamic loads and temperatures. For example, in a typical paper mill, large numbers of rolls are used not only for transporting the web sheet which becomes paper, but also for processing the web itself into finished paper. These rolls are precision elements of the system which should be precisely balanced with surfaces that are maintained at specific configurations.
One type of roll that is subjected to particularly high dynamic loads is a calendar roll. Calendaring is employed to improve the smoothness, gloss, printability and thickness of the paper. The calendaring section of a paper machine is a section where the rolls themselves contribute to the manufacturing or processing of the paper rather than merely transporting the web through the machine.
In order to function properly, calendar rolls generally have extremely hard surfaces. For example, typically calendar rolls are covered with a thermoset resin having a Shore D hardness between 84-95 and an elastic modules between 1,000-10,000 MPa. Most commonly, epoxy resins are used to cover calendar rolls because epoxy resins form extremely hard surfaces. Epoxy resins with characteristics suitable for forming the surfaces of calendar rolls are cured at relatively high temperatures (in the range of 100-150° C.).
It is well known that an increase in curing temperature for heat resistant thermoset resin systems typically indicates an increased thermal resistance of the resulting cover. Present day demands of paper mills require rolls, particularly calendar rolls, with higher thermal resistances. Thus, it is desirable to produce covers for such rolls which can be cured at 150-200° C.
However, curing at such high temperatures can cause so much residual stress within the cover that it tends to crack, rendering it unusable. A discussion of the physical chemistry of such a roll cover can be found in a paper entitled, “The Role Of Composite Roll Covers In Soft And Super Calendaring,” J. A. Paasonen, presented at the 46ème Congres Annuel Atip, Grenoble Atria World Trade Center Europole, Oct. 20-22, 1993, the teachings of which are incorporated herein by reference. Indeed, one important challenge to the manufacture of roll covers is to develop roll covers that can withstand the high residual stresses induced during manufacturing. Problems from residual stresses are most significant in harder compounds and often result in cracking, delamination, and edge lifting. In addition, residual stresses often cause premature local failure or shorter than desired life cycles. This is especially true for high performance, hard polymeric roll coverings, for which the basic approach has been to tolerate a production level of residual stresses that is still acceptable for product performance. Therefore, there is a need to develop methods of roll cover construction that reduce residual stresses in the product.
Consideration of residual stresses is especially critical during the manufacture of the roll cover. In particular, heating and curing processes must be given careful consideration, as these conditions are often the most significant factors in the development of such stresses. Residual stresses most often develop in polymer based covers as a result of the mismatch in thermal shrinkage properties between and/or among the cover materials and the core materials and from chemical shrinkage. Polymers typically have a coefficient of thermal expansion that is an order of magnitude greater than that of steel, the typical material of the core.
One suggestion to alleviate stresses caused by processing covered rolls is to produce a cover as a finished product and bond the fully cured cover to a core structure. This can be accomplished by wrapping a cover (topstock) over a mold, then demolding and bonding the cover to a core structure at a lower temperature level than the cover cure temperature, or by casting the cover separately and bonding it to a metal core at a lower temperature than the casting temperature.. Under these processes, the thermal stresses that would arise between the cover and the core from cooling the cover should be reduced.
Unfortunately, although adhesives for bonding the cover to the core are available, some adhesives exhibit poor bonding strengths when the roll is subjected to industrial applications. In general, adhesives that are suitable for high temperature performance also cure at high temperatures. Thus, subjecting the core to high temperature bonding conditions can result in stresses that were avoided by separately producing the cover.
In addition, manufacturing costs would be increased by producing the cover first as a separate cylindrical structure, then fitting it over a roll core at a lower processing temperature than was required for processing the cover. These casting methods require that an open cavity be created between the cover and the roll core, which necessitates multiple process steps and the use of inner mandrels. Even if the cover is separately manufactured via a centrifugal casting method, additional costs and steps are required for an outer mold.
Another possible solution is to develop a cover material having a thermal shrinkage as close to the metallic core as possible. While composite structures may be developed with the expansion coefficients tailored to match the metal core, such methods are expensive and may not produce the desired thermomechanical response for certain industrial applications. Thus, the need exists to develop methods to reduce the residual stress levels in current production materials.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of this invention to reduce the problems caused by chemical and thermal shrinkage that develop during the manufacture of a covered roll.
The problems caused by chemical and thermal shrinkage of hard roll covers are reduced in accordance with the present invention by separately casting the cover with the inclusion of at least one intermediate compressive layer over a disposable inner mold. The inner mold is formed of a material that is rigid enough to support the cover during processing, and easily removed and discarded after processing. The intermediate layer which is applied over the mold is compressible enough to deform and absorb the stresses which develop as the cover is shrinking during processing.
The problems caused by chemical and thermal shrinkage are further reduced in accordance with the present invention through a method comprising the steps of applying the intermediate compressive layer over a disposable inner mold, applying a polymeric cover material over the intermediate compressive layer, and curing the cover material into a cylindrical cover at an elevated temperature. Next, the cover is permitted to shrink during curing or hardening, and the disposable inner mold is disposed of. The roll is completed by applying the cylindrical cover over a roll core base to form an intermediate roll having a circumferential gap layer, sealing both ends of the intermediate roll, and filling the gap layer with a filler material.
In another embodiment of the present invention, a metal roll core having an applied base layer is substituted in place of the disposable mold. An intermediate layer comprising a wax or other dissolvable material is applied over the roll base. The cover is then cast or wrapped over the intermediate compressive layer and roll base. Then the intermediate layer is dissolved away and the resulting gap is filled with an adhesive layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a prior art roll having a multi-layered covering which diagrammatically shows the thermal and residual stresses within the cover directed towards the metal roll core.
FIG. 2 is a cross-sectional view of a covered roll of the present invention having an intermediate compressive layer applied over a disposable inner mold which diagrammatically shows how the thermal and residual stresses within the cover are absorbed by the intermediate compressive layer.
FIG. 3 is a cross-sectional view of a covered roll of the present invention after removing (demolding) the disposable inner mold and fitting the resulting composite cover over a metal roll core base to create a circumferential gap layer.
FIG. 4 is a cross-sectional view of a covered roll of the present invention having a dissolvable intermediate compressive layer applied over a polymeric roll core base which diagrammatically shows how the thermal and residual stresses within the cover are absorbed by the intermediate compressive layer.
FIG. 5 is a longitudinal-sectional view of a covered roll of the present invention having a first circumferential gap layer and compressive layer surrounding a disposable inner mold.
FIG. 6 is a cross-sectional view of FIG. 5 taken along lines 6 — 6 .
FIG. 7 is an exploded perspective view of a metal roll core base and an extender assembly used to assist in the manufacturing of rolls in accordance with the present invention.
FIG. 8 is a perspective view of an extender assembly as it is fitted flush with the surface of a metal roll core base in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described more particularly hereinafter with reference to the accompanying drawings, in which present embodiments of the invention are shown. The invention may, however, be embodied in many different forms and is not limited to the embodiment set further herein; rather, these embodiments are provided so that the disclosure will fully convey the scope of the invention to those skilled in this art.
At the outset, the roll having a composite roll cover and the process for making the covered roll are described in their broadest overall aspects with a more detailed description following. In general, high performance covered rolls are manufactured with reduced residual stresses through a method which casts or wraps a composite roll cover as a separate step to form a tube-like cylindrical structure.
In a primary processing phase, an intermediate compressive layer is applied over a disposable inner mold or mandrel. An outer mold is fitted over the intermediate compressive layer and inner mold assembly so as to create a first circumferential gap layer between the intermediate layer and the outer mold. This first circumferential gap layer is filled with a polymer material.
The purpose of the intermediate compressive layer is to absorb the thermal stresses and chemical volume changes created during the processing of the gap layer. After an initial cure of the first circumferential gap layer, the inner mold is discarded. Further, post-curing of the resulting cylindrical tube-like structure forms a finished composite cover.
In a secondary processing phase, the resulting composite cover is applied circumferentially to a prepared metal roll core. This step creates a second circumferential gap layer that is intermediate to the cover and the core. In a final processing step, the second circumferential gap layer is filled, preferably with a thermoset resin which is cured at a lower temperature than that of the cover.
With reference now to the drawings, FIG. 1 shows a covered roll 1 of the prior art. The arrows identified by the letter P in FIG. 1 indicate how residual stresses and thermal shocks within the cover 2 are directed towards the metal roll core base 3 . Although not indicated by arrows in FIG. 1, the residual stresses and thermal shrinkages occur in other directions within the roll 1 as well, such as axially and radially. Eventually, these internal stresses can lead to premature cracking of the roll 1 .
FIG. 2 shows a composite roll cover 10 comprising a polymer cover layer 12 and an intermediate compressive layer 14 surrounding a disposable inner mold 16 (an outer mold is not shown). The arrows identified by the letter P in FIG. 2 indicate how the intermediate compressive layer 14 allows the cover layer 12 to shrink in the direction as shown during the processing of this layer 12 . Although not indicated by arrows in FIG. 2, the intermediate compressive layer 14 allows for shrinkage and shock absorption in axial, radial and other directions within the roll 10 .
FIG. 3 shows how, in the secondary processing phase of this embodiment, after discarding the inner mold 16 and post-curing the resulting composite cover 10 , the composite cover 10 cover is fitted circumferentially over a prepared metal roll core 18 having an applied base layer 22 so that a second circumferential gap layer 20 is created between the core 18 and the cover 10 . In the final stages of production the second circumferential gap layer 20 is filled, preferably with a thermoset resin forming system which cures at a lower temperature than that of the cover layer 12 .
FIG. 4 shows another embodiment of the present invention wherein the disposable inner mold 16 is not employed; rather, a metal roll core 18 having an applied base layer 22 is substituted for an inner mold (“non-disposable inner mold”). An intermediate layer comprised of a wax or other dissolvable material 24 , is applied over this roll base 18 . The cover 12 is then either cast or wrapped over the intermediate compressive layer 24 , roll base 18 , and base layer 22 . After absorbing the residual stresses and post-curing, the intermediate layer 24 is dissolved away and the cover 12 removed, and the surface of the roll base 18 is prepared (cleaned up and an adhesive applied). This is followed by replacement of the cover 12 over the roll base 18 and filling of the resulting gap layer with an adhesive layer to form a solid roll.
As will be apparent to one skilled in the art, more than one compressive layer may be used if the roll design so dictates. It should also be readily apparent to one skilled in the art that different kinds of compressive materials may be used as an intermediate layer. The compressive layer is preferably formed from a silicone foam tape, although other materials are suitable. A preferred silicone foam tape is sold under the trade name of SI-Schaum vierkant available from BIW Isolierstoffe GmbH, Postfach 11 15, D-58240, Ennepetal, Germany. Typically, this material is purchased in 150 by 4 mm strips and has a shore G hardness in the range of 8-15 (tolerance 10%).
As is explained in detail below, the filling material used to fill the gap between the cover 12 and the core 18 is typically a resin system similar to the resin system used to form the cover, but which cures at a lower temperature than the cover.
In manufacturing a roll in accordance with the embodiment of FIGS. 2 and 3 and with reference to FIGS. 5 and 6, the disposable inner mold 16 is sized to the desired length of the roll cover 12 . Preferably, the disposable inner mold 16 is formed of cardboard, but other suitable disposable materials can be used. Wooden rings 22 a are fitted (“corked”) inside both ends of the inner mold 16 to provide structural rigidity (only the left wooden ring 22 a is shown in FIG. 5 ). As known in the art, other structures may be used for supporting the inner mold 16 , such as wooden plugs or plugs made out of a suitable temperature resistant material.
A groove, illustrated with phantom lines at 24 a , is machined longitudinally along the length of the mold 16 to a distance of approximately 10 cm from each end (groove 24 a does not penetrate through the mold). Through holes 26 are drilled into the mold interior at each end of the groove. A cable 28 is nestled into the groove and through the interior of the mold 16 to form a continuous loop.
The inner mold 16 is wrapped with a compressive material to form the layer 14 . The wrapping is done preferably in two passes to create an overlap. The preferable material for the compressive layer is a silicone foam material. The silicone foam tape is preferable because of its high release properties, as it tends not to stick to the inner mold 16 after processing. During processing, the silicone foam tape acts an intermediate compressive layer 14 between the inner mold 16 and the cover layer 12 .
An outer metal mold 30 is fitted over the inner mold 16 and silicone compressive layer 14 to form a first circumferential gap layer 20 a . The ends of the first circumferential gap layer 20 a are sealed with end-seals 32 and caulk. Preferably, the end-seals 32 are formed out of wood; however, any suitable sealing material capable of withstanding the processing temperatures can be used. The end-seals 32 are preferably ring shaped so as to fit in space between the intermediate layer 14 and the outer mold 30 . The metal outer mold 30 has a thin ring-like extension on one end. The ring-like extension has eye-hooks attached for vertically supporting the mold assembly. As known in the art, attachments for vertically supporting the roll can be accomplished in a variety of ways, such as drilling holes into tabs extensions.
At least one end of the metal outer mold is drilled, tapped and equipped with at least one inlet port and valve (not shown). A suitable resin material is pumped into the first circumferential gap layer 20 a through the valve and inlet port.
During casting, the mold assembly is maintained in a vertical or near vertical position while the resin material gels. The initial temperature of the resin material is in the range of 40-45° C. During the curing process, the residual stresses are absorbed by the compressive layer 14 and reduce the tendency of the roll to crack. Then, the roll is demolded, which includes the step of discarding the inner mold by pulling the cable 28 to collapse the inner mold 16 . The resulting composite cover 10 is further cured in an oven without the need for any supporting structures.
Following the post-cure of the composite cover, the inner cylindrical cavity of the composite cover is prepared by a suitable blasting media, such as, grit blasting. The composite cover 10 now comprises a tube-like cylindrical structure which is ready to be applied over a suitable roll core base.
As known in the art, a polymer or reinforced polymer layer is applied to a metal roll core as a base layer. The prepared roll with the base layer is fitted with an extension can assembly and end-seals to accommodate the composite cover. To facilitate the filling of the second circumferential gap layer, FIG. 7 shows how an extender cap assembly 20 b is placed on each end of the prepared roll core base. The extender cap assembly comprises a substantially circular plate 21 b and a cylindrical section 22 b . Preferably, the plate 21 b is made out of wood and the cylindrical section is made of the same material as the roll core base 23 b . However, other suitable extender cap assemblies can be made entirely out of wood or other equivalent materials, and may include other configurations, such as annular rings with a bolt-on top plate or other cap shapes, including shoulder plates integral with the ring, and equivalents thereof.
FIG. 8 is a perspective and cut-away view of the extender can assembly 20 b in place on one end of the metal roll core base 23 b prior to the application of any layers, and shows how the outer circumference of the cylindrical section 22 b matches the circumference of the metal roll core base 23 b.
The composite cover is sleeved over the roll core base and positioned with an end seal on the bottom end and a collar at the top end. The assembled roll is then placed in the vertical casting station. A journal extension is used to fix the roll in the station. A filler material is pumped into the second circumferential gap layer. As before, the filler material is allowed to gel at room temperature. Then the entire assembly is post-cured in an oven at 60-80° C. It is an important aspect of the present invention that the second circumferential gap layer 20 is filled with a polymer that cures at a lower temperature than the cover layer 12 , thus providing strength to the finished roll and reducing the likelihood of roll cover 10 cracking.
Rolls in accordance with the present invention can utilize two systems which yield two different polymers upon curing. The polymer forming the cover, is preferably a thermoset resin and can be any polymer normally used in the art. Most commonly an epoxy resin is used for the cover, such as an epoxy resin based on a Diglycidylether of Disphenol A, commercially known as DER 331 from Dow Chemical Co. This can be cured in a temperature range from 130-150° with an aromatic amine, such as Diethylenetoulenediamine (DETDA 80) from Lonza Aq, Switzerland. Alternatively, the cover can be made from a Cyanate Ester modified Novolac Resin system supplied from Allied Signal Inc., U.S.A.
Preferably, the second circumferential gap layer is filled with a thermoset forming system that cures at a lower temperature than the polymer system used for the topcoat. The second circumferential gap layer can be filled with a resin; the filler material for the second circumferential gap layer is preferably a thermoset resin. As with the cover, the preferred epoxy resin is based on a diglycidylether of Disphenol A, commercially known as DER 331 from Dow Chemical Co., but cured in the temperature range of 70-90° C. with a suitable aliphatic amine, such as Jeffamine T-403 supplied by Texaco Chemical Co., U.S.A.
In an exemplary embodiment, the circumferential gap layer is filled with a thermoset or thermoplastic polymer under such conditions in which the development of higher than desired residual stresses in the cover and also in the circumferential gap layer itself can be prevented. For base systems which require high temperature resistance, tailored thermoset resin systems may be used in a way that the glass transition temperature in the base can be adjusted to the required level.
The composite roll cover and the method of making a covered roll using circumferential gap layers are further illustrated with the following specific example of a Duren casting procedure.
1. A cardboard mold is used for the inner mold. It is equipped with wooden rings to provide additional structural support at each end. Two slots are machined down the length of the mold except for approximately 10 cm on each end. Through holes are drilled at the ends of the slots. A metal cable is nested in the slot and drawn through the through holes into the inner mold. This cable is used to collapse the mold after the cast.
2. The prepared mold is wrapped with two passes of a silicone foam material. This foam provides a compressible surface during casting and is not adhesive to the matrix.
3. A metal outer mold is sleeved over the prepared paper mold and fitted with caulk against the prepared end-seal.
4. The metal mold is tapped and equipped with an inlet port and valve.
5. The fillers are sifted into a mixing vat through a vibrating 60 mesh screen into the pre-weighed resins. The material is then mixed and screened again. The vibration equipment reportedly greatly improved the screening time. The resin is heated and degassd. The pre-weighed curative component is added and mixed for ten minutes. The material is then pressurized to fill the prepared mold. Typically, three tubes may be cast with one batch of material. The mold assembly is held vertical during casting and gels with its exotherm. The initial temperature is 40-45° C. The batch size is up to 2000 kgs.
6. The tube is demolded and then post-cured in the oven. No special support is needed during the post-cure step.
7. The ID of the tube is then prepared by grit-blasting. The tube is tapped to receive the intermediate layer filling ports.
8. A standard PU base layer is applied to the core. The core is equipped with extension cans and end-seals to accommodate the tube.
9. An extension arm is attached to one end of the prepared core. This arm is used to support the roll while the tube is being sleeved on.
10. The cast tube is sleeved on and positioned with the end seal at the bottom end and with a collar at the top end.
11. The assembled roll is placed in the vertical PU casting station. A journal extension is used to fix the roll in the station. The intermediate layer is simply mixed and pressurized through lines attached to the two valve-equipped portals. The material gels at room temperature. The entire assembly is post-cured at 60-80° C.
In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereunto without departing from the spirit and scope of the invention as set forth in the appended claims. The drawing and specification are, accordingly, to be regarded in an illustrative rather than in a restrictive sense.
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The problems caused by chemical and thermal shrinkage of hard roll covers, are reduced by the inclusion of one or more intermediate compressive layers between a roll core base and cover. The compressive layer has the properties of being rigid enough to allow the cover to be applied to the roll, and compressible enough to deform and absorb the stresses which occur as the cover is shrinking during processing. In one embodiment, the compressive layer is separately cast with the cover over a disposable inner mold so as to form a composite roll cover. The composite roll cover is fitted over a roll core base and the resulting circumferential cavity is then filled with a thermoset resin.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority to Application No. 101 41 440.4, filed in the Federal Republic of Germany on Aug. 23, 2001, which is expressly incorporated herein in its entirety by reference thereto.
FIELD OF THE INVENTION
The present invention relates to a tripod joint.
BACKGROUND INFORMATION
Tripod joints are used, for example, as side shafts of motor vehicles. In this case, the tripod joints are used for transmitting driving torques between two driving elements of a drive train. The tripod joints permit a relative displacement and a relative pivoting of the driving elements to be compensated for. For the use in the case of side shafts of a motor vehicle, relative movements of this type are caused by spring deflections of the vehicle wheels.
Conventional tripod joints have a joint outer part and a joint inner part held therein. Rolling bodies are inserted in the force flux between the joint outer part and joint inner part. With a rolling movement of the rolling bodies, the joint outer part is axially displaceable and/or pivotable with respect to the joint inner part about an axis transverse to the plane defined by the longitudinal axes of the joint outer part and of the joint inner part with the transmission of a driving torque being ensured. Use is made of cylindrical rolling bodies which, for the purpose of transmitting large driving torques, may be advantageous in comparison with spherical rolling bodies due to the linear contact formed by the adjacent components.
In the case of components configured in such a manner, it may be disadvantageous that mechanical impairments of the transmission function may occur in the case of three-dimensional movements of a tripod joint, which, in the worst case, may result in the drive train vibrating and/or producing noise and in resultant impairments of comfort.
It is an object of the present invention to provide a tripod joint which is improved with regard to the mechanical transmission properties.
SUMMARY
The above and other beneficial objects of the present invention are achieved by providing a tripod joint as described herein.
In accordance with one example embodiment of the present invention, longitudinal axes of adjacent rolling bodies are orientated at an acute angle with respect to one another.
The investigations on which the present invention is based have shown that in the case of an axial, translatory displacement of the joint inner part with respect to the joint outer part, a pure rolling movement of the rolling bodies with optimized frictional conditions arises for cylindrical rolling bodies. When the joint parts pivot, which is unavoidable (additional) in practice with rotating driving elements, a kinematically necessary, two-dimensional movement of the pin with respect to the joint outer part is produced. This gives rise to a movement component in the longitudinal direction of the rolling bodies, which component may be compensated only by a sliding movement of the rolling bodies with respect to the adjacent components. These sliding movements cause (sliding) frictional forces which constitute the cause of the undesirable mechanical impairments. The frictional forces form non-linear forces and result, in particular, in a third-order excitation of vibration. The orientation according to the present invention of the longitudinal axes of adjacent rolling bodies with respect to one another enables the rolling bodies to have different, preferred rolling directions, as a result of which the sliding fractions do not compulsorily occur at all rolling bodies, but rather occur in a minimized manner only for individual rolling bodies or do not occur at all for particular, three-dimensional forms of movement. In addition to avoiding the abovementioned disadvantages, the reduced sliding fraction may have a positive effect on the wear or the service life of the joint, the rolling bodies or the running paths of the rolling bodies. In the case of a skillful, kinematic configuration of the transmission elements, self-centering of cages, which hold the rolling bodies, with respect to the pins of the tripod joint may be obtained, and so centering devices, such as springs, etc. may be omitted or may be constructed more simply or cost-effectively. The components are not required to have any play in the circumferential direction. The components may even be built over with a lightweight covering. The freedom from play may result in improved comfort in the vehicle, e.g., in the case of load-change processes.
According to an example embodiment of the present invention, the longitudinal axes of a plurality of rolling bodies assigned to a running path have a common intersecting point. For pivoting the joint inner part about the common intersecting point, an optimized rolling and sliding behavior of the tripod joint arises, since all of the rolling bodies move on a circular path for which the pure rolling movement of the rolling bodies is orientated tangentially to the circular path, with the result that no sliding movement occurs. For a pure translatory movement, i.e., a pure axial displacement of the joint inner part with respect to the joint outer part, the intersecting point ideally lies in infinity®=∞), while for a pure pivoting movement the intersecting point may be in the region of the central point of the tripod star at the distance R=R G . For complex three-dimensional forms of movement, an ideal distance 0<R<∞ is to be defined. The ideal distance, from which the acute angle, which is to be selected, between adjacent longitudinal axes results, may be determined according to the rolling bodies selected, the component dimensions, the forces to be transmitted and the relative displacements and pivotings occurring during operation. For example, a typical movement profile may be taken as a basis here, based on which the sliding movements occurring during operation are determined and, by varying the acute angle, are minimized. In this manner, relatively large sliding frictional forces may be displaced into operating ranges which rarely occur while relatively low sliding frictional forces are to be accumulated in operating ranges which occur frequently.
According to an example embodiment of the present invention, a tripod joint for transmitting a driving torque between two driving elements of a drive train includes: a joint inner part having a tripod star with a pin; a joint outer part holding the joint inner part; and rolling bodies inserted in a force flux between the joint outer part and the joint inner part, the rolling bodies having a cylindrical lateral surface. The joint outer part and the joint inner part may be at least one of axially displaceable and pivotable with respect to each other in accordance with rolling movement of the rolling bodies. The longitudinal axes of adjacent rolling bodies may be orientated at an acute angle with respect to one other.
According to an example embodiment of the present invention, the longitudinal axes of a plurality of rolling bodies may have a common intersecting point. The intersecting point may be located in a region of a central point of the tripod star.
According to an example embodiment of the present invention, the tripod joint may include a cage and a plurality of rolling bodies accommodated in the cage. The longitudinal centers of the rolling bodies of the cage may be located on a straight line or arranged on a curved, planar curve. Further, the longitudinal center of the rolling bodies of the cage may be located on one of a circular arc and a cutout of an ellipse.
Exemplary embodiments of the tripod joint according to the present invention are explained in greater detail below with reference to the Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is longitudinal cross-sectional view of a tripod joint according to the present invention.
FIG. 2 is a cross-sectional view of a tripod joint according to the present invention.
FIG. 3 is a cross-sectional view of a joint pin according to the present invention with pressure element, moving cage, rolling bodies and centering elements taken along the line A—A illustrated in FIG. 2 .
FIG. 4 illustrates a moving cage according to the present invention with rolling bodies.
FIG. 5 illustrates a moving cage according to the present invention with rolling bodies and a pressure element illustrated by dashed lines.
FIG. 6 illustrates a moving cage according to the present invention with rolling bodies and a pressure element illustrated by dashed lines.
FIG. 7 is a cross-sectional view of a joint pin according to the present invention with pressure element, moving cage, rolling bodies and centering elements, taken along the line A—A illustrated in FIG. 2 .
FIG. 8 is a cross-sectional view of a tripod joint according to the present invention.
DETAILED DESCRIPTION
A tripod joint 10 has a joint inner part 11 and a joint outer part 12 holding the latter. The joint inner part 11 and the joint outer part 12 are in each case connected, at least in a rotationally fixed manner, to a driving element of a drive train of a motor vehicle, for example, to a drive shaft and a vehicle wheel. The tripod joint 10 is used for transmitting a driving torque between the joint inner part 11 and the joint outer part 12 while ensuring a relative displacement along the longitudinal axis 13 — 13 of the joint inner part 11 and along the longitudinal axis 14 — 14 of the joint outer part 12 , a relative pivoting of the joint inner part 11 with respect to the joint outer part 12 , which pivoting is associated with a change in the angle 15 between the longitudinal axes 13 — 13 and 14 — 14 , and a three-dimensional movement which arises from a combination of the above-mentioned forms of movement.
The joint inner part 11 has, at the end arranged on the inside, three pins 16 which are formed as a single piece of a number of pieces together with the latter, are orientated radially and are distributed in each case at 120° in the circumferential direction and form a tripod star. The pins 16 have in each case a partially spherical ball body 17 . In order to transmit forces in both circumferential directions, the ball body 17 bears, in each case in the region of the spherical lateral surface, against a correspondingly configured recess 18 of a pressure element 19 . On the opposite side of the pressure element 19 , which side faces a flat mating surface 20 of the joint outer part 12 , the pressure element is of flat configuration with a running surface 21 . The mating surface 20 may be formed by a relatively large, flat surface or else may be provided in a path or groove 22 of the joint outer part 12 . The running surface 21 and the mating surface 20 are orientated parallel to each other. Cylindrical rolling bodies 23 , e.g., rollers or needles, are held between the latter forming a linear contact. That is, cylindrical rolling bodies 23 are inserted in a force flux between the joint outer part 12 and the joint inner part 11 . A plurality of rolling bodies are guided in a cage 24 . In order to transmit circumferential forces in the opposite direction, each pin 16 is configured with the associated pressure elements 19 , the rolling bodies 23 and the surfaces 20 , 21 symmetrically to a pin central plane accommodating the longitudinal axis 13 — 13 .
The running surface 21 of a pressure element 19 may have a rectangular form, with the result that as many rolling bodies 23 as possible form a load-bearing contact with the surface pressure being reduced. However, circular or oval pressure elements 19 are also possible.
The joint outer part 12 has a recess 25 orientated in the direction of the longitudinal axis 14 — 14 with an essentially circular, central hole 26 and three receiving spaces 27 which are orientated radially and are distributed in each case at 120° in the circumferential direction and are used in each case for receiving and supporting a pin 16 , two pressure elements 19 and rolling bodies 23 . In the section illustrated in FIG. 2 , the receiving spaces 27 have an essentially U-shaped contour open in the direction of the hole 26 , the side limbs of the U-shaped contour being formed by the mating surfaces 20 . In the exemplary embodiment illustrated in FIG. 1 , the side limbs are of rectilinear configuration without a transitional region to the mating surfaces 20 . An additional or sole guidance of the rolling bodies 23 and cages 24 by the joint outer part may be achieved if grooves 28 , as shown in FIG. 8 , are introduced into the side limbs, the mating surfaces 20 forming the base of the groove and the cages 24 being guided in the radial direction by the side surfaces of the grooves 28 .
Two pressure elements 19 , as shown in FIG. 2 , and two cages 24 , as shown in FIG. 2 , may be used per pin 16 . As an alternative, the two pressure elements 19 may be connected to each other via connecting regions or webs 34 to form a pressure body 35 , as shown in FIG. 3 , and/or the two cages 24 may be configured as a single-piece cage 30 , as shown in FIG. 7 .
As illustrated in FIG. 2 , the rolling bodies 23 are guided in a cage 24 . The rolling bodies 23 are guided in the cages 24 with the relative position of the longitudinal axes 31 of the rolling bodies 23 with respect to each other being ensured. The cages 24 are guided in the radial direction with respect to the pressure element 19 via shoulders 32 engaging around and enclosing the pressure element 19 . The cages 24 may be “clipped” via the shoulders 32 onto the pressure element 19 , as illustrated. The cages 24 may furthermore be centered in the running direction of the rolling bodies 23 via spring elements 33 . Two cages 24 of a pin 16 may be guided and centered via a common spring element 33 .
According to an example embodiment of the present invention, the longitudinal axes 31 of a plurality of rolling bodies 23 assigned to a running path have a common intersecting point 39 . For pivoting the joint inner part 11 about the common intersecting point 39 , an optimized rolling and sliding behavior of the tripod joint arises, since all of the rolling bodies 23 move on a circular path for which the pure rolling movement of the rolling bodies 23 is orientated tangentially to the circular path, with the result that no sliding movement occurs. For a pure translatory movement, i.e., a pure axial displacement of the joint inner part 11 with respect to the joint outer part 12 , the intersecting point 39 ideally lies in infinity (R=∞), while for a pure pivoting movement the intersecting point 39 may be in the region of the central point of the tripod star at the distance R=RG. For complex three-dimensional forms of movement, an ideal distance 0<R<∞ is to be defined. The ideal distance, from which the acute angle, which is to be selected, between adjacent longitudinal axes 31 results, may be determined according to the rolling bodies 23 selected, the component dimensions, the forces to be transmitted and the relative displacements and pivotings occurring during operation. For example, a typical movement profile may be taken as a basis here, based on which the sliding movements occurring during operation are determined and, by varying the acute angle, are minimized. In this manner, relatively large sliding frictional forces may be displaced into operating ranges which rarely occur while relatively low sliding frictional forces are to be accumulated in operating ranges which occur frequently.
According to the exemplary embodiment illustrated in FIG. 2 and FIG. 3 , two spring elements 33 are connected to the pressure element 19 , the pressure body 35 or the ball body 17 via a respective fastening arrangement 36 . The spring elements 33 in each case have two elastic fingers 37 which bear against the opposite cages 24 or are connected thereto, for the purpose of supporting them.
As illustrated in FIG. 4 , the longitudinal axes 31 of the cylindrical rolling bodies 23 are inclined with respect to each other at an acute angle 38 in an essentially rectangular cage 24 , 30 and intersect at a common intersecting point 39 . The longitudinal centers 40 of the rolling bodies 23 are on a straight line 41 which is spaced apart from the central point 42 of the tripod star at a distance R. The intersecting point 39 may be located in a region of the central point 42 of the tripod star.
As illustrated in FIG. 5 , the longitudinal centers 40 ′ may be on a circular path having the radius R, the cage 24 ′, 30 ′ in this case being configured in the form of a segment of a circle and, e.g., the central point of the segments of a circle bounding the cage 24 ′, 30 ′ corresponds to the intersecting point 39 . The contour 43 of the pressure element 19 ′, which has an outer contour in the form of a segment of a circle and, on the side arranged opposite the rolling bodies, has the partially spherical recess 18 for receiving the ball body 17 ,is illustrated by dashed lines in FIG. 5 .
As a departure from this, as illustrated in FIG. 6 —with the cage 24 ″, 30 ″ and the rolling bodies 23 configured according to FIG. 5 —the pressure element 19 ″, 20 may have a circular outer contour 44 arranged concentrically to the outer contour of the recess 18 .
According to the exemplary embodiment illustrated in FIG. 7 , the cages 24 ′″, which are arranged on the opposite sides of the ball body 17 , are connected to each other via connecting regions 45 to form a single-piece cage 30 ′″. In this case, it may be ensured that the position of the cages 24 ′″ in the running direction coincides. The cage 30 ′″ may be centered with respect to pressure elements 19 ′″, pressure body 29 or the ball body 17 via one or two spring elements 33 of simplified configuration. In the exemplary embodiment illustrated in FIG. 7 , two compression springs 46 are arranged in the running direction on both sides of the pressure elements 19 ′″. The compression springs 46 are configured as leaf springs having a central bulge 47 , the end regions of which are supported on the pressure elements 19 ′″ and which bear in the region of the bulge 47 against a connecting region 45 .
In the exemplary embodiment illustrated in FIG. 8 , the mating surfaces are formed in grooves 28 in receiving space 27 ′ of a joint outer part 12 ′. In these grooves 28 , the rolling bodies 23 are guided together with the cages 24 in the radial direction. In this case, the radial guidance of the cages 24 with respect to the pressure elements 19 via the shoulders 32 as illustrated in FIG. 2 may be omitted.
The longitudinal centers 40 , 40 ′ of adjacent rolling bodies 23 may be on a curve, a straight line or a circular arc.
The cages 24 , 30 may execute purely translatory movements with respect to the mating surfaces 20 . According to the exemplary embodiment illustrated in FIG. 8 , the cages 24 are guided in rectilinear grooves 28 of the joint outer part 12 ′. In this case, the shoulders 32 of the cages 24 are omitted, with the result that there is no radial guidance of the cages 24 with respect to the pressure elements 19 , 19 ′ and the pressure elements 19 , 19 ′ may execute relative movements and pivotings in the radial direction with respect to the cages 24 .
In the exemplary embodiment illustrated in FIG. 2 , the cages 24 are pivoted with the radial distance from the pin 16 remaining the same. In this case, the cage 24 does not execute a rectilinear movement with respect to the joint outer part 12 , but rather a curved pivoting movement. For this purpose, coordinated, curved grooves 28 or else—as illustrated in FIG. 1 —mating surfaces 20 which are not arranged in grooves are to be provided in the joint outer part 12 .
The kinematic limits of the pivoting movement are formed by the geometry of the cage 24 and of the joint outer part 12 . During operation of the tripod joint 10 , in borderline situations controlling contact of the pressure elements 19 , 19 ′ by the end stops of the cage 24 or else radial contact of cage 24 and joint outer part 12 may occur. These contacts do not have a negative effect on the operating comfort because the forces occur stochastically only in borderline situations and therefore do not lead to periodic excitation.
The abovementioned arrangements of guiding the cages 24 with respect to the joint outer part 12 and the pressure elements 19 or 19 ′ may also be entirely omitted or may be of elastic configuration. In this case, an undefined form of movement of the cage 24 with respect to the adjacent components arises, which may result in a minimization of wear. As an alternative, the movement may occur in a self-centering manner, in particular by the arrangement according to the present invention of the longitudinal axes 31 of the rolling bodies 23 at an acute angle 38 , the rolling path of the cage 24 being automatically established on the mating surface 20 on account of the effective outer and inner rolling-body guiding forces.
Without departing from the principle on which the present invention is based, it is possible to form groups of adjacent or non-adjacent rolling bodies 23 , rolling bodies 23 of one group having longitudinal axes 31 orientated parallel to one another, and these longitudinal axes 31 forming a second, acute angle 38 with respect to the longitudinal axes 31 of the rolling bodies 23 of other groups. As an alternative or in addition, the longitudinal axes 31 of adjacent rolling bodies 23 of one group may be inclined with respect to one another at a first angle 38 while the rolling bodies 23 of a second group are inclined with respect to one another at a second angle 38 . Different angles 38 for adjacent longitudinal axes 31 , for example angles 38 which rise or fall in the running direction from the center of the cage 24 , are possible.
The arrangements according to the present invention may be used in conjunction with any desired tripod-joint configurations, for example tripod joints corresponding to those described in U.S. Pat. Nos. 4,619,828 or 4,708,693.
The essentially cylindrical rolling bodies 23 may have a contour which is slightly curved in the longitudinal direction of the lateral surface, as a result of which the sliding fraction in the case of a movement component in the direction of the longitudinal axis 31 of the rolling bodies 23 or in the case of rotational movements of the rolling bodies transversely with respect to the longitudinal axis 31 may be further reduced.
Furthermore, the use of tapered rollers (with a small tapered opening angle) is possible as rolling bodies 23 , for which the pivoting may be further simplified. In this case, in order to ensure a translatory displacement, a further degree of freedom of the joint may be provided.
The example embodiments described involve configurations only given by way of example. A combination of the described features for different embodiments is possible. Further features, in particular features which have not been described, of the device parts belonging to the invention are to be taken from the device-part geometries illustrated in the drawings.
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Tripod joints have a joint outer part and a joint inner part which are in driving connection to each other with cylindrical rolling bodies being connected in between and axial displacement and pivotability being ensured. The longitudinal axes of adjacent rolling bodies are arranged at an acute angle to one another. This may result in an improved mechanical behavior of the tripod joint particularly during pivoting. The tripod joints may be suitable for the displaceable and pivotable driving connection of two shaft ends, in particular in conjunction with drive trains or side shafts of motor vehicles.
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BACKGROUND OF THE INVENTION
This invention relates to swimming pool filter systems and more particularly to such a system including an over-pressure alarm.
Conventional pool filter systems have a pump and a filter connected in a hydraulic loop with the pool.
The filter for large commercial pools is usually of the sand type wherein the water is pumped down through a bed of sand that collects the dirt from the water.
Smaller and less heavily used family pools, on the other hand, employ a low cost diatomaceous earth type filter wherein a finely woven membrane or the like that is water permeable separates the inlet chamber of the filter from the outlet water chamber, and the inlet side of the membrane is coated with diatomaceous earth which cannot pass through the membrance but collects dirt.
In either system employing a sand filter or a diatomaceous earth filter represented in FIG. 1 a pressure gauge 11 is normally installed at the inlet port of the filter 13 providing a pressure reading that increases as the filter collects more dirt and restricts the water flow through the filter 13. The supplier of the filter system normally recommends back washing the filter to remove the dirt when the pressure gauge indicates a high pressure of a predetermined value. Backwashing requires additional pipes and valves not shown here, for reversing the flow of water through the filter while flushing the dirt and diatomaceous earth to the outside.
In one diatomaceous earth filter, Model No. EC-65 System III made by Hayward Pool Products, Inc. of Elizabeth, N.J., removal of the dirt is not accomplished by back washing but rather by moving and shocking the membrane to redistribute the diatomaceous earth in the inlet chamber of the filter and, with the inlet and outlet ports shut closed, draining the inlet chamber. Such a cleaning and dirt removal operation is said to take about 5 minutes and should be done when the inlet port pressure gauge rises more than 10 psi (pounds per square inch) in less than a 24 hour period or when cloudy water returns to the pool for longer than 30 seconds after a "regeneration" step.
The frequency at which the filter must be cleaned by the above-noted cleaning/draining step in this system is substantially less than that for a more conventional diatomaceous earth filter system having only the capability of being backwashed because the Hayward filter can be regenerated, i.e. agitated, by shocking the movable filter membrane relative to the filter housing, each time the pressure rises to within 7 to 10 psi above the pressure read just after the last cleaning operation. During this simple regeneration, the clogged cake is shaken off of the membrane so that the dirt having coated the diatomaceous earth coating, and the diatomaceous earth itself, are redistributed, before resuming normal pumping and filtering and recoating the membrane with the more permeable redistributed mixture of dirt and diatomaceous earth.
Under normal operation this system typically should be regenerated every two or three days, while draining to clean the filter is needed only after 3 to 10 weeks by the above-noted criteria. However, these times vary greatly with pool usage and weather conditions.
In practice, a family pool filter system is only checked when some one of the family members happens to think about it, and the chances are especially great that both regeneration and draining to clean the filter will be done too infrequently. This is particularly true after hot summer days when algae, if any, grows faster and pool usage is generally high, both increasing the dirt load to be filtered and drastically increasing the frequency of regeneration that is needed. Furthermore, besides the deteriorating condition of the swimming pool water, the pump will run inefficiently and uselessly. And in those systems wherein chloride is automatically dispensed into the water conduits from the pump to the pool, the pool can turn green with algae within hours on a hot day of high usage when water flow is blocked by a clogged filter.
It is, therefore, an object of the present invention to provide in a diatomaceous-earth pool-filter system of the regeneration type, an alarm that is activated when regeneration and/or cleaning is needed.
It is a further object of this invention to provide such a pool filter system wherein the number of regenerations executed is automatically counted, so that the count from the time of the previous filter cleaning operation may be used as an indication of the need for the next filter cleaning operation.
SUMMARY OF THE INVENTION
A swimming pool filter system in comprised of a water pump, a water filter of the diatomaceous earth type, a water conduit means for hydraulically series connecting the pump and the filter in a hydraulic loop with a swimming pool and a pressure sensitive switch means. The switch means is hydraulically connected to the inlet port of the filter for actuating an alarm when the water pressure at near the filter inlet port exceeds a predetermined magnitude corresponding to a degree of accumulation of dirt in the filter that can substantially reduce the water flow rate through the filter.
Alternatively the pressure sensitive switch means is for producing a number of switch closures, one each time said pressure exceeds said predetermined magnitude, and the system additionally includes a resettable counter that counts and resets when the count reaches a predetermined number and actuates the alarm.
The filter system of this invention is particularly advantageous when the filter is a Hayward type filter, because of its capability for being regenerated several times in each operating period between cleanings. Each regeneration involves dropping the water flow rate to near zero and shaking the diatomaceous earth and accumulated dirt loose to mix homogenously in the filter inlet chamber. When the water flow is reestablished, the mixture recoats the porous filter membrane and the filter is generally operable again, on the average for a few days, before regeneration is required again. The filter tends to require more frequent attention after several regenerations, however, since the frequency of regenerations needed accelerates. Thus, unless one keeps track of the number of regenerations since the last cleaning and the time the last regeneration was executed, it is not possible to predict the next one. The alternative is to check the pressure gauge often which can be inconvenient and likely neglected.
The filter system of this invention entirely overcomes these problems by signaling the start of each regeneration and cleaning operation.
BRIEF DESCRIPTION OF THE DRAWING
5 FIG. 1 shows a schematic diagram of a swimming pool serviced by a conventional swimming pool filter system.
FIG. 2 shows in side sectional view a swimming-pool-filter of the regenerative diatomaceous earth type in combination with an alarm system shown in the form of a schematic diagram according to a preferred embodiment of this invention.
FIG. 3 shows a schematic diagram of a swimming pool served by a swimming-pool filter system according to another preferred embodiment of this invention.
FIG. 4 shows in side sectional view a swimming-pool-filter of the regenerative diatomaceous earth type in combination with an automatic regeneration and alarm means according to a third preferred embodiment of this invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
The swimming pool filter system 10 of the prior art shown in FIG. 1, has an electric motor driven pump 12, a filter 13 and pipes 14, 15 and 16 connecting the pump 12 and filter 13 in a hydraulic loop with a swimming pool 18. Valves 21, 22 and 23 make it possible to hydraulically isolate either the filter 13 or pump 12 or both for purposes of maintenance and repair.
Referring to FIG. 2, the construction of a Hayward type filter 25 is shown wherein the central feature is an elongated filter tube 27, that is typical of a plurality of tubes in this filter. The other tubes, not shown in FIG. 2, are of identical structure to tube 27. Tube 27 has a closed bottom and a flared open end like a laboratory test tube. The walls of tube 27 are permeable to water but not to diatomaceous earth, a coating 28 of which covers the outer walls of tube 27. The water permeable walls of the filter tube 27 may consist of a wire frame covered by a closely woven fabric of a synthetic fiber, such as NYLON.
The flared lips of the tubes 27 are clamped between two plates 30 and 31. Plates 30 and 31 also clamp between them at their peripheries an elastic washer 34 that with a bellows-like fold extends radially outward and is clamped between the top and bottom sections 35 and 36 of the filter housing, so that the filter tubes 27 and plates (30 and 31) assembly is movable in a vertical direction relative to the filter housing.
A rod 36 enters the housing top 37 through a water tight bushing 39 and is fastened to the plates 30 and 31. A bar 40 is hingedly connected to the rod 36 and to an upwardly extending pivot portion of the housing top 35 so that an operator may grasp the bar handle 41 and move it vertically to impart vertical movement to the filter tubes 27, A bolt and nut assembly or a rivet 43 is, among others (not shown), for holding the plates 30 and 31 together. A bolt and nut assembly 45, among others (not shown), holds the housing top 35 and housing bottom 36 together. A protective cap 47 is fitted over the housing top 35 and has a slot 48 through which bar 40 passes and is free to move vertically.
In operation, water from a swimming pool (not shown) is pumped through the filter inlet port 50 into the filter inlet chamber 52. The water in chamber 52 is forced through the diatomaceous earth coating 28 and further through the water permeable walls of tube 27. It then flows upward through the interior of tubes 27 and passes through hole(s) 54 provided therefor in plate 31. The water enters the filter outlet chamber 56 and exits through the filter outlet port 58.
Another port 60 is provided in the bottom housing member 36 hydraulically connecting the filter inlet chamber 52 with a pressure sensitive switch 61, illustrated here as having a flexible membrane 62, an electrical switch 64 and a mechanical linkage 66 therebetween. When the water pressure in the filter inlet chamber 52 rises to a critical level to which the pressure sensitive switch 61 has been adjusted, e.g., by changing the length of bar 66, then the electrical switch 64 is closed.
When switch 64 closes, the voltage from an electrical energy source, the battery 68, is impressed at the input of the electric impulse counter 70 of the automatic reset type. The counter 70 resets when it has accumulated a count representing the number of times switch 64 has closed (and/or opened) which count is the maximum to which counter 70 is adjusted or designed to count before automatically resetting. Upon resetting, counter 70 produces a signal at the input of alarm 72 that is a signal to an operator indicating a heavy accumulation of dirt within the filter 25 at which filtering and water flow rate even with another regeneration will be intolerably impaired, and thus at which cleaning of the filter should be initiated.
In a second preferred embodiment of this invention water filter 25 and the pressure sensitive switch 61 of FIG. 2 is connected to an alarm 76 whereby the alarm 76 is energized from the AC power mains 78 when the switch 64 closes. The pump 80 is energized from the same power mains 78.
The filter system of this second embodiment is suitable for providing a warning every time the pressure at the filter inlet port 60 exceeds the aforementioned predetermined value indicating the need for an operator to manually regenerate the filter 25.
In a more fully automatic embodiment of this invention as depicted in FIG. 4, the filter 85 employs the housing bottom 36, the plate assembly including plates 30 and 31 and the filter tubes 27 that made up the major portion of filter 25 in FIG. 2. Also, the same pressure sensitive switch 61 is mounted in the housing bottom 36 as before.
However, the filter housing top 87 is modified to hold by a soft iron band 86 a solenoid 88, and the rod 36 has mounted on the upper end thereof an iron core 90 that is free to move with rod 36 and plates 30 and 31 relative to the solenoid and supporting housing top 87. A protective cap 91 is fitted over the top 87 and covers solenoid 88.
In this embodiment, regeneration of the filter is accomplished by shutting off the pump 89 and driving the solenoid 88 electrically to shake the diatomaceous earth 28 and accumulated dirt which will thereby be homogeneously dispersed and mixed in the still water inside the filter inlet chamber 52.
This is accomplished automatically each time that the pressure sensitive switch 64 responds to the aforementioned high pressure and actuates the solenoid driver 92 that for a period, preferably of about thirty seconds, applies a voltage to the solenoid 88 via wires 93. This driver voltage may be a 110V 60 Hz line voltage to vibrate the core 90 or may be a series of pulses to shock the core 90 which in either case effects the shaking loose of the diatomaceous earth 28 and dirt from the tubes 27. Simultaneously with the driving of the solenoid 88, the driver 92 effects the turning off of the pump 89. For this purpose the driver 92 may include an internal solenoid (not shown) linked mechanically via mechanical link 95 to open the line breaker 97.
A resulting counter 99 is connected as in the first embodiment to count the number of times that the pressure sensitive switch 64 has operated which corresponds to the number of times the filter 85 has been automatically regenerated. When the counter 99 resets, after counting up to the predetermined reset count number, the counter 99 actuates alarm 100 to indicate the need for cleaning the filter 85.
Experiments under a variety of weather and pool usage conditions show that when a pressure sensitive switch 64 is set to close and initiate regeneration every time the inlet chamber pressure of the filter reaches about 15 psi, enough dirt will have been accumulated in the filter to substantially reduce the flow rate and that periods between regenerations become short, usually less than a 24 hour day. Thus, the resettable counter should be reset at 5 for the particular system tested. Considering the effects upon the optimum reset count of small changes in filter capacity, pool size, pump size and the like, an optimum count reset number will fall between 4 and 9 for filter systems of this invention.
The alarms 72, 76 and 100 in the embodiments described here may be of any standard type. For example, a visual alarm may consist of a flashing lamp, or an acoustic alarm may employ a buzzer, horn or bell.
Also, the pressure sensitive switch 61 may be replaced by a linear pressure to voltage transducer (e.g. a transducer incorporating a stressed silicon diaphram or a diaphram with strain gauge) combined with an electronic threshold detector (e.g. of the standard Scmitt trigger type) wherein the threshold is adjusted to correspond to the aforementioned predetermined pressure.
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A swimming pool filter system is comprised of a pump, a filter and a water conduit means for hydraulically connecting the pump and filter in a hydraulic loop with a swimming pool. The filter is a Hayward regenerable filter wherein the diatomaceous earth coating may be periodically shaken off the filter membrane to mix with the dirt and recoat the membrane several times between cleanings to extend the time between filter cleanings. A pressure sensitive switch, mounted at the filter inlet port, closes when the inlet pressure exceeds a predetermined magnitude to energize an alarm each time regeneration is needed or after five regenerations when cleaning will be required.
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This application claims priority from U.S. Provisional Patent Application 60/153,825 filed Sep. 14, 1999.
FIELD OF THE INVENTION
The present invention relates to a treated fiber and a method of forming a treated fiber. Such treated fibers find many applications, for example, in nonwoven fabrics, yarns, carpets, and otherwise where fibers having one or more modified properties are desired.
BACKGROUND OF THE INVENTION
Nonwoven fabrics are finding increasing use in various applications, including personal care absorbent articles such as diapers, training pants, incontinence garments, mattress pads, wipers, and feminine care products (e.g., sanitary napkins), medical applications such as surgical drapes, gowns, wound care dressings, and facemasks, articles of clothing or portions thereof including industrial workwear and lab coats, household and industrial operations including liquid and air filtration, and the like.
It is often desirable to modify the properties of the nonwoven fabric to perform a function or meet a requirement for a particular application. One means of modifying the properties is through the use of treatments. Treatments are generally added by either topically treating the fibers or fiber web or by mixing the treatment with the polymer prior to forming fibers by melt extrusion or the like. Examples of typical types of treatments include, but are not limited to, stabilizers, delusterants, flame retardants, fillers, antimicrobial agents, optical brighteners, extenders, colorants, lubricants, antistatic agents, alcohol repellents, softeners, soil repellents, wetting agents, processing aids, and other functional chemistries.
Once an appropriate treatment is identified for an application, the means of applying the treatment to the fiber or fiber web often presents challenges. Some treatments may be applied either internally or topically, depending on the chemical structure of the treatment and any process limitations.
Topical treatment, or coating, of a formed fiber or fiber web may be accomplished by various techniques, including foam treating as disclosed in U.S. Pat. No. 4,095,558 (Ellegast et al.), roll coating as disclosed in U.S. Pat. No. 3,993,805 (Roberts), spray coating as disclosed in U.S. Pat. No. 3,032,813 (Stalego), slot coating as disclosed in U.S. Pat. No. 4,457,034 (Simmen) and U.S. Pat. No. 5,679,158 (Holzer, Jr. et al.), brush treating as disclosed in European Patent No. 0 594 983 A1 (Garavaglia et al.), and dip and squeeze treating, which consists of submerging the fiber in a treatment bath followed by blotting or squeezing to remove the excess, as disclosed in U.S. Pat. No. 5,151,321 (Reeves et al.). When only a low level of treatment is required, such systems may result in poor treatment uniformity on the fiber or fiber web surface. As a result, it is often necessary to increase the treatment level or dilute the treatment to form a treatment bath. The treatment process may then be followed by a costly and/or cumbersome drying step that may adversely impact the physical properties, such as strength, of the fiber or fiber web. Further, the application of multiple immiscible treatments may require a multi-step coating and drying process.
Traditionally, internal treatment has been achieved by compounding a treatment into a polymer and blending the compounded product with untreated polymer pellets prior to extrusion as disclosed in U.S. Pat. No. 4,167,503 (Cipriani), or by directly combining the treatment with the molten polymer during extrusion as disclosed in U.S. Pat. Nos. 4,857,251 and 5,057,262 (Nohr et al.). Such processes require extensive mixing to attain uniformity of the treatment in the fiber and lengthy purge times to remove the treatment from the extruder during typical manufacturing process changes.
An alternative approach, exemplified by U.S. Pat. No. 5,516,476 (Haggard et al.), blends the treatment with the molten polymer by passage through mixer channels in the spin pack plates immediately upstream of the spinning orifices of a spinneret. This approach shortens the purge time but does not use all treatments efficiently, as many treatments are functional only on the fiber surface and provide little or no benefit when in the interior of the fiber. Treatments that are not miscible with the polymer may migrate to the fiber surface over time, but even highly migratory treatments may not diffuse to the surface completely. As a result, higher treatment levels are often required to achieve the desired fiber properties. As with the topical treatment systems, internal treatment systems may be limited to use of a single treatment or blends of miscible treatments, since the incorporation of multiple immiscible treatments may result in fiber formation difficulties and poor treatment uniformity on the surface of the fiber.
Thus, traditional topical treatment systems are limited in terms of uniformity, cost, and flexibility, but are useful for applying the treatment only to the surface of a fiber or fiber web where its functional benefit is often desired. Internal treatment systems may simplify the treatment process, but are often inefficient due to long polymer purge times or increased treatment level requirements to obtain the desired properties on the surface of the fiber. Thus, a system that offers the benefits of both topical treatment and internal treatment is highly desirable.
The prior art has not presented a method nor an apparatus for selectively applying one or more treatments to the surface of an advancing molten polymer without mixing with the polymer. Such a process would allow for rapid product changes, highly efficient use of treatment and polymer, the use of multiple immiscible treatments, minimal drying requirements, if any, and reduced processing interruptions.
SUMMARY OF THE INVENTION
The present invention provides a treated fiber and a method of forming a treated fiber. A molten polymer is delivered to a fiber spinning assembly adapted to form and distribute a polymer stream. At least one treatment is applied in a liquid state to at least one region on the surface of the molten polymer stream within the fiber spinning assembly. A substantial portion of the treatment remains on the surface of the formed fiber within the region to which the treatment was applied.
Any polymer that is suitable for a fiber formation process may be used to form a treated fiber of the present invention. Similarly, any type of treatment may be used, for example, wetting agents, skin care treatments, medicinal treatments, and antistatic agents, provided that the treatment is able to withstand the processing conditions used during fiber formation processes and does not adversely impact fiber formation. The level of treatment may range from about 0.05% to about 3.0% by weight of the fiber, for example, and preferably ranges from about 0.1% to about 1.5% by weight of the fiber. The treatment is preferably a liquid or in a form which can be transported in a liquid carrier, i.e, in a liquid state.
In one embodiment, one or more regions on the surface of the molten polymer are treated with a single treatment or blend of multiple treatments. The region may be circumferential, i.e., in a direction around the fiber, or longitudinal, i.e., in a direction along the length of the fiber. The region may be continuous or discontinuous. The degree of coverage may vary from little coverage to complete coverage of the fiber surface, depending on the requirements for the particular application.
In another embodiment, two or more treatments are applied to multiple regions on the surface of the fiber. The regions may be in contact with one another or may be separate and distinct. The treatments may be miscible or immiscible.
In still another embodiment, a nonwoven web is produced with selectively treated fiber regions. This is accomplished through design of one or multiple fiber spinning assemblies to treat selected fibers or to apply multiple treatments. The regions of the fibers in the nonwoven web may vary in treatment type, amount, or degree of coverage.
The method of forming a treated fiber and the treated fiber of the present invention can be used to make nonwoven fabrics for a variety of applications. The broad scope of the applicability of the present invention will become apparent to those of skill in the art from the details given hereafter. However, it should be understood that the detailed description of the preferred embodiments of the present invention is given only by way of illustration because various changes and modifications well within the spirit and scope of the invention should become apparent to those of skill in the art in view of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exemplary method of forming a treated fiber according to the present invention.
FIGS. 2 ( a )- 2 ( d ) are fiber cross-sections with various treatment configurations according to the present invention.
FIGS. 3 ( a ) and 3 ( b ) are fiber cross-sections with circumferentially continuous and circumferentially discontinuous treatment regions, respectively.
FIGS. 4 ( a ) and 4 ( b ) are side views of a fiber with a longitudinally continuous treatment region and a longitudinally discontinuous treatment region, respectively.
FIG. 5 is an exemplary nonwoven web with multiple treatment regions which may be made according to the present invention.
FIG. 6 is an exemplary nonwoven web with multiple treatment layers which may be made according to the present invention.
DEFINITIONS
As used herein, “treatment” refers to any substance used to modify the physical or chemical properties of a fiber or fiber web. A treatment may be a single substance or a blend of two or more substances. As used herein, “internal treatment” refers to any treatment that is substantially mixed with a molten polymer at any stage during a fiber forming process. As used herein, the term “topical treatment” refers to any treatment that is applied externally to a fiber or fiber web.
As used herein the term “blend” means a mixture of two or more polymers or treatments. “Miscible” and “immiscible” describe a blend having a negative and positive value, respectively, for the free energy of mixing. As used herein, a “liquid” is any predominantly nonparticulate, nongaseous substance which can assume the shape of a container. As used herein, the term “liquid state” describes a substance having the properties of a liquid, including, for example, slurries, suspensions, emulsions, and the like.
As used herein, the term “fiber” refers to the basic element of fabrics and other textile structures. A fiber is characterized by having a length as formed of at least about 100 times its width or diameter. A fiber may be made of a natural polymer, e.g., alginic or cellulose-based fibers, a synthetic polymer, e.g., polyester, polypropylene, polyethylene, polyurethane, and polyvinyl fibers, or a mineral, e.g., glass. Such fibers are discussed in the Dictionary of Fiber & Textile Technology by Hoechst Celanese, copyright 1990 at pages 59 and 94.
As used herein, the term “nonwoven fabric” or “web” or “fiber web” means a web having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted fabric. As used, herein, the term “web” or “layer” when used in the singular can have the dual meaning of a single element or a plurality of elements. The basis weight of a nonwoven fabric is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm) and the fiber diameter is usually expressed in microns. (Note that to convert from osy to gsm, multiply osy by 33.91). Another frequently used expression of fiber diameter is “denier”, which is defined as grams per 9000 meters of a fiber and may be calculated as fiber diameter in microns (μm) squared, multiplied by the density in grams/cc, multiplied by 0.00707. A lower denier indicates a finer fiber and a higher denier indicates a thicker or heavier fiber. For example, the diameter of a polypropylene fiber given as 15 microns (μm) may be converted to denier by squaring, multiplying the result by 0.89 g/cc and multiplying by 0.00707. Thus, a 15 micron (μm) polypropylene fiber has a denier of about 1.42(15 2 ×0.89×0.00707=1.415). Outside the United States the unit of measurement is more commonly the “tex”, which is defined as the grams per kilometer of fiber. Tex may be calculated as denier/9.
As used herein the term “spunbond fibers” refers to small diameter fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced as by, for example, in U.S. Pat. No. 4,340,563 to Appel et al., and U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartman, and U.S. Pat. No. 3,542,615 to Dobo et al. The contents of each of the foregoing patents are incorporated herein by reference in their entirety. Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers are generally continuous and have average diameters (from a sample of at least 10) larger than 7 microns (μm), often between about 10 and 20 microns (μm).
As used herein, the term “coform” means a process in which at least one meltblown diehead is arranged near a chute through which other materials are added to the fibers web while forming the web. Such other materials may be pulp, superabsorbent particles, cellulose or staple fibers, for example. Coform processes are shown in commonly assigned U.S. Pat. No. 4,818,464 to Lau and U.S. Pat. No. 4,100,324 to Anderson et al, the entire contents of which are incorporated herein in their entirety. Webs produced by the coform process are generally referred to as coform materials.
As used herein the term “meltblown fibers” means fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity, usually hot, gas (e.g., air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241 to Butin et al, incorporated herein in its entirety. Meltblown fibers, which may be continuous or discontinuous, are generally smaller than 10 microns in average diameter and are often tacky when deposited onto a collecting surface.
As used herein the term “microfibers” means small diameter fibers having an average diameter not greater than about 25 microns (μm), for example, having an average diameter of from about 0.5 microns (μm) to about 20 microns (μm), or more particularly, microfibers may have an average diameter of from about 2 microns (μm) to about 10 microns (μm).
As used herein the term “monocomponent fibers” refer to fibers formed from one or more extruders using only one polymer. This is not meant to exclude fibers formed from one polymer to which small amounts of additives have been added for colors, anti-static properties, lubrication, hydrophilicity, etc. These additives, e.g., titanium dioxide for colors, are normally present in an amount less than 5 weight percent and more typically about 2 weight percent.
As used herein the term “conjugate fibers” refers to fibers which have been formed from at least two polymers extruded from separate extruders but spun together to form one fiber. Conjugate fibers are also sometimes referred to as “multicomponent fibers” or “bicomponent fibers”. The polymers are usually different from each other though conjugate fibers may be monocomponent fibers. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the conjugate fibers and extend continuously along the length of the conjugate fibers. The configuration of such a conjugate fiber may be, for example, a sheath/core arrangement wherein one polymer is surrounded by another or may be a side by side arrangement, a pie arrangement or an “islands-in-the-sea” arrangement. Conjugate fibers are taught in U.S. Pat. No. 5,108,820 to Kaneko et al., U.S. Pat. No. 4,795,668 to Krueger et al., and U.S. Pat. No. 5,336,552 to Strack et al. Conjugate fibers are also taught in U.S. Pat. No. 382,400 to Pike et al. and may be used to produce crimp in the fibers by using the differential rates of expansion and contraction of the two (or more) polymers. Crimped fibers may also be produced by mechanical means and by the process of German Patent DT 25 13 251 A1. For two component fibers, the polymers may be present in ratios of 75/25, 50/50, 25/75 or any other desired ratios. The fibers may also have shapes such as those described in U.S. Pat. No. 5,277,976 to Hogle et al., U.S. Pat. No. 5,466,410 to Hills, and U.S. Pat. Nos. 5,069,970 and 5,057,368 to Largman et al., which describe fibers with unconventional shapes.
As used herein the term “biconstituent fibers” refers to fibers which have been formed from at least two polymers extruded from the same extruder as a blend. Biconstituent fibers do not have the various polymer components arranged in relatively constantly positioned distinct zones across the cross-sectional area of the fiber and the various polymers are usually not continuous along the entire length of the fiber, instead usually forming fibrils or protofibrils which start and end at random. Biconstituent fibers are sometimes also referred to as “multiconstituent fibers”. Fibers of this general type are discussed in, for example, U.S. Pat. Nos. 5,108,827 and 5,294,482 to Gessner. Bicomponent and biconstituent fibers are also discussed in the textbook Polymer Blends and Composites by John A. Manson and Leslie H. Sperling, copyright 1976 by Plenum Press, a division of Plenum Publishing Corporation of New York, IBSN 0-306-30831-2, at pages 273 through 277.
As used herein the term “polymer” generally includes but is not limited to, homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, etc. and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible geometrical configurations of the molecule. These configurations include, but are not limited to isotactic, syndiotactic and random symmetries.
As used herein and in the claims, the term “comprising” is inclusive or open-ended and does not exclude additional unrecited elements, compositional components, or method steps.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a molten polymer 10 is delivered to a fiber spinning assembly 12 , which generally contains a series of thin distribution plates (not shown) having channels for distribution and holes for passage therethrough. A stream of treatment 14 is brought into the fiber spinning assembly and is delivered to the perimeter of the holes via conduit 16 . The channels and holes used to deliver the polymer are separate from those used for the treatment, so there is no mixing of the treatment and the molten polymer. At a point prior to where the polymer stream enters the final plate 18 , known as the spinneret plate, the treatment is contacted with the molten polymer such that the treatment is applied to one or more regions on the surface of the molten polymer stream. The treated polymer then passes through an orifice 20 in the spinneret plate and a treated fiber 22 is formed. A similar fiber would be formed upon passage through orifice 24 in the spinneret plate, but is not illustrated for the purpose of clarity. A substantial portion of the treatment remains on the surface of the fiber within the treated region, resulting in a more efficient use of treatment as compared with traditional topical or internal treatment methods.
The fiber may then be collected or combined with other fibers to form a nonwoven web, yarn, or the like. If desired, the fiber spinning assembly may be designed to apply the treatment only to fibers in certain region or layers of the resulting nonwoven web, or to create regions on the nonwoven web with varying degrees or types of treated fibers. Examples of such nonwoven web processes that may be useful in the present invention include meltblowing processes, spunbonding processes, coforming processes and bonded carded web processes. Other useful processes will be apparent to those skilled in the art.
The nonwoven web formed from fibers of the present invention may be a mixture of various types of fibers with or without particulates. For an example of such a mixture, reference is made to a process in which elastomeric and non-elastomeric fibers are commingled to form a single coherent web of randomly dispersed fibers. Another example of such a web would be one made by a technique such as disclosed in U.S. Pat. No. 4,741,949 to Morman et al, which discloses a nonwoven material which includes a mixture of meltblown thermoplastic fibers and other materials. The fibers and other materials are combined in the gas stream in which the meltblown fibers are bome so that an intimate entangled commingling of meltblown fibers and other materials occurs prior to collection of the fibers upon a collecting device to form a coherent web of randomly dispersed fibers. Examples of some particulates that may be used include, but are not limited to, wood pulp, staple fibers or particulates, such as activated charcoal, clays, starches, or hydrocolloid (hydrogel) particulates commonly referred to as super-absorbent materials.
The fiber of the present invention may be formed from any suitable thermoplastic polymer or blend containing the same, and may be monocomponent, conjugate, or biconstituent. Useful polymers include polyolefins, for example, polyethylene, polypropylene and polybutene, ethylene copolymers, propylene copolymers and butene copolymers, high density polyethylene, low density polyethylene, and linear low density polyethylene. Other suitable thermoplastic polymers include cellophane, polyvinyl acetate, polyvinyl alcohol, polycaprolactam, polyester, polyamide, polyethylene terephthalate, polybutylene terephthalate, polytetrafluoroethylene, or mixtures or coextrusions of one or more of these materials.
The fiber of the present invention may also be formed from an elastomeric thermoplastic polymer such as a block copolymer including polyurethanes; copolyester elastomers like copolyetheresters; polyamide polyether block copolymers; copolymers of ethylene and at least one vinyl monomer, for example, vinyl acetates such as ethylene vinyl acetate (EVA), unsaturated aliphatic monocarboxylic acids, and esters of such monocarboxylic acids; block copolymers having the general formula A-B-A′, A-B or A-B-A-B like copoly(styrene/ethylene-butylene), styrene-poly(ethylene-propylene)-styrene, styrene-poly(ethylene-butylene)-styrene, (polystyrene/poly(ethylene-butylene)/polystyrene, poly(styrene/ethylene-butylene/styrene), polystyrene-poly(ethylene-propylene)-polystyrene-poly(ethylene-propylene) and the like. Also, the new class of polymers referred to as single site catalyzed polymers such as “metallocene” polymers produced according to a metallocene process are also useful. For a more detailed description of the metallocene polymers and the process for producing the same which are useful in the present invention see commonly assigned PCT Patent Application No. WO 98/29246 to Gwaltney et al., which is incorporated herein by reference in its entirety.
The method of the present invention offers a high degree of flexibility in forming a treated fiber. The treatment configurations that may be formed are limited only by the ability to construct spinning plates with sufficiently sized holes and by the ability to accurately meter a particular treatment level to the fiber spinning assembly. The thickness and degree of coverage of the treatment on the surface of the fiber is determined by the flow rate of treatment metered to the fiber spinning assembly and the dimensions of the contact area between the treatment and the advancing molten polymer stream. The level of treatment may range, for example, from about 0.05% to about 3.0% by weight of the fiber, and preferably ranges from about 0.1% to about 1.5% by weight of the fiber. The treatment is preferably a liquid or in a form which can be transported in a liquid carrier, i.e, in a liquid state.
FIGS. 2 ( a )- 2 ( d ) generally exemplify some potential fiber treatment configurations. For the purpose of clarity, the illustrations included herein are not drawn to scale. FIG. 2 ( a ) generally shows a cross-section of a fiber 24 having a single treatment region 26 , in which the treatment may be one treatment or a blend of two or more treatments. FIG. 2 ( b ) generally shows a cross-section of a fiber 28 having a two treatment regions 30 and 30 ′ with a single treatment. FIG. 2 ( c ) generally shows a cross-section of a fiber 32 having two treatment regions 34 and 36 with two different treatments. FIG. 2 ( d ) generally shows a cross-section of a fiber 38 with multiple treatment regions 40 , 42 , 44 , and 44 ′ and multiple treatments. The treated region 50 may be continuous around the circumference of a fiber 52 (FIG. 3 ( a )) or may consist of multiple, generally separate and distinct regions 56 and 56 ′ on the surface of a fiber 54 (FIG. 3 ( b )). The treated region 60 on the surface of a fiber 62 may be generally continuous in a longitudinal dimension, i.e., along the length of a fiber, as in FIG. 4 ( a ), or the treated regions 64 on the surface of a fiber 66 may be generally discontinuous in a longitudinal dimension as in FIG. 4 ( b ).
In general, any treatment that is able to maintain a liquid state at the temperature reached in the fiber forming process and which does not adversely affect the ability to form a fiber may be used to impart a property to the resulting fiber or nonwoven web. Typical fiber forming process temperatures for polyolefin thermoplastics, for example, range from about 300° F. (149° C.) to about 550° F. (288° C.). The treatment is preferably beneficial on the exterior surface of the fiber and sufficiently compatible with the polymer so that it does not have a tendency to bead up and drip off the fiber or evaporate from the surface of the fiber. Examples of such possible treatments include, but are not limited to, stabilizers, delusterants, flame retardants, fillers, antimicrobial agents, optical brighteners, extenders, colorants, lubricants, antistatic agents, alcohol repellents, softeners, soil repellents, wetting agents, processing aids, and other functional chemistries.
Some treatments may be selected for their ability to spread across the surface of a fiber. A highly mobile treatment, for example, a silicone polyether wetting agent, applied to narrow regions on the molten polymer stream will spread across the surface of the fiber over time. Thus, a low level of a highly mobile treatment may be applied in, for example, a dual treatment region configuration to form a treated fiber with a very thin layer of treatment and a high degree of coverage. Therefore, less treatment is needed to form a very thin layer of treatment on the entire surface of the fiber than would be required using a traditional internal treatment process. Further, uniformity is improved over that which may be obtained using a traditional topical treatment method.
With some treatments, however, it may be undesirable to obtain a high degree of coverage of the surface of the fiber. For example, in medical applications, such as surgical drapes and garments, it is necessary to obtain high liquid barrier properties in addition to electrical conductivity. The use of an alcohol repellent (e.g., fluorochemical) and an antistatic agent (e.g., alkyl phosphate ester) may be appropriate for such an application. A disadvantage of many antistatic agents is that such treatments are also wetting agents; thus, using certain antistatic agents may compromise the barrier properties of the nonwoven fabric or garment. With the present invention, however, a low level of an antistatic agent may be applied to a narrow and discrete region on the fiber while a higher level of an alcohol repellent treatment may be applied to a second discrete region on the fiber, creating a conductive path needed for electrical conductivity without substantially inhibiting the barrier properties of the nonwoven fabric or garment.
The method of the present invention may also be used to produce fibers of nonwoven web with similar flexibility in overall treatment configuration and coverage. FIG. 5 generally shows a nonwoven web 70 with treated fibers 72 (single treatment region) and 74 (two treatment regions) in selected areas 76 and 78 , respectively, made according to the present invention, and an area 80 of the nonwoven in which the fibers 82 are not treated. Examples of applications in which such nonwoven webs may find use include, but are not limited to, personal care articles, in which it may be desirable to have one or more regions treated with a wetting agent for liquid permeability, wound care dressings, in which it may be desirable to have one or more regions treated with medicinal treatments (e.g., antibacterial agent) or other skin care treatments (e.g., aloe), and in medical fabrics (e.g., surgical drapes or garments), in which it may be desirable to have one or more regions with differing degrees or types of treatment to alter the coefficient of friction or antistatic properties.
FIG. 6 generally depicts a nonwoven web 90 in which layers 92 and 94 of the nonwoven web have different treatment types and/or configurations. The top layer 92 has two sections 96 and 96 ′ in which the fibers 98 and 98 ′ are treated in a single treatment region on the fiber and a center area 100 in which each fiber 102 is not treated. The bottom layer 94 has two sections 102 and 102 ′ in which the fibers 104 and 104 ′ are not treated and a center area 106 in which each fiber 108 is treated in two treatment regions. Examples of applications in which such a nonwoven web may find use include, but are not limited to, personal care articles, in which varying levels of wetting agents may be applied to two or more layers to create a surface energy gradient for enhanced liquid permeability or in which it may be desirable to have a layer treated with a skin care treatment (e.g., aloe) or medicinal treatment (e.g., antibacterial agent) and an additional layer that is hydrophilic, and medical garments, for example surgical gowns, in which it may be desirable to have a surface that is blood and/or alcohol repellent and an additional layer that is antistatic.
The present invention is further described with the following example and comparative example which are provided to demonstrate the advantages of the present invention. The example is presented solely for purposes of illustration and should not be construed as limiting the invention. It should be understood by those skilled in the art that the parameters of the present invention will vary somewhat from those provided in the following Example depending on the particular processing equipment that is used. It is intended to include within the invention as defined by the claims all alternatives, modifications, and equivalents to those elements that are specifically described.
EXAMPLE
Polypropylene spunbond nonwoven fabric samples were prepared on 14 in. (35.6 cm) wide pilot equipment using a fiber forming process similar to that disclosed in U.S. Pat. No. 3,802,817 (Matsuki et al.) to demonstrate the improved efficiency and performance of the present invention. A hydrocarbon-based wetting agent, Atmer 688 available from ICI Surfactants, Inc. in Wilmington, DE, was selected as the treatment for its ability to withstand processing temperatures of about 430° F. (221° C.).
After the molten polymer passed through the fiber spinning assembly, the fibers were laid on a moving wire and thermally point bonded to form a nonwoven web. The resulting nonwoven material had a basis weight of about 1.35 osy (45.8 gsm) and a denier of about 2.5. The samples were evaluated for water wettability by placing the sample on a flat surface and using a disposable pipette to place a few drops of distilled water on the sample. In general, a highly wettable substrate will allow drops of water to instantaneously wet the fibers and pass through the nonwoven. The results of the evaluation are summarized in Table 1.
Samples 1 and 2 were produced according to the present invention using a positive-displacement pump to precisely meter the treatment under high pressure to the fiber spinning assembly through a heated supply line. The treatment was then metered to individual holes using a series of thin distribution plates. Treatment levels of about 0.25% and about 0.50% by weight of the fiber were applied to individual molten polymer streams using a continuous dual treatment region configuration to produce Samples 1 and 2, respectively. Upon contact with water, the resulting nonwoven webs exhibited instantaneous wettability.
Samples 3 and 4 were produced according to traditional internal treatment methods by blending the treatment with the molten polymer at levels of about 1% and about 2% by weight, respectively, of the fiber. The treatment and the molten polymer were thoroughly mixed prior to entering the fiber spinning assembly. When the resulting nonwoven webs were contacted with water, neither Sample 3 nor Sample 4 exhibited any degree of wettability.
TABLE 1
Sample
Treatment Level
Result
1
0.25%
Wettable
2
0.50%
Wettable
3
1%
Not wettable
4
2%
Not wettable
The results of the evaluation demonstrate that a treatment can be applied to the surface of an advancing molten polymer stream prior to exiting a fiber spinning assembly. At treatment levels 4 and 8 times higher than that applied according to the present invention, the internally treated nonwoven web exhibited no degree of wettability. Thus, even at high treatment levels Samples 3 and 4 did not have a sufficient amount of treatment on the surface of the fibers to impart wettability to the nonwoven web.
The method of the present invention offers a significant advantage over current internal treatment systems, since treatments that do not tend to migrate to the surface of the fiber can be used to successfully impart the desired property to the fiber without using very high treatment levels or having to wait for the treatment to migrate to the surface of the fiber over time. Additionally, even when using a highly migratory treatment, a lower treatment level can be used to achieve the same result as would be obtained with a higher treatment level incorporated into the nonwoven web fiber as an internal additive.
Having thus described the invention in detail, it should be apparent that various modifications can be made in the present invention without departing from the spirit and scope of the following claims.
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The present disclosure is directed to a method of forming a treated fiber. A molten polymer is delivered to a fiber spinning assembly adapted to form and distribute polymer streams. At least one treatment is applied in a liquid state to at least one region on the surface of at least one molten polymer stream within the fiber spinning assembly. A substantial portion of the treatment remains on the surface of the resulting fiber within the treated region. One or more regions on the surface of the molten polymer may be treated with one or multiple treatments. The degree of coverage may vary from little coverage to complete coverage of the fiber surface. The treated regions may be in contact with one another or may be separate and distinct. A nonwoven web may be produced with selectively treated fiber regions by designing one or more fiber spinning assemblies to treat selected fibers or to apply multiple treatments. The regions of the nonwoven web may vary in treatment type, amount, or degree of coverage.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH & DEVELOPMENT
[0001] This invention was made with United States Government support under ATP/NIST Contract 70NANB7H7043 awarded by NIST. The United States Government has certain rights in the invention.
BACKGROUND
[0002] The field relates generally to fabrication of conductors, and more specifically to conductors that incorporate carbon nanotubes (CNTs) and the methods for fabricating such conductors.
[0003] Utilization of CNTs in conductors has been attempted. However, the incorporation of carbon nanotubes (CNTs) into polymers at high enough concentrations to achieve the desired conductivity typically increases viscosities of the compound containing the nanotubes to very high levels. The result of such a high viscosity is that conductor fabrication is difficult. A typical example of a high concentration is one percent, by weight, of CNTs mixed with a polymer.
[0004] Currently, there are no fully developed processes for fabricating wires based on carbon nanotubes, but co-extrusion of CNTs within thermoplastics is being contemplated, either by pre-mixing the CNTs into the thermoplastic or by coating thermoplastic particles with CNTs prior to extrusion. Application of CNTs to films has been shown, but not to wires.
[0005] Utilization of CNTs with thermosets has also been shown. However, thermosets are cross-linked and cannot be melted at an elevated temperature. Finally, previous methods for dispersion of CNTs onto films did not focus on metallic CNTs in order to maximize current-carrying capability or high conductivity.
[0006] The above mentioned proposed methods for fabricating wires that incorporate CNTs will encounter large viscosities, due to the large volume of CNTs compared to the overall volume of CNTs and the polymer into which the CNTs are dispersed. Another issue with such a method is insufficient alignment of the CNTs. Finally, the proposed methods will not produce the desired high concentration of CNTs.
BRIEF DESCRIPTION
[0007] In one aspect, a conductive wire is provided. The wire includes a plurality of thermoplastic filaments each comprising a surface, and a coating material having a plurality of carbon nanotubes dispersed therein. The coating material is bonded to the surface of each thermoplastic filament. The thermoplastic filaments are bundled and bonded to each other to form a substantially cylindrical conductor.
[0008] In another aspect, a method for fabricating a conductive polymer is provided. The method includes providing a plurality of thermoplastic filaments, applying a coating material to a surface of the filaments, along an axial length thereof, the coating material including carbon nanotubes dispersed therein, and melt-processing the coated filaments to bond the coating to the filaments.
[0009] In still another aspect, a method for fabricating a conductor is provided. The method includes applying a coating material that includes magnetically aligned carbon nanotubes to a plurality of thermoplastic filaments and heating the coated filaments to bond the coating material to the filaments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a flowchart illustrating a conductor fabrication process that incorporates carbon nanotubes.
[0011] FIG. 2 is a series of cross-sectional diagrams further illustrating a conductor fabricated utilizing the process of FIG. 1 .
[0012] FIG. 3 is a block diagram that illustrates the individual components utilized in fabricating a carbon nanotube-based conductor.
DETAILED DESCRIPTION
[0013] The described embodiments seek to overcome the limitations of the prior art by placing carbon nanotubes (CNTs) on the outside of a polymer-based structure or other desired substrate to avoid the processing difficulties associated with dispersion of CNTs within the polymer before the structure is fabricated.
[0014] One embodiment, illustrated by the flowchart 10 of FIG. 1 , includes a method for producing high-conductivity electrical wires based on thermoplastics and metallic carbon nanotubes (CNTs). First, a plurality of continuous, thermoplastic, filaments are provided 12 . A coating is applied 14 to the outer surface of the fine, continuous thermoplastic filaments. The coating includes the CNTs. The coated filaments are then melt-processed 16 to form CNT-enhanced, high-conductivity thermoplastic wires. The melt-processing 16 steps include bonding the coating to the individual filaments and bonding the filaments together into a bundle onto which an outer coating, such as wire insulation, can be applied.
[0015] The process illustrated by the flowchart 10 allows for high volume fractions of aligned carbon nanotubes to be applied to the surface of a thermoplastic to produce high-conductivity wires using a continuous process. Such a process avoids the necessity for having to mix nanoparticles and/or nanotubes into a matrix resin, since the combination of the two may result in a compound having an unacceptably high viscosity. Continuing, the high viscosity may make processing of the resulting compound difficult.
[0016] FIG. 2 includes a series of cross-sectional diagrams further illustrating a conductor fabricated utilizing the process of FIG. 1 . A plurality of individual, uncoated, thermoplastic filaments 50 are provided. Through coating, one method of which is further explained with respect to FIG. 3 , the individual filaments 50 are coated with an outside layer 52 that includes the carbon nanotubes. The coated filaments 50 are then subjected to heating that bonds the coating 52 to the filaments 50 and further results in a bonding of the filaments 50 in a carbon nanotube-based conductor 60 .
[0017] The described embodiments do not rely on dispersing CNTs into a resin as described by the prior art. Instead, CNTs are placed on the outside of small-diameter thermoplastic wires as described above. One specific embodiment utilizes only high-conductivity, single-walled, metallic CNTs to maximize electrical performance. Such an embodiment relies on very pure solutions of specific CNTs instead of mixtures of several types to ensure improved electrical performance. The concentrations levels of CNTs for coating are optimized for wire, in all embodiments, as opposed to concentrations that might be utilized with, or dispersed on, films, sheets and other substrates. Specifically, in a wire-like application, high strength is not required and high stiffness is not desirable.
[0018] FIG. 3 is a block diagram 100 that illustrates the individual components utilized in fabricating a carbon-nanotube-based conductor. As mentioned herein, coating methodologies are utilized to introduce sufficiently high concentrations of CNTs into polymeric materials for high-conductivity wire as opposed to previously disclosed methods that disclose the mixing of CNTs into a resin. It is believed the currently disclosed solutions are preferable because no current solution exists for making CNT-based wires, though some methods have been proposed, as described above.
[0019] Now referring specifically to FIG. 3 , fabrication of the thermoplastic filaments is described. A thermoplastic material 102 is input 104 into an extruder 106 configured to output a thin filament 108 of the thermoplastic material which is gathered, for example, onto a take up spool 110 .
[0020] In a separate process, a solution 130 is created that includes, at least in one embodiment, thermoplastic material 132 , a solvent 134 , and carbon nanotubes (CNTs) 136 . The solution 130 , in at least one embodiment, is an appropriate solution of CNTs 136 , solvent 134 , and may include other materials such as surfactants suitable for adhering to the outer surface of the small-diameter thermoplastic filaments. In one embodiment, the solution 130 includes one or more chemicals that de-rope, or de-bundle, the nanotubes, thereby separating single-walled nanotubes from other nanotubes.
[0021] To fabricate the above described conductor, separate creels 150 of individual thermoplastic filaments 108 are passed through a bath 154 of the above described solution 130 . As the filaments 108 pass through the bath 154 , a magnetic field 156 is applied to the solution 130 therein in order to align the carbon nanotubes 136 . In a specific embodiment, which is illustrated, the CNTs 136 are single-walled nanotubes.
[0022] The magnetic field 156 operates to provide, at least as close as possible, individual carbon nanotubes for attachment to the filaments 108 . The magnetic field 156 operates to separate the de-bundled CNTs into different types and works to extract metallic CNTs that have an “armchair” configuration, which refers to the CNT having a hexagonal crystalline carbon structure aligned along the length of the CNT. Such CNTs have the highest conductivity.
[0023] The embodiments represented in FIG. 3 all relate to a continuous line suitable for coating thin, flexible, polymeric strands (filaments 108 ) with a layer of the CNT solution 130 at a sufficient thickness to achieve a desired concentration or conductivity. The magnetic field 156 , which may be the result of an electric field, is utilized to align the CNTs 136 in the solution 130 into the same direction as the processing represented in the Figure.
[0024] In one embodiment, the filaments 108 emerge from the solution 130 as coated strands 170 that may be gathered onto spools for post-processing into wire via a secondary thermoforming process. Alternatively, and as shown in FIG. 3 , the coated strands 170 may be subjected to heating, for example, in a heated die 180 to make material suitable for twisting into wire 190 . Finally, though not shown in FIG. 3 , a suitable, flexible outer coating may be applied to the wire 190 and subsequently packaged in a fashion similar to that used for metallic wire.
[0025] This written description uses examples to disclose certain embodiments, including the best mode, and also to enable any person skilled in the art to practice those embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
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A conductive wire includes a plurality of thermoplastic filaments each having a surface, and a coating material having a plurality of carbon nanotubes dispersed therein. The coating material is bonded to the surface of each thermoplastic filament. The thermoplastic filaments having the coating bonded thereto are bundled and bonded to each other to form a substantially cylindrical conductor.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to hand held devices for tamping, smoothing or impressing a specifically desired pattern or form onto recently poured concrete which has not set or cured, such as a sidewalk or another selected surface. The devices of this invention are commonly known as tampers, pounders or stampers.
[0003] 2. BACKGROUND OF THE INVENTION
[0004] U.S. Pat. No. 7,387,466 discloses a known device for imprinting patterns on concrete. The device includes a base with a cylindrical recess for receiving a cylindrical handle. The cylindrical handle is secured to the base with a pin which extends through the cylindrical recess and the cylindrical handle. One shortcoming of the '466 Patent is that it can be difficult to align a hole in the cylindrical recess with a hole the cylindrical handle to pass the pin through both holes.
SUMMARY OF THE INVENTION
[0005] A general object of the invention is to provide an improved device for tamping, smoothing or impressing a specifically desired pattern or form onto freshly poured concrete, such as on a sidewalk or another selected surface.
[0006] The improved device of this invention includes a base that is attached and secured to a handle with a pin. The base includes an opening with a non-circular cross-section for receiving the handle. The handle includes a non-circular shaped end that corresponds to the non-circular cross-section of the opening. The improved device provides a rigid connection between the handle and the base and a simple means for aligning a hole in the handle with a hole in the base so that the pin can easily pass through both holes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] These and other objects and features of this invention will be better understood from the following detailed description taken in conjunction with the drawings, wherein:
[0008] FIG. 1 is a perspective angled side view of a tamper, in accordance with one embodiment of the invention, for smoothing or impressing a pattern onto freshly poured concrete; and
[0009] FIG. 2 is a perspective side view of the tamper shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0010] The present invention provides an improved device for smoothing or impressing a specifically desired pattern or form onto uncured concrete such as, but not limited to sidewalks, driveways, streets, curbs, concrete floors or other surfaces.
[0011] FIGS. 1 and 2 illustrate a tamper 10 according to one embodiment of this invention. The tamper 10 preferably includes a base 12 and a handle 14 that are secured to each other with a pin 16 which passes through a hole in each of the base 12 and the handle 14 . In the embodiment of FIGS. 1 and 2 , the tamper 10 includes a plurality of pins 16 .
[0012] The base 12 of this invention is preferably manufactured of an elastomeric material including, but not limited to, Shore A urethane (such as Shore A urethane with a durometer in the range of 25 to 100), Shore D urethane, silicone and/or latex. The elastomeric material reduces the physical impact on a user tamping freshly poured concrete. Alternatively, the base 12 can be made of any other material useful for tamping freshly poured concrete, such as, but not limited to, metal or composite materials. Further, those skilled in the art and guided by the teachings herein provided will understand and appreciate that the base 12 can be desirably fabricated or manufactured by various techniques including, for example, injection molding. In another alternative embodiment, the base 12 may be manufactured with a core material which is a different material than a surrounding material, for example, but not limited to, a metal core surrounded by an elastomeric material.
[0013] The base 12 includes a platform 18 with a collar 20 extending from an upper surface of the platform 18 . In this embodiment, the platform 18 comprises a square or rectangular shape however, the platform 18 may comprise any shape. In an embodiment of this invention, a lower surface of the platform 18 includes a textured surface for impressing a pattern or texture onto recently poured concrete which has not set. Such as a pattern in the form or appearance of brick, stone, rock, wood or other material as may be desired in a specific or particular application. In an alternative embodiment, the lower surface of the platform 18 includes a smooth surface for tamping and/or smoothing a surface of recently poured concrete which has not set.
[0014] The collar 20 is preferably integrally formed with and extends from the upper surface of platform 18 . In this embodiment, the collar 20 comprise four surfaces that extend from the platform 18 and gradually narrow, in a pyramid-like fashion near the bottom, and transition into generally vertical surfaces that end at a generally flat top surface. However, the collar 20 is not limited to this shape and may comprise any shape capable of receiving a portion of the handle 14 . As shown in the figures, the collar 20 includes a receiver 22 comprising an opening in the flat top surface and a void extending into the collar 20 for receiving a portion of the handle 14 . In a preferred embodiment, the receiver 22 comprises a polygon-shaped cross-section that matches with an insert portion of the handle 14 allowing for easy alignment of holes for receiving the pin 16 . In the embodiment of FIGS. 1 and 2 , the receiver 22 comprises a square-shaped opening however, the receiver 22 may comprise any non-circular shape including, but not limited to, a triangular shape, a rectangular shape, an elliptical shape, a star shape, a pentagon shape and a hexagon shape.
[0015] As shown in FIGS. 1 and 2 , the handle 14 includes a polygon-shaped handle terminal end 24 that is designed to match the polygon-shaped receiver 22 of the base 12 . In this embodiment, the handle 14 includes an upper cylindrical portion that transitions into a polygon-shaped handle terminal end 24 . In an alternative embodiment, the handle 14 may comprise a uniform polygon-shape along an entire length of the handle without a transition portion. The polygon-shaped handle terminal end 24 of FIGS. 1 and 2 comprises a square shape however, the handle insert 24 may comprise any non-circular shape including, but not limited to, a triangular shape, a rectangular shape, an elliptical shape, a star shape, a pentagon shape and a hexagon shape.
[0016] The collar portion 20 and the handle terminal end 24 each include holes which must be aligned so that the pin 16 can pass through both holes to secure the base to the handle. The polygon-shaped receiver 22 and the matching polygon-shaped handle terminal end 24 simplifies the alignment process by restricting the number of ways that the handle terminal end 24 can fit into the receiver 22 .
[0017] In an alternative embodiment of this invention, the tamper 10 may be used with a mat, not shown, that includes a surface with a textured or smooth surface for impressing a pattern or texture onto recently poured concrete or for smoothing recently poured concrete. The mat may be placed on uncured concrete and the tamper 10 may be used to press the mat into the uncured concrete to create a surface impression in the concrete.
[0018] The invention illustratively disclosed herein suitably may be practiced in the absence of any element, part, step, component, or ingredient which is not specifically disclosed herein.
[0019] While in the foregoing detailed description this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purposes of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.
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A hand held device tamping, smoothing or impressing a specifically desired pattern or form onto freshly poured concrete, such as on a sidewalk or another selected surface. The hand held device including a base and a handle, the base having a non-circular shaped receiver which matches with a non-circular cross-section portion of the handle to provide a rigid connection between the handle and the base and a simple means for aligning a hole in the handle with a hole in the base for a pin to pass through.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application having Ser. No. 61/798,551, filed on Mar. 15, 2013, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This disclosure relates generally to electrical circuits, and more particularly to a radio frequency (RF) transmission apparatus with reduced power consumption.
[0004] 2. Description of Related Prior Art
[0005] FIG. 1 , panel A, depicts a top view of a conventional wireless communication device 100 . Common wireless communication devices include cellular phones, wireless networking devices, wireless handsets, personal digital assistants (PDAs), laptop and desktop computers, routers, and key fobs. As shown, the wireless communication device 100 includes a battery 102 , a digital signal processor (DSP) 104 , a transceiver 106 , a power amplifier 108 , an antenna 110 , and other electronic circuitry 112 . The battery 102 provides direct current (DC) power to other device components. The digital signal processor (DSP) 104 manipulates communication signals between analog and digital signal processing domains, while the transceiver 106 up and down converts the communication signals between low frequencies and RF frequencies. The power amplifier 112 amplifies a power of the signal output from the transceiver to drive a transmission signal into the antenna 110 . In turn, the antenna 110 transmits the transmission signal into free space. A receiver of another wireless communication device (not shown) may receive the radiated signal through a receiver antenna and process the received signal, thus allowing wireless communication of information between the wireless communication device 100 and the other wireless communication device.
[0006] Panel B depicts a side view of the conventional wireless communication device 100 . As shown, the antenna 110 and electronic circuitry components 140 (e.g., the DSP 104 , the transceiver 106 , etc.) are mounted on a substrate 130 such as a printed circuit board (PCB). In addition, the wireless communication device 100 includes an electrical shield 150 which can serve two purposes: (1) preventing internally generated electrical signals from radiating out to affect the function of other components; and (2) preventing externally generated electrical signals from radiating in to affect the function of the components 140 .
[0007] FIG. 2 depicts an enclosure of a convention wireless communication device. Panel A shows a wireless phone device 200 and panel B shows a wireless tablet device 250 . As illustrated in panel A, the wireless phone device 200 includes antenna(s) 210 for transmitting and/or receiving radio frequency signals. The wireless phone device 200 further includes a key pad 220 for tactile input and a display screen 230 for display and/or tactile input. Although a physical key pad 220 is shown, the wireless phone device 200 may alternatively include a virtual key pad (not shown), which is a software component that permits key stokes to be made via, e.g., a touch screen. In addition, the wireless phone device 200 includes casing which holds all the electronic components and component mounting substrates of the wireless phone device 200 . The casing may also electrically isolate the internal components of the wireless phone device 200 from the exterior. A back cover (not shown) of the wireless phone device 200 may also include casing made from various materials. Similarly, the wireless tablet device 250 includes antenna(s) 260 , a key pad 270 (or a virtual keypad), and a display screen 280 which may generally perform the same functions as the antenna(s) 210 , the key pad 220 , and the display screen 230 of the wireless phone device 200 . In addition, the wireless tablet device 250 may also include a casing that encloses electronic components and component mounting substrates and electrically insulates these components, as well as a back cover.
SUMMARY OF INVENTION
[0008] Embodiments of the invention described herein enable radio frequency (RF) transmission devices to receive transmission power that is radiated onto the surfaces of the devices. In one embodiment, a wireless device is provided. The wireless device includes a transmitter having a transmitter antenna and configured to transmit a signal. The wireless device also includes an energy receiver having a plurality of energy receiver antenna elements positioned across one or more surfaces of the wireless device. The energy receiver antenna elements are each configured to receive a portion of the signal, convert the portion of the signal into (DC) power, and provide the (DC) power to one or more components of the wireless device.
[0009] In another embodiment, a wireless device is provided that includes a transmitter having a transmitter antenna and an energy receiver antenna. The transmitter antenna is configured to transmit a signal. The wireless device also includes an energy receiver having a receiver antenna and configured to receive a portion of the signal, convert the portion of the signal into power, and provide the power to one or more components of the wireless device. The receiver antenna is configured as a weakened antenna which does not efficiently receive the portion of the signal.
[0010] In yet another embodiment, a wireless device is provided that includes a transmitter having a transmitter antenna and an energy receiver having first and second receiver antennas. The transmitter antenna is configured to transmit a signal. The first and second receiver antennas are configured to receive a portion of the signal, convert the portion of the signal into power, and provide the power to one or more components of the wireless device. Frequency centers of the transmitter antenna and the first receiver antenna are matched, while frequency centers of the transmitter antenna and the second receiver antenna are not matched.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of 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.
[0012] FIG. 1 illustrates top and side views of a conventional wireless device.
[0013] FIG. 2 depicts an enclosure of a convention wireless communication device.
[0014] FIG. 3 is a block diagram of a wireless communication device configured to receive power from its own transmissions, according to an embodiment.
[0015] FIG. 4 illustrates matched energy receiver antennas substantially covering the surface of a wireless communication device, according to an embodiment.
[0016] FIG. 5 illustrates mismatched energy receiver antennas substantially covering the surface of a wireless communication device, according to an embodiment.
[0017] FIG. 6 illustrates combining matched and mismatched energy receiver antennas to substantially cover the surface of a wireless communication device, according to an embodiment.
[0018] FIG. 7 illustrates use of energy receiver antennas as electrical shields in a wireless communication device, according to an embodiment.
[0019] For clarity, identical reference numbers have been used, where applicable, to designate identical elements that are common between figures. It is contemplated that features of one embodiment may be incorporated in other embodiments without further recitation.
DETAILED DESCRIPTION
[0020] FIG. 3 depicts a wireless communication device 302 configured to receive power from its own transmissions, according to an embodiment. As shown, the wireless communication device 302 includes direct current (DC) power source(s) 306 that provide power to a modulator 310 , power amplifier(s) 312 , and components performing other functions of the wireless communication device transmitter (TX) 308 which may include a transmit processor having a time variant transmit carrier frequency or frequencies (Fc or Fc(s)). The wireless communication device 302 further includes (optional) regulators 314 , 316 , 318 that respectively provide correct voltage and/or current regulation to the components 308 , the modulator 310 , and the power amplifier(s) 312 . The modulator 310 may include a voltage controlled oscillator and phase lock loop to select a given transmit frequency from a range of possible transmit frequencies. The power amplifier 312 amplifies a power of a modulated signal output from the modulator 310 . The output of the power amplifier 312 (also referred to herein as “TX signal power”) is transmitted through a transmit antenna 328 into free space. Remote receiver antenna(s) 332 may then receive the radiated signal and process the received signal, thus allowing wireless communication of information between the wireless device 302 and the remote wireless device 340 .
[0021] RF transmit (TX) signal power radiated by transmit antenna(s) 328 may be high in order to compensate for the distance from remote receiver antenna(s) 332 and to compensate for any signal power lost due to DC power signal(s) circuitry objects blocking the signal path. As is well known, RF signal power degrades by distance squared. For example, if transmit antenna(s) 328 transmit 1-2 Watts of RF signal power, the remote receiver antenna(s) 332 might only receive a few uW of RF signal power. This low level of RF signal power is typically enough for functional wireless communication.
[0022] As shown, the wireless communication device 302 includes an energy receiver 320 that includes an energy receiver (ERX) antenna 330 and energy receiver circuitry element(s) 322 configured to receive a time variant communication signal and alternating current (AC) to DC converter(s) 324 configured to convert the received communication signal into DC power. That is, RF transmission signal power generated by the transmit antenna(s) 328 is received and converted into DC power which can provide electrical power to the wireless device 302 for operation and/or battery charging. The energy receiver 320 further includes a DC power management circuit 326 that can provide proper voltage levels of DC power to circuits (or components) within the wireless communication device 302 .
[0023] As shown, the energy receiver antenna(s) 330 are placed within a short, fixed distance D short (s) from transmit antenna(s) 328 . Because the distance between the transmit antenna(s) 328 and the energy receiver antenna(s) 330 is short, a substantial amount of transmission signal power can be received at the energy receiver antenna(s) 330 and converted for DC power use. One approach for receiving and converting such transmission signal power is described in U.S. Pat. No. 8,416,721, which is hereby incorporated by reference in its entirety.
[0024] FIG. 4 illustrates matched energy receiver antennas substantially covering the surface of a wireless communication device 400 , according to an embodiment. As shown in panel A, the wireless communication device 400 includes transmit antenna(s) 402 and one or more matched energy receiver antenna(s) 404 covering a surface of the wireless phone device 400 . Illustratively, the frequency of the energy receiver antenna(s) 404 are deliberately matched to the transmission frequency of the wireless device's 400 own transmit antenna(s) 402 . Panel B illustrates a graph of the transmission signal power spectral envelope density versus frequency in the wireless communication device 400 having energy receiver antenna(s) 404 matching the frequency of transmit antenna(s) 402 . As shown, the frequency 401 of the energy receiver antenna is matched to the frequency center of the transmit antenna. The matching of the frequency of the energy receiver antenna(s) 404 to the transmission frequency of the transmit antenna(s) 402 permits the energy receiver antenna(s) 404 to most efficiently receive the transmission power radiated onto the surface of the wireless phone device 400 .
[0025] In one embodiment, the surface of the wireless device 400 may be maximally covered by energy receiver antenna(s) 404 , except for areas needed for other critical functions, such as the screen, key pad, and transmit/receiver antennas. In another embodiment, energy receiver antenna(s) 404 may also be placed under the key pad, screen, etc. Trial and error and/or antenna software simulation may be used to determine the spacing needed between energy receiver antenna(s) 404 and transmit antenna(s) 402 to prevent interference to the transmission and receiving functions required by the wireless device 400 . More specifically, an effective distance between the energy receiver antenna(s) 404 and the transmit/receiver antenna(s) may be determined based on various optimization factors, such as maximizing the energy received, with the least amount of interference to the transmission, and placing the energy receiver antenna(s) at an effective distance to the transmit antenna(s) 404 .
[0026] Experience has shown that, in a particular embodiment, a 34% power consumption reduction was achieved when the surface of a typical wireless device was covered with matched antenna(s), with the entire back surface and the left, right, and bottom sides covered with matched antenna(s) and only the keypad, screen and half an inch within the transmit/receiver antenna being left un-covered. Further, no significant transmission/reception signal impairment was measured.
[0027] FIG. 5 illustrates mismatched energy receiver antennas substantially covering the surface of a wireless communication device 500 , according to an embodiment. As shown, the wireless communication device 500 includes antenna(s) for transmission of signals as well as energy receiver antenna(s) 504 configured to receive transmission power from the transmit antenna(s) 502 so that the transmission power can be converted to energy for use by the wireless communication device 500 .
[0028] The energy receiver antenna(s) 504 are deliberately weakened so as to not efficiently receive the transmission power radiated by the transmit antenna 502 (s). A number of organic and non-organic materials such as human tissue, printed circuit boards, wireless device casing, are capable of absorbing radiated RF transmission power to varying degrees. For example, human tissue acts as an inefficient antenna which does not match a transmit antenna frequency center. In one embodiment, the energy receiver antenna(s) 504 may be constructed from such materials.
[0029] In another embodiment, energy receiver antenna(s) 504 may be deliberately weakened by shifting the frequency center of the energy receiver antenna(s) 504 away from the frequency center of the transmit antenna(s) 502 by, e.g., calibrating the energy receiver antenna(s) 504 to be mismatched with the transmit antenna(s) 502 . Panel B illustrates a graph of the transmission signal power spectral envelope density versus frequency in the wireless communication device 500 having mismatched energy receiver antenna(s) 504 . This mismatching makes the energy receiver antenna(s) 504 less efficient at receiving the transmission power radiated onto the surface of the wireless device 500 . As a result, one or more mismatched energy receiver antenna(s) 504 may be placed next to the transmit/receiver antenna 502 , at a closer distance than matched energy receiver antennas could be placed, without affecting normal RF functions. Because transmission RF power degrades by distance squared, less efficient energy receiver antennas placed closer to the transmit antenna(s) 502 may actually be equal to or more efficient than matched energy receiver antennas placed further away from the transmit antenna(s) 502 .
[0030] Illustratively, the wireless device 500 is maximally covered by the mismatched energy receiver antenna(s) 504 , except for regions needed for other critical functions, such as a key pad, display screen, and transmit/receiver antenna(s). In another embodiment, energy receiver antenna(s) may also be placed underneath the key pad and/or the display screen. If necessary to prevent interference to transmission/reception functions, the spacing between the energy receiver antenna(s) 504 and transmit/receiver antennas may be obtained by trial and error and/or antenna software simulation.
[0031] Experience has shown that in a particular embodiment, in which a wireless devices with non-matching transmit antennas having different communication standards/frequencies than energy receiver antennas were placed in close proximity to the energy receiver antennas, the energy receiver antennas still received non-matching transmission power which could be converted to DC power. In addition, no substantial transmission/reception signal power degradation was measured.
[0032] FIG. 6 illustrates combining matched and mismatched energy receiver antennas to substantially cover the surface of a wireless communication device 600 , according to an embodiment. As shown in panel A, the wireless communication device 600 includes two rows of mismatched, and deliberately less efficient, antenna(s) 604 placed close to the wireless device's 600 transmit antenna(s) 602 . As discussed, the deliberately less efficient antenna(s) 604 may be, e.g., made of materials capable of absorbing radiated RF transmission power but not interfering with transmission or reception of RF signals. The less efficient antenna(s) 604 may also have frequency center(s) that are mismatched with frequency center(s) of the transmit antenna(s) 602 . The wireless device 600 also includes rows of matched antennas 606 placed further away from the wireless device's 600 transmit antenna(s) 602 than the mismatched antenna(s) 604 are placed. As discussed, the matched antenna(s) 606 can receive radiated transmission power more efficiently than the mismatched antennas 604 . Panel B illustrates a graph of the transmission signal power spectral envelope density versus frequency in the wireless communication device 600 having both matched energy receiver antenna(s) 606 and mismatched energy receiver antenna(s) 604 . Once again, to prevent interference to the transmission/reception functions of the wireless device 600 , the spacing needed between energy receiver antenna(s) 604 , 606 and transmit/receiver antenna(s) may be obtained by trial and error and/or antenna software simulation. By using both mismatched antennas 604 and matched antennas 606 , it is possible to maximize the space on the surface of the wireless device 600 on which energy receiver antennas are placed.
[0033] FIG. 7 depicts use of energy receiver antennas as electrical shields in a wireless communication device 700 , according to an embodiment. As shown, the wireless communication device 700 includes a transmit antenna 710 and electronic circuitry components 740 mounted on a substrate 730 . The transmit antenna 710 , electronic circuitry components 740 , and substrate 730 may be similar to the transmit antenna 110 , electronic circuitry components 140 , and substrate 130 of the wireless communication device 100 , discussed above. Rather than the electrical signal shields 150 of the wireless communication device 100 , however, the wireless communication device 700 includes energy receiver antennas 750 . The energy receiver antenna(s) 750 may have any feasible shape, including the same shape as the electrical signal shields 150 . In addition to receiving radiated transmission power, the energy receiver antenna(s) 750 may also perform the same function as the electrical signal shields 150 , namely preventing internally generated electrical signals from radiating out and affecting the function of other devices and preventing externally generated electrical signals from radiating in to affect the function of the electronic circuitry components 740 . As a result, energy receiver antennas 750 may replace electrical signal shields which are grounded. Replacing such electrical signal shields with energy receiver antennas 750 permits maximal use of available space for energy receiver antennas.
[0034] Advantageously, wireless devices disclosed herein include energy receiver antennas that receive the wireless devices' own transmission signals that are radiated onto the surfaces of the wireless devices. The received transmission signals are then converted to DC power that can be provided to various components of the wireless devices. Doing so reduces power consumption by the wireless devices and extends battery life.
[0035] While the forgoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof.
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A system for enhancing power efficiency of a wireless device is disclosed. In one embodiment, the wireless device includes a transmitter having a transmitter antenna and configured to transmit a signal, as well as an energy receiver having a plurality of energy receiver antenna elements positioned across one or more surfaces of the wireless device. The energy receiver antenna elements are each configured to receive a portion of the signal, convert the portion of the signal into power, and provide the power to one or more components of the wireless device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/549,994, now U.S. Pat. No. 8,605,393, filed on Jul. 16, 2012, which is a continuation of U.S. patent application Ser. No. 13/281,078, now U.S. Pat. No. 8,228,648, filed on Oct. 25, 2011, which is a continuation of U.S. patent application Ser. No. 12/388,972, now U.S. Pat. No. 8,045,302, filed on Feb. 19, 2009, which claims the benefit of U.S. Provisional Application No. 61/030,105, filed on Feb. 20, 2008. The entire disclosures of the applications referenced above are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to grid fault detection and compressor protection, and more particularly to low grid voltage detection.
BACKGROUND
[0003] The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
[0004] Compressors are used in many residential and commercial settings, such as for heating, ventilation, and air conditioning (HVAC) systems and cooling/refrigeration systems. While starting, current drawn by the compressor is often high because the compressor motor's inductance has a very low resistance at low frequencies. As the speed of the motor increases, the current decreases.
[0005] However, as the voltage supplied to the compressor drops, the current increases. When power is provided to the compressor from an electrical grid, decreases in voltage of the electrical grid will cause the compressor's current to increase. A voltage decrease may occur on the grid in various circumstances, such as if a substation or transmission line fails. This voltage decrease may result in a dramatic increase in current drawn by the compressor.
SUMMARY
[0006] A compressor monitoring system includes current and voltage monitors, current and voltage averaging modules, a control module, and a switch. The current monitor measures a current drawn by a motor of a compressor. The current averaging module generates first and second average current values based on the current measured by the current monitor. The voltage monitor measures a utility power voltage. The voltage averaging module generates first and second average voltage values based on the voltage measured by the voltage monitor. The control module selectively generates a fault signal when a first ratio is greater than a first predetermined threshold and a second ratio is less than a second predetermined threshold. The first ratio is based on the first and second average current values. The second ratio is based on the first and second average voltage values. The switch deactivates the motor when the fault signal is generated.
[0007] In other features, the first ratio is based on the second average current value divided by the first average current value. The second ratio is based on the second average voltage value divided by the first average voltage value. The second average current and voltage values are generated after the first average current and voltage values. The first predetermined threshold is approximately 2. The second predetermined threshold is approximately 0.8.
[0008] In further features, the current averaging module generates each of the first and second average current values by averaging M contiguous current values from the current monitor. The voltage averaging module generates each of the first and second average voltage values by averaging N contiguous voltage values from the voltage monitor, wherein M and N are integers greater than one. M and N are equal to eight.
[0009] In still other features, each of the current values from the current monitor corresponds to a period of a periodic input power signal, Each of the voltage values from the voltage monitor corresponds to the period of the periodic input power signal. The second average current and voltage values are generated P periods after the first average current and voltage values, and wherein P is equal to one of M and N. The control module determines an operating current threshold and generates the fault signal when current values from the current monitor exceed the operating current threshold for a predetermined length of time. The control module sets the operating current threshold based on a peak startup current.
[0010] In other features, the control module determines the peak startup current based on a maximum one of the current values during a startup period of time after the motor starts. The startup period of time is approximately 200 ms. The predetermined length of time is approximately 800 ms. The control module generates the fault signal when the current value at an end of the startup period of time exceeds the operating current threshold. The control module determines the operating current threshold based on a product of the peak startup current and approximately 0.4.
[0011] In further features, the compressor monitoring system further comprises a mass flow sensor that measures a mass flow of gas in the compressor and outputs mass flow values. The control module generates the fault signal when the mass flow values decrease by more than a predetermined amount. The compressor monitoring system further comprises a temperature sensor that measures a temperature of the compressor and outputs temperature values. The control module generates the fault signal when a rate of change of the temperature values exceeds a predetermined rate.
[0012] In still other features, the compressor monitoring system further comprises a vibration sensor that determines a vibration profile of the compressor. The control module generates the fault signal when the vibration profile changes by more than a predetermined amount. The vibration profile includes a fundamental frequency of vibration. The compressor monitoring system further comprises a power factor monitoring module that determines a power factor of the motor and outputs power factor values. The control module generates the fault signal when the power factor values decrease by more than a predetermined amount.
[0013] A method comprises measuring a current drawn by a motor of a compressor; generating first and second average current values based on the measured current; measuring a utility power voltage; generating first and second average voltage values based on the measured voltage; determining a first ratio based on the first and second average current values; determining a second ratio based on the first and second average voltage values; selectively generating a fault signal when the first ratio is greater than a first predetermined threshold and the second ratio is less than a second predetermined threshold; and deactivating the motor when the fault signal is generated.
[0014] In other features, the method further comprises determining the first ratio based on the second average current value divided by the first average current value; and determining the second ratio based on the second average voltage value divided by the first average voltage value. The second average current and voltage values are generated after the first average current and voltage values. The first predetermined threshold is approximately 2. The second predetermined threshold is approximately 0.8.
[0015] In further features, the method further comprises generating each of the first and second average current values by averaging M contiguous current values; and generating each of the first and second average voltage values by averaging N contiguous voltage values, wherein M and N are integers greater than one. M and N are equal to eight. Each of the current values corresponds to a period of a periodic input power signal. The first and second voltage values correspond to the period of the periodic input power signal. The second average current and voltage values are generated P periods after the first average current and voltage values, and wherein P is equal to one of M and N.
[0016] In still other features, the method further comprises determining an operating current threshold; and generating the fault signal when current values from the current monitor exceed the operating current threshold for a predetermined length of time. The method further comprises setting the operating current threshold based on a peak startup current. The method further comprises determining the peak startup current based on a maximum one of the current values during a startup period of time after the motor starts. The startup period of time is approximately 200 ms. The predetermined length of time is approximately 800 ms.
[0017] In other features, the method further comprises generating the fault signal when the current value from the current monitor at an end of the startup period of time exceeds the operating current threshold. The method further comprises determining the operating current threshold based on a product of the peak startup current and approximately 0.4. The method further comprises measuring a mass flow of gas in the compressor; and generating the fault signal when measured mass flow decreases by more than a predetermined amount.
[0018] In further features, the method further comprises measuring a temperature of the compressor; and generating the fault signal when a rate of change of the measured temperature exceeds a predetermined rate. The method further comprises determining a vibration profile of the compressor; and generating the fault signal when the vibration profile changes by more than a predetermined amount. The vibration profile includes a fundamental frequency of vibration. The method further comprises determining a power factor of the motor; and generating the fault signal when the power factor decreases by more than a predetermined amount.
[0019] A compressor monitoring system comprises a current monitor, a voltage monitor, a power factor monitor, an averaging module, a control module, and a switch. The current monitor measures a current drawn by a motor of a compressor. The voltage monitor measures a voltage of the motor. The power factor monitor calculates a power factor of the motor based on the measured current and the measured voltage and generates power factor values. The averaging module generates a first average power factor value based on the power factor values and later generates a second average power factor value based on the power factor values. The control module selectively generates a fault signal when a ratio is less than a predetermined threshold. The control module calculates the ratio based on the second average power factor value divided by the first average power factor value. The switch deactivates the motor when the fault signal is generated.
[0020] In other features, the predetermined threshold is approximately 0.8. The averaging module generates each of the first and second average power factor values by averaging M contiguous power factor values, wherein M is an integer greater than one. M is equal to eight. Each of the power factor values corresponds to a period of a periodic input power signal. The averaging module generates the second average power factor value M periods after the first average power factor value.
[0021] Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0023] FIG. 1A is a graphical depiction of a compressor motor turn-on event;
[0024] FIG. 1B is a graphical depiction of a compressor motor turn-on event where a rotor of the compressor has stalled;
[0025] FIG. 2 is a graphical depiction of gradual motor failure during motor operation;
[0026] FIG. 3 is a graphical depiction of rapid motor current increase as may happen during a grid failure;
[0027] FIG. 4 is a graphical depiction of measured voltage and current for a compressor motor during a grid fault;
[0028] FIGS. 5A-5B are flowcharts depicting exemplary operation of a control system that implements rotor stall detection and grid stall detection;
[0029] FIG. 6 is a functional block diagram of an exemplary implementation of a compressor system;
[0030] FIG. 7 is a functional block diagram of another exemplary implementation of a compressor system; and
[0031] FIGS. 8-9 are functional block diagrams of exemplary integrated compressor systems.
DETAILED DESCRIPTION
[0032] The following description is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical OR. It should be understood that steps within a method may be executed in different order without altering the principles of the present disclosure.
[0033] As used herein, the term module refers to an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.
[0034] When a problem occurs within an electrical distribution grid, the grid voltage may decrease. This decrease in voltage causes compressors connected to the grid to increase their current draw rapidly. As there are often many compressors connected to the grid, the increase in current is amplified. The operator of the electrical grid may isolate a problem area, such as a failed substation or transmission line, and remove the problem area from the grid.
[0035] However, by the time the problem is isolated, the compressors may already be drawing such a large current that the remaining parts of the grid cannot meet the current requirements, causing the voltage to sag further. The positive feedback between voltage sagging and compressor current increasing causes the current to increase rapidly. At a certain voltage, compressors may begin to stall. A stalled compressor draws a large current, which may be similar to the current it would draw upon start-up.
[0036] Eventually, the high current heats the compressor to a point where a thermal protection circuit powers off the compressor. Before thermal protection turns off most of the compressors, the original electrical grid fault may have been remedied. In addition, supplemental generation facilities and/or energy storage facilities may have been brought online in an attempt to meet the increased current demand.
[0037] Once the compressors turn off due to thermal overload, the demand on the grid decreases. The presence of the supplemental facilities may then cause the electrical grid voltage to overshoot the desired grid voltage. The additional generation and storage facilities may then be deactivated to reduce the grid voltage. As the grid voltage is decreasing to the desired voltage, the compressors, which had previously powered down due to thermal overload, may have cooled enough to come online once more. This increased demand may trigger another low voltage event. These problems may be difficult to mitigate at the grid level, motivating the desire for a solution that applies to the individual compressor.
[0038] Referring now to FIG. 1A , a graphical depiction of a compressor motor turn-on event is presented. At time zero, the motor turns on, and the motor current quickly increases to a peak 102 . The current at the peak 102 may define a peak current 104 . During normal operation, the peak 102 may occur within a predetermined time, such as 200 milliseconds (ms). The peak current 104 may therefore be determined by determining the largest current value within that predetermined time.
[0039] An operating current threshold 106 may be defined. The operating current threshold 106 may be defined proportionally to the peak current 104 . For example only, the operating current threshold 106 may be equal to 0.4 times the peak current 104 . Alternatively, the operating current threshold 106 may be a predetermined value. During normal operation, the motor current remains below the operating current threshold 106 . The motor current may typically fall from the peak current 104 to below the operating current threshold 106 within a predetermined time after start-up, such as 800 ms.
[0040] Referring now to FIG. 1B , a graphical depiction of a compressor motor turn-on event where a rotor of the compressor has stalled is presented. Upon start-up, the motor current increases to a peak 120 . A peak current 122 is defined at the peak 120 , and an operating current threshold 124 is determined. In FIG. 1B , the rotor of the compressor has stalled, and so the motor current does not drop below the operating current threshold 124 by a predetermined time, such as 800 ms. If the motor current has not dropped below the operating current threshold 124 , a fault may be identified. Eventually, the high current would heat the compressor and trip thermal overload protection. However, the compressor can be powered off immediately upon identifying the fault.
[0041] Referring now to FIG. 2 , a graphical depiction of gradual motor failure during motor operation is presented. At the left side of the graph, the motor is operating with a current below an operating current threshold 202 . The motor current begins to increase, and eventually crosses the operating current threshold, as indicated at 206 . A fault may immediately be declared if the current exceeds the operating current threshold 202 . However, this may cause false positives when a transient causes the motor current to only briefly exceed the operating current threshold 202 .
[0042] To prevent false positives, a delay may be defined. If the motor current remains above the operating current threshold 202 for the length of the delay, a fault may be declared. For example only, the length of the delay may be 800 ms. This value may correspond to the time at which the motor current has decreased from the peak current level, as shown in FIG. 1A , or may be determined independently.
[0043] As shown in FIG. 2 , the motor current is still above the operating current threshold 202 after 800 ms, as indicated at 210 . A fault may then be declared, and may be classified as a rotor stall event. Without the rotor stall detection, the motor current may continue to increase until the high current heats the compressor, and thermal overload eventually occurs, as indicated at 214 .
[0044] Referring now to FIG. 3 , a graphical depiction of rapid motor current increase, as may happen during a grid failure, is presented. At the left of FIG. 3 , the motor current is below an operating current threshold 250 . In response to a grid fault, which may cause a sudden decrease in grid voltage, the motor current begins to rapidly increase, as indicated at 252 .
[0045] At 254 , the motor current has exceeded the operating current threshold 250 . When using rotor stall detection, such as is described above with respect to FIG. 2 , the compressor will be turned off after 800 ms. Without rotor stall detection, the compressor may turn off due to thermal protection after between approximately 3.5 and 10 seconds. The fact that the current rises so rapidly may be used to identify a fault without waiting for the delay (such as 800 ms) of rotor stall detection.
[0046] For example, if a moving average of the current is calculated, and that moving average doubles, a fault may be declared and the compressor may be powered off. For example, a doubling of the current moving average may be ascertained within 200 ms. This fault may be characterized as a grid stall. Grid stalls may also be identified by decreases in voltage. For example, a grid stall may be identified when a moving average of current doubles while a moving average of voltage decreases by a percentage, such as 20 percent. Further measurements that may detect grid stalls, such as vibration, mass flow, temperature, and power factor, are discussed below with respect to FIG. 8 .
[0047] The amount of decrease in voltage or increase in current used to identify grid faults may vary based upon the parameters of the grid and the characteristics of the compressor. For example, the percentage increase in current may be increased to prevent false positives, where a fault is identified when none exists. The current percentage may be decreased to prevent false negatives, where a grid fault is missed because it did not occur quickly enough. The chosen current percentage may balance these factors for a particular system. For example only, the current percentage may be approximately 100 percent or a greater or lesser value.
[0048] In addition, the percentage decrease in voltage may be chosen similarly. Identifying a stall only when a large percentage decrease occurs between adjacent averages may cause slower-occurring grid faults to be missed. Using a small percentage decrease may misidentify normal grid voltage changes as grid faults. For example only, the voltage percentage may be approximately 20 percent, approximately 30 percent, a value between 20 and 30 percent, or a greater or lesser value. For ease of explanation only, a current percentage of 100 percent and a voltage percentage of 20 percent will be described herein.
[0049] Referring now to FIG. 4 , a graphical depiction of measured voltage and current for a compressor motor during a grid fault is presented. Each division along the x-axis may represent a line cycle. For example, with 50 Hertz (Hz) power, a line cycle occurs approximately every 20 ms. For 60 Hz power, a line cycle occurs approximately every 17 ms. A moving average may be calculated for both the voltage and the current.
[0050] For example only, the moving average may be performed over the last 8 line cycles. The moving average calculated at any point may be compared to the moving average calculated eight line cycles before. In other words, the windows that are being compared may be two consecutive eight-line-cycle windows. For example only, as shown in FIG. 4 , after measurements of current and voltage have been performed at cycle 147 , the moving averages for both voltage and current can be compared.
[0051] The most recent moving average covers the eight previous samples (line cycles 140 - 147 ), while the comparison moving average covered line cycles 132 - 139 . It appears from FIG. 4 that the moving average of current for the second set of line cycles is double that for the first set of line cycles. In addition, the average of voltage for the second set of line cycles is more than 20 percent below the average for the first set of line cycles.
[0052] At the end of line cycle 147 , a grid fault may therefore be declared, and the compressor shut down. The length of the moving average, the percentage increase in current, and the percentage decrease in voltage are presented for example only, and can be tailored for the application. In addition, they may be adapted based on such factors as previous grid faults and/or compressor operating conditions.
[0053] Referring now to FIGS. 5A-5B , flowcharts depict exemplary operation of a control system that implements rotor stall detection and grid stall detection. Control begins in step 302 , where variables RotorStallCount and GridStallCount are initialized. RotorStallCount tracks the number of times that a rotor stall event has been declared.
[0054] RotorStallCount may be reset after a predetermined period of time where no rotor stall events have been declared. In addition, RotorStallCount may be reset by a service technician, either onsite or remotely. GridStallCount may track the number of grid faults that have been declared. GridStallCount may be reset after a predetermined period of time where no grid faults have been declared. Additionally, GridStallCount may be reset at times when RotorStallCount is reset.
[0055] Control continues in step 304 , where control determines whether the measured voltage is greater than 175 Volts (V). If so, control continues in step 306 ; otherwise, control transfers to step 308 . The comparison in step 304 is performed to ensure that there is adequate voltage to start the compressor.
[0056] The value of 175 V is presented for example only and may correspond to 240 V power. The value of 175 V may correspond to a value below which the compressor will stall and/or will draw substantially more current. In various implementations, step 304 may monitor the grid voltage for a predetermined period of time before continuing. For example, control may determine whether the grid voltage remains above 175 V for a predetermined period of time, such as 400 ms.
[0057] In step 308 , control waits until the voltage increases above 185V. Once the voltage increases above 185 V, control transfers to step 306 ; otherwise, control remains in step 308 . In various implementations, control only transfers to step 306 after the voltage is above a threshold for a predetermined period of time. For example, control may transfer to step 306 after the voltage has been above 185 V for 15 seconds.
[0058] The predetermined period of time may be adjusted based on the lowest value measured for the grid voltage. Alternatively, the predetermined period of time may be adjusted based on the grid voltage measured in step 304 . The predetermined period of time may be determined such that the compressor is not started before the grid voltage has stabilized at a sufficient level.
[0059] In step 306 , a PeakCurrent variable is initialized. In addition, two timers, labeled Timer and Ontime, are reset. Timer is used to track various time periods, and Ontime is a measure of how long the compressor has been running. Control continues in step 310 , where the compressor is started.
[0060] Control continues in step 312 , where the maximum of PeakCurrent and the latest measured current value is stored back into PeakCurrent. Control continues in step 314 , where control determines whether Timer has reached 200 ms. If so, control transfers to step 316 ; otherwise, control returns to step 312 . This 200 ms value is presented for example only, and corresponds to the length of time within which the peak motor current should have been achieved.
[0061] In step 316 , control determines whether Timer has exceeded 800 ms. If so, control transfers to step 318 ; otherwise, control remains in step 316 . The value of 800 ms is presented for example only, and corresponds to the length of time within which the motor current should have fallen below the operating current threshold.
[0062] In step 318 , the most recently measured current value is compared to the operating current threshold. For example, the operating current threshold may be defined as 0.4*PeakCurrent. If the most recently measured current value is above the operating current threshold, control transfers to step 320 ; otherwise, control continues in step 319 .
[0063] In step 319 , control resets Timer and a second timer (Timer2), and control continues via letter A in step 322 of FIG. 5B . In step 320 , control turns off the compressor. Control continues in step 324 , where RotorStallCount is incremented to reflect the detection of a rotor stall event. Control continues in step 326 , where control determines whether RotorStallCount is greater than or equal to a predetermined threshold. If so, control transfers to step 328 ; otherwise, control continues in step 330 . The value of 4 is presented for example only, and may reflect the number of times that a rotor stall may occur before a systemic problem is suspected.
[0064] In step 328 , the compressor is locked out and control ends. Locking the compressor out may require a service call to determine the cause of the rotor stall events. This may be implemented according to safety regulations and/or safety policies of the manufacturer. In step 330 , control waits for the motor to cool, and hopefully for the cause of the rotor stall to dissipate. For example, control may wait for ten minutes before attempting to restart the compressor. Control then continues in step 304 .
[0065] Referring now to FIG. 5B , in step 322 , control determines whether the moving average of the voltage has decreased by a percentage, such as 20 percent. If so, control transfers to step 350 ; otherwise, control transfers to step 352 . In step 350 , control determines whether the moving average of the current has increased by a percentage, such as 100 percent. If so, control transfers to step 354 ; otherwise, control transfers to step 352 . In step 354 , the moving average of the voltage has decreased by 20 percent and the moving average of the current has increased by 100 percent, and the compressor is therefore turned off.
[0066] Control continues in step 356 , where the voltage measured when the compressor stalled is stored into a StallVoltage variable. In addition, the stalled voltage is saved as a LowVoltage variable. The stalled voltage may be recorded once the moving average of the current has increased by 100 percent. Alternatively, the stalled voltage may be recorded at some other point, such as when the moving average of the voltage has decreased by 20 percent. In addition, the stalled voltage may be determined at a point of inflection of the motor current, such as point 252 of FIG. 3 .
[0067] Control continues in step 358 , where GridStallCount is implemented. Control continues in step 360 , where control determines whether GridStallCount is greater than or equal to a predetermined threshold. If so, control continues in step 362 ; otherwise, control continues in step 364 . For example only, the predetermined threshold may be 5. This predetermined threshold may be established by the utility company and/or the manufacturer.
[0068] In step 362 , the compressor is locked out, and control ends. GridStallCount may be reset remotely, such as by the utility company, and control may then resume at either step 302 or 304 . In step 364 , control resets Timer. Control continues in step 366 . In step 366 , control stores the minimum of LowVoltage and the most recently measured voltage back into LowVoltage.
[0069] Control continues in step 368 , where control determines whether the most recently measured voltage is above a recovery threshold. The recovery threshold may be determined by the maximum of 185 V and 1.1*StallVoltage. The value 185 V is once again only an example, and may correspond to various implementations using 240 V power.
[0070] If StallVoltage, where the compressor began or continued to stall, is close to or above 185 V, 1.1*StallVoltage will be greater than the 185 V value. Control may then wait to restart the compressor until the voltage has increased ten percent beyond StallVoltage. If the voltage has increased above the recovery voltage, control transfers to step 370 ; otherwise, control returns to step 362 . The value of ten percent is for example only, and the value chosen may be higher or lower than ten.
[0071] In step 370 , control determines a wait time. The wait time may be determined based upon LowVoltage. For example, the wait time may be inversely related to LowVoltage. Alternatively, the wait time may be a predetermined constant, which may be determined by the utility company, the manufacturer, and/or the installation or repair technician. In addition, the wait time may be based on the present voltage and/or any other suitable parameter.
[0072] The wait time may also depend upon GridStallCount. For example, the wait time may increase, such as linearly or exponentially, with GridStallCount. For example only, the wait time may be determined using a random delay, where the parameters for the random delay depend upon the factors described above. For example, the random delay may be selected from a range between a lower and an upper limit. As GridStallCount increases, the upper limit may increase exponentially. If Timer is greater than the wait time, control returns to step 306 of FIG. 5A via letter B. This allows control to attempt to restart the compressor. If Timer has not yet reached the wait time, control returns to step 366 .
[0073] Referring now to step 352 , control determines whether the most recently measured current is greater than the operating current threshold. If so, control transfers to step 374 ; otherwise, control transfers to step 376 . The operating current threshold may be defined as 0.4*startup peak current. In step 374 , control determines if Timer is greater than 800 ms. If so, a stall event has been detected, and control transfers to step 320 of FIG. 5A via letter C. Otherwise, control transfers to step 378 .
[0074] Rotor stall detection is used to determine whether the rotor has stalled upon startup. Rotor stall detection may also be useful once the compressor is running, even when grid fault detection is implemented. For example, a slow enough increase in motor current will not trigger the 100 percent increase of step 350 . As such, step 374 will identify more gradual events such as rotor stalls.
[0075] In step 376 , Timer is reset and control continues in step 378 . In step 378 , control determines whether the measured voltage is less than a predetermined value, such as 175 Volts. If so, control transfers to step 380 ; otherwise, control transfers to step 382 . In step 380 , control determines whether Timer2 is greater than a predetermined period of time, such as 400 ms. If so, control transfers to step 384 ; otherwise, control transfers to step 386 .
[0076] In other words, control transfers to step 384 when the voltage has been below a threshold for a predetermined period of time. The exemplary value of 400 ms may be replaced by a value that reduces the occurrence of false fault detections during temporary voltage sags. In step 384 , control turns off the compressor, and control continues in step 308 of FIG. 5A via letter D. In step 382 , control resets Timer2, and continues in step 386 .
[0077] In step 386 , control determines whether OnTime is greater than two hours. If so, control transfers to step 388 ; otherwise, control returns to step 322 . In step 388 , GridStallCount is reset, and control returns to step 322 . GridStallCount is therefore reset after a predetermined period of time has passed with the compressor remaining on. For example only, that predetermined period of time is shown as two hours in FIG. 5B . In this way, GridStallCount can be used to measure grid faults that are related to each other, and not spaced apart in time.
[0078] Referring now to FIG. 6 , a functional block diagram of an exemplary compressor system according to the principles of the present disclosure is presented. A compressor unit 402 includes a power supply 404 , a compressor 406 , a switch 408 , and control logic 410 . The power supply 404 normally provides power to the compressor 406 via the switch 408 .
[0079] The control logic 410 , which may be powered by the power supply 404 , controls the switch 408 . The control logic 410 may control the switch 408 based upon a measured temperature and/or a command from a heating, ventilation, and air conditioning (HVAC) system. The compressor unit 402 may have been installed at a location without the monitoring system 420 .
[0080] The monitoring system 420 may be later added to the compressor unit 402 . The electrical connection between the switch 408 and the compressor 406 may be broken, and the current monitor 422 and a second switch 424 inserted between the switch 408 and the compressor 406 . The monitoring system 420 may be grounded to the same ground as the compressor unit 402 .
[0081] A voltage monitor 426 monitors the power grid voltage, as received from the utility. Alternatively, the voltage monitor 426 may monitor the output voltage of the power supply 404 and may be connected to either terminal of the current monitor 422 or of the second switch 424 . The current monitor 422 outputs a current value to a shift register 430 . The shift register 430 may include multiple shift cells 432 . Each of these shift cells 432 may include multiple flip-flops for storing each bit of a digital current signal.
[0082] The digital current signal may be produced by an analog to digital converter, which may be located in the current monitor 422 . The values stored in the shift register 430 may be read by first and second averaging modules 434 and 436 . For example only, the shift register 430 may include eight shift cells 432 , and the averaging modules 434 and 436 may each read four of the shift cells 432 . In other implementations, the shift register 430 may include sixteen shift cells 432 , and the averaging modules 434 and 436 may each read eight of the shift cells 432 .
[0083] Outputs of the averaging modules 434 and 436 are received by a comparison module 438 . The comparison module 438 generates an output signal, which is transmitted to an AND gate 440 . The comparison signal may reflect whether the most recent average, from the averaging module 434 , is more than twice that of a previous average, from the averaging module 436 .
[0084] Similar to the implementation for current, the monitoring system 420 may include a second shift register 450 , including multiple shift cells 452 , that receives voltage values from the voltage monitor 426 . Averaging modules 454 and 456 may receive values of the shift cells 452 . A comparison module 458 compares output values from the averaging modules 454 and 456 .
[0085] The comparison module 458 outputs a comparison signal to the AND gate 440 . For example only, the comparison module 458 may generate the comparison signal based upon whether the most recent average, from the averaging module 454 , is 20 percent lower than a previous average, from the averaging module 456 . In various implementations, the monitoring system 420 may omit the voltage monitor 426 and associated components, such as the second shift register 452 , the averaging modules 454 and 456 , the comparison module 458 , the AND gate 440 , and the minimum detector 468 .
[0086] The AND gate 440 outputs a result of a logical AND operation to a control module 460 . The control module 460 controls the second switch 424 , and may instruct the second switch 424 to open circuit its terminals when the value from the AND gate 440 is active. The control module 460 may also receive values from the current monitor 422 , the voltage monitor 426 , a peak detector 464 , and a minimum detector 468 .
[0087] For example only, the peak detector 464 may measure the peak current value from the current monitor 422 . For example only, the minimum detector 468 may measure the minimum voltage value from the voltage monitor 426 . The control module may store and access counters in a counter module 470 , timers in a timer module 472 , and values in a nonvolatile memory 474 .
[0088] In addition, the nonvolatile memory 474 may store operating code and/or constants for use by the control module 460 . For example only, the control module 460 may operate according to FIGS. 5A-B . Various functional blocks depicted in FIG. 6 may be implemented as software stored in the nonvolatile memory 474 and executed on a processor of the control module 460 .
[0089] Referring now to FIG. 7 , a functional block diagram of another exemplary implementation of a compressor system is presented. In FIG. 7 , the electrical connection between the control logic 410 and the switch 408 is broken. The output of the control logic 410 is transmitted to a first input of a second AND gate 504 . The output of the control module 460 is output to a second input of the second AND gate 504 .
[0090] An output of the second AND gate 504 controls the switch 408 . The current monitor 422 is still interposed between the switch 408 and the compressor 406 . The AND gate 504 enables the switch 408 when the control logic 410 is attempting to turn the compressor 406 on and the control module 460 indicates that turning the compressor 406 on is acceptable.
[0091] Referring now to FIG. 8 , a functional block diagram of an exemplary integrated compressor system 602 is presented. The integrated compressor system 602 may be manufactured as one or more units by an original equipment manufacturer. The power supply 404 provides power to a compressor 604 , such as a scroll compressor, via the switch 408 . A power factor monitor 606 may be interposed between the switch 408 and the compressor 604 .
[0092] The power factor monitor 606 may include a current monitor 608 . In addition, the power factor monitor 606 may include other components (not shown) to determine the power factor of the compressor 604 . The power factor monitor 606 determines a current power factor based on the current and a voltage from the voltage monitor 426 . The power factor monitor 608 transmits the power factor to a control module 620 . The current monitor 608 transmits the measured current to the control module 620 .
[0093] The compressor 604 may be monitored by various sensors. For example, a mass flow sensor 622 may monitor the mass of gas being compressed by the compressor 604 . A vibration sensor 624 may measure vibration of the compressor 604 . For example, the vibration sensor 624 may include an accelerometer and/or a gyroscope. A temperature sensor 626 may monitor temperature of the compressor 604 . These monitored values may be received by the control module 620 .
[0094] The control module 620 may also receive values from the voltage monitor 426 , the minimum detector 468 , and the peak detector 464 . The control module 620 may execute code and/or use values from a non-volatile memory 640 . The control module 620 receives a grid stall fault signal from the AND gate 440 , which may cause the control module 620 to turn off the switch 408 .
[0095] The integrated compressor system 602 may also include activation logic 642 , which determines when the compressor 604 should be activated. The activation logic 642 may make activation decisions based on control by a thermostat and/or an HVAC controller. In various implementations, the control module 620 may implement the functions of the activation logic 642 .
[0096] The control module 620 may detect grid faults using a variety of mechanisms. These mechanisms may be redundant and/or complementary. Various fault detection mechanisms may be omitted in favor of other fault detection mechanisms. The sensors and/or functional blocks associated with the omitted mechanisms may also be omitted.
[0097] In one exemplary fault detection mechanism, the AND gate 440 indicates when a moving average of voltage has changed by a predetermined amount and the moving average of the current has also changed by a predetermined amount. This may indicate that a grid fault has occurred.
[0098] The control module 620 may also determine that a grid fault has occurred when a value from the mass flow sensor 622 decreases. This decrease may be measured in absolute terms, relative terms, and/or as a rate of change. The control module 620 may also determine that a fault has occurred when a vibration characteristic sensed by the vibration sensor 624 has changed. For example, a change in the fundamental frequency of vibration may indicate that a fault is altering operation of the compressor 604 . For example only, the vibration sensor 624 may perform a Fast Fourier Transform (FFT) and determine the frequency having the greatest magnitude.
[0099] In addition, a sudden change in temperature from the temperature sensor 626 and/or a change in the derivative of the temperature may indicate that a fault is present. In addition, a rapid change and/or decrease in power factor as monitored by the power factor monitor may indicate that a fault has occurred. In various implementations, a fault may be declared when any of these inputs indicate that a fault has occurred.
[0100] Further, the control module 620 may determine that a grid fault has occurred when a voltage from the voltage monitor 426 decreases by more than a predetermined amount and does not recover within a predetermined time period. For example only, the predetermined amount may be 40% or 50%. The predetermined time period may be an absolute time, such as 50 milliseconds, or may be a number of line cycles, such as three line cycles.
[0101] Alternatively, a fault may be declared once two or more methods have identified a fault. In addition, a time value may be associated with each fault detection mechanism implemented. If the fault is detected by various mechanisms within a predetermined period of time, the confidence in the presence of a fault may be increased. In addition, if an apparent fault has been sensed for a longer period of time, the confidence may increase.
[0102] Referring now to FIG. 9 , a functional block diagram of an exemplary integrated compressor system 702 is presented. A control module 704 executes code stored in a nonvolatile memory 706 . A power factor monitor 708 determines a power factor. The power factor monitor 708 may determine the power factor based on current from the current monitor 608 and voltage from the voltage monitor 426 .
[0103] The power factor monitor 708 outputs a power factor value to a shift register 710 . The shift register 710 may include multiple shift cells 712 . When the power factor value is an N-bit binary number, each of the shift cells 712 may include N flip-flops. The values stored in the shift register 710 are read by first and second averaging modules 714 and 716 . In various implementations, the shift register 710 may include sixteen shift cells 712 . The averaging modules 714 and 716 may each read eight of the shift cells 712 .
[0104] The averaging modules 714 and 716 output averaged values to a comparison module 720 . The averaged values may be updated after each new value is shifted into the shift register 710 . The averaged values are therefore moving averages. The comparison module 720 may compare the averaged values each time they are updated. The comparison module 720 may calculate a ratio equal to the averaged value from the first averaging module 716 divided by the averaged value from the second averaging module 714 .
[0105] When the ratio is less than a predetermined threshold, the comparison module 720 may output a power factor event indication to the control module 704 . For example only, the predetermined threshold may be 0.8, which means that the averaged value has decreased by 20%. Based on the power factor event indication, the control module 704 may turn off the switch 408 , thereby halting the compressor 604 .
[0106] Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification, and the following claims.
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A system includes a control module and a monitor module. The control module selectively operates a component of the system in an ON state. The system receives power from an electrical grid. The monitor module selectively detects a fault event of the electrical grid in response to (i) an amount of current drawn by the component or (ii) a voltage of power received by the component. In response to detecting the fault event, the control module switches the component from the ON state to a second state, determines a first delay period according to a random process, identifies an apparent conclusion of the fault event, and in response to the apparent conclusion of the fault, waits for the first delay period before switching the component back to the ON state. The component consumes less power in the second state than in the ON state.
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FIELD OF THE INVENTION
The present invention relates generally to security devices implemented in the trucking industry and, more particularly, to a kingpin locking device having a stoppable sliding member to provide protection to components when influenced by force from theft or abuse.
BACKGROUND OF THE INVENTION
Conventional kingpin locks are typically designed with a receiving aperture or wrap-around device that permits lockable engagement with a trailer kingpin to discourage or even prevent theft of trailers and their contents. With the trailer kingpin surrounded by the device, a thief is without means of attaching the trailer to a secondary vehicle. As such, various designs and techniques have been implemented with kingpin locks in an attempt to promote this theft prevention goal. However, conventional systems present innate drawbacks.
First, many conventional devices are unnecessarily complex. Namely, it is common for lock designs to employ complicated and proprietary components. For instance, integrated locks and latching systems are often utilized wherein the interplay of the components is inflexible. These conventional designs introduce undesirable manufacturing and repair costs. The occurrence of part malfunctions increases, and ease of interchangeability is impractical. As such, consumer appeal is negatively affected such that these conventional features bring down public interest in the products.
Second, many of the devices that implement these complicated and/or intricate systems, often fail to consider the urgency of a theft scenario. A thief is not generally interested in consuming valuable time analyzing a system. Instead, thieves are likely to employ force in an attempt to break the locks. Since many conventional and often-complex locks include components undesirably exposed outside the kingpin lock housing, vulnerability is relatively high. Integrated locks, sliding bars, and similar components that are accessible outside the lock housing can be subjected to substantial force with tools such as sledge hammers to initiate breakage.
Even advanced designs that have addressed the problems with these conventional lock systems leave room for improvement. For instance, U.S. Pat. No. 4,620,718, incorporated herein by reference, comprises a kingpin lock device having a system of locking the trailer kingpin that employs a simple design, with some standard components, wherein the vast majority of the components are protected within the lock housing. Namely, a standard padlock is fully insertable within the housing to latchably engage a portion of a sliding member such that the engagement of the padlock to the sliding member restricts movement of the housing away from or off of the trailer kingpin. With a minimum level of component exposure, forceable damage to the lock is substantially avoided. However, while the ′718 Patent is a significant improvement over conventional kingpin lock designs, the design can be improved to further advance the goal of theft prevention. As the sliding member must be selectively slidable in and out of the sliding chamber of the lock housing, it is equipped with a handle groove at one end that must be externally accessible for adjustment of the sliding member once the lock has been disengaged. As such, it is possible for the sliding member to be forced inward into contact with the engaged lock such that damage can occur to the lock and/or the sliding member. With an extremely high level of force, it is possible to break either of the components to obtain disengagement of the kingpin lock from the trailer kingpin.
As a result, there is a need for a kingpin lock device that will substantially solve the problems plaguing conventional designs and techniques. Namely, complex and proprietary designs must be avoided while still furthering the goal of theft prevention. All of this must be accomplished with a device that does not impose burdensome manufacturing costs and user inconvenience.
SUMMARY OF THE INVENTION
The lockable kingpin system of the present invention substantially solves the problems with conventional devices. Namely, a device of simple design is presented that does not require expensive manufacturing materials and components, while still promoting theft prevention with component designs that are not vulnerable to damage from externally exerted forces.
The kingpin lock device of the present invention generally includes a lock housing, a selectively engageable lock, and a sliding member. The lock housing can include a kingpin receiving aperture, a lock receiving channel, and a sliding channel. The sliding member can include a concave portion at one end for engaging the surface of the kingpin, a slot portion intermediate the sliding member for receiving the selectively engageable lock, and a stop lip/flange portion at the end distal the curved portion. The stop flange portion includes at least one lip for engaging the outer surface of the lock housing upon positioning of the sliding member within the sliding channel. As such, movement of the sliding member within the sliding channel is limited and the introduction of a substantial longitudinal force on the sliding member will not bring the lock into damaging forceable contact with the slot portion of the sliding member. Despite force from a tool such as a sledgehammer, the sliding member will not enter into the sliding channel beyond the predetermined distance defined by the location of the stop flange portion. The flange can take on a myriad of shapes and sizes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a kingpin lock device in accordance with an embodiment of the present invention;
FIG. 2 is a top cross-section view of an embodiment of a kingpin lock device engaging a kingpin in accordance with the present invention;
FIG. 3 is a top view of an embodiment of a sliding member for use with a kingpin lock device in accordance with the present invention; and
FIG. 4 is a perspective view of an embodiment of a sliding member for use with a kingpin lock device in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1-4, a kingpin lock device 10 in accordance with the present invention is generally shown. The lock device 10 generally includes a lock housing 12 , a sliding member 14 , and a selectively latchable lock 16 . Further, the device 10 is selectively lockably engageable with a kingpin 18 , such as those commonly known for employment on tractors or trailers.
Referring primarily to FIGS. 1-2, the lock housing 12 can include a kingpin receiving aperture 20 , a lock receiving channel 22 , a sliding member channel 24 , and a front portion 26 . The front portion 26 generally includes a stop surface 28 . The lock housing 12 is generally constructed of a durable steel, iron, or aluminum, but it is envisioned that other durable materials designed to accommodate the environmental and strength requirements of a kingpin lock can also be employed. The receiving aperture 20 is shaped and sized to receive the kingpin 18 such that kingpins of various sizes can pass into and through the housing 12 with a measurable amount of extra room left between the outside surface of the kingpin 18 and the inner diameter of the generally cylindrical-shaped receiving aperture 20 , as shown in FIG. 2 . The lock receiving channel 22 is in fluid communication and generally transverse to the longitudinal axis of the kingpin receiving aperture 20 . The lock receiving channel is sized and shaped to fully accept various latchable locks 16 to substantially shroud the locks 16 . The sliding member channel 24 is also generally transverse to the longitudinal axis of the kingpin receiving aperture 20 . The sliding member channel 24 provides a channel of fluid communication through the front portion 26 of the housing into the cylindrical cavity of the kingpin receiving aperture 20 . As such, each of said apertures and channels 20 - 24 are in fluid communication with each other to create an area of connectability within the lock housing 12 .
Further, the lock housing 12 can include a pin aperture 32 substantially parallel with the longitudinal axis of the kingpin receiving aperture 20 such that the pin aperture 32 provides a chamber that preferably does not completely pass through the housing 12 . As a result, a roll pin 33 , an expand pin, or the like can be inserted through the pin aperture 32 to securely rest at a stop position, as shown in FIG. 2 . At this stop position the roll pin 33 can be forceably engaged using various known tools to removably lockably engage the pin 33 . As further discussed herein, the pin 33 , in the forceably engaged stop position, will provide a displacement restriction on an engaged sliding member 14 through the sliding member channel 24 . In various embodiments, a handle 30 can be included which is attached to the housing 12 at handle bores 31 defined through the housing 12 to promote and facilitate device 10 portability.
Referring primarily to FIGS. 3-4, embodiments of the sliding member 14 generally includes a stop flange portion 34 , a concave end portion 36 , a slot portion 38 , a handle portion 40 , and a pin guide 42 . The stop flange 34 is at an end of the member 14 distal the concave end portion 36 and defines a portion of the member 14 measurably larger than the width of the sliding member channel 24 . Flanges 34 of varying shapes and sizes can be employed as well without deviating from the spirit and scope of the present invention. For instance, alternative embodiments can include a flange 34 design wherein the lip of the flange extends along a plane parallel to the receiving aperture 20 , is transverse to the longitudinal length of the sliding member; 14 , includes arcuate flanges 34 , or incorporates a myriad of other variations.
The slot portion 38 comprises a groove or cut out of a predefined distance along one side of the member 14 , wherein the slot portion 38 is substantially intermediate the stop flange portion 34 and the concave end portion 36 . In addition, a handle portion 40 can be included proximate the stop flange portion 34 to facilitate user manipulation of the sliding member 14 , as best seen in FIGS. 1 and 4. Generally, the handle portion 40 will include. grooves within the sliding member 14 to create a surface contour change for ease-of-handling.
To prevent inadvertent loss of the sliding member 14 , and to ensure that the displacement of the sliding member 14 within the sliding member channel 24 is limited, a displacement system is employed. In one embodiment, the displacement system includes the pin 33 which will preferably pass through the pin aperture 32 of the housing 12 and through the pin guide 42 of the sliding member 14 . As such, displacement of the sliding member 14 when the pin 33 is engaged in the stop position will be limited to the abuttable contact of the pin 33 within and along the corresponding length of the pin guide 42 . Other known means of limiting such displacement can also be employed without deviating from the spirit and scope of the present invention. In alternative embodiments, the pin guide 42 will be located at an edge opposite the slot 38 , as shown in FIG. 4 . With such embodiments, the pin guide 42 will limit displacement of the sliding member 14 , but will do so without employing a pass-through slot central the member 14 . Further, alternative embodiments of the pin guide 42 can simply include a groove or recess, along a portion of the sliding member 14 that does not completely pass through the sliding member 14 . Regardless, and unlike the conventional practice of utilizing a set screw for limiting displacement, the pin 33 and pin guide 42 technique of the present invention makes it difficult to remove the displacement device either intentionally or accidentally. It is difficult for thieves to force out the roll pin 33 from its stop position. Further, travel, storage, and every day use will not result in undesirable loosening of a displacement device such as the conventional set screw.
As shown in FIG. 2, the latchable lock 16 can include a body 44 , a shackle 46 , and a key (not shown). The key can be used to selectively engage and disengage the shackle from the lock body 44 . Various latchable locks known to one skilled in the art can be implemented with the present invention. When originally configuring or manufacturing the device of the present invention 10 , the sliding member 14 is inserted into the sliding member channel 24 and the pin aperture 32 is aligned to match up with a portion of the pin guide 42 . As such, the pin 33 can be forceably engaged within the pin aperture 32 , through or to the pin guide 42 , to create stop positions along the longitudinal travel path of the sliding member 14 within the sliding channel 24 . This fundamental configuration technique will generally exist and remain despite the selective implementation of various locks, or the selective connection of the device 10 to a myriad of trailers and respective kingpins 18 . With movement of the sliding member 14 being controlled within the channel 24 , the slot portion 38 is generally aligned with the lock receiving channel 22 for ease of operation. To house a particular lock within the kingpin lock housing 12 , the sliding member 14 is removed or pulled back within the channel 24 prior to inserting the pin 33 , or after removing the pin 33 , such that the shackle 46 of the lock 16 can be positioned within the lock receiving channel 22 . Once positioned, the sliding member 14 can be slidable adjusted to pass through the loop of the shackle 46 . Again, following this insertion and adjustment of a defined lock 16 within the lock receiving channel 22 , the pin 33 limits the travel path defined by the pin guide 42 configuration.
At engagement, the shackle 46 of the lock 16 selectively engulfs or surrounds the slot portion 38 of the sliding member 14 . With the lock 16 abuttably and lockably surrounding the slot portion 38 , the sliding member 14 is yet further limited in its movement within the sliding member channel 24 . By unlocking the shackle 46 of the lock 16 , the lock body 44 can be withdrawn a distance back from the proximate slot portion 38 to again increase moveability of the sliding member 14 .
In operation, a kingpin lock device 10 in accordance with the present invention is selectively engageable with a standard kingpin 18 . Typical standard kingpins 18 are of a common shape and size and can include an annular groove. To secure these kingpins 18 from unwanted tampering or unauthorized connectivity, the user will unlock the latchable lock 16 (i.e., a padlock) with the key. The lock body 44 may then be partially withdrawn from the lock receiving channel 22 , and its position against the slot portion 38 . However, as stated herein, uninhibited movement of the sliding member 14 is limited in this state by the engaged roll pin 33 .
When the lock 16 is partially engaged with the slot portion 38 , permissible movement of the sliding member 14 along the defined path of pin guide 42 enables the user to adjust engagement of the concave end portion 36 with the circumferential surface of the kingpin 18 . The annular groove portion can provide longitudinal limits on movement of the kingpin 18 from engagement with the abutted concave portion 36 of the sliding member 14 . When the sliding member 14 is measurably withdrawn, the concave end 36 is drawn at least partially out of the kingpin receiving aperture 20 , thus permitting the trailer kingpin 18 to pass through. After the lock housing 12 is placed over the trailer kingpin 18 , the concave end 36 may be pushed into contact engagement with the surface of the kingpin 18 , or into the annular groove. The lock body 44 can then be pushed into lockable engagement with the corresponding shackle 46 within the slot portion 38 to substantially prevent movement of the member 14 relative to the lock housing 12 and its sliding member channel 24 .
With conventional techniques, engaged kingpin locks are still vulnerable to tampering caused by excessive force from a tool such as a sledgehammer. With the present invention, a blow following the longitudinal axis of the sliding member 14 will meet at least two levels of resistance to substantially assist in maintaining the integrity of the lock device 10 and its position on the engaged kingpin 18 . First, the longitudinal movement of the sliding member 14 is limited by the inevitable abutment of the stop flange portion 34 against the stop surface 28 of the lock housing 12 . In addition, the restricted movement of the member 14 caused by the path defined by the roll pin 33 within pin guide 42 is also beneficial. It should be noted that the implementation of the roll pin 33 and pin guide 42 system without the flange stop 34 would leave the latchable lock 16 vulnerable to forceable contact with the sliding member 14 and the roll pin 33 itself.
Those skilled in the art will appreciate that other embodiments in addition to the ones described herein are indicated to be within the scope and breadth of the present application. Accordingly, the applicant intends to be limited only by the claims appended hereto.
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A kingpin lock device generally including a lock housing, a selectively engageable lock, and a sliding member. The lock housing can include a kingpin receiving aperture, a lock receiving channel, and a sliding channel. The sliding member can include a concave portion at one end for engaging the surface of the kingpin, a slot portion intermediate the sliding member for receiving the selectively engageable lock, and a stop lip/flange portion at the end distal the curved portion. The stop flange portion includes at least one lip for engaging the outer surface of the lock housing upon positioning of the sliding member within the sliding channel. As such, movement of the sliding member within the sliding channel is limited and the introduction of a substantial longitudinal force on the sliding member will not bring the lock into damaging forceable contact with the slot portion of the sliding member.
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FIELD OF THE INVENTION
The present invention relates to the manufacture of metal tubes, pump housings, manifolds, and welded assemblies, and, more particularly, to the cleaning and pressure testing of tubes, pump housings, manifolds, and welded assemblies, after fabrication.
BACKGROUND OF THE INVENTION
Tubular metallic structures, pump housings, manifolds, and welded assemblies (collectively referred to as “tubular structures”) are commonly manufactured for use in a variety of applications, such as industrial machinery, automobiles, and aerospace applications. Newly fabricated tubular structures undergo a number of cleaning and testing phases before they are passed on for actual use. For instance, when a tube is used as a transport medium for liquids or gases, the inside of the tube must be cleaned to ensure that the inside of the tube is free of contaminants and debris that might contaminate the fluid being transported. When a tubular structure is to be used for transport of high-pressure fluids, the structure must be properly pressure tested to verify structural integrity prior to use.
The cleaning of the interior of tubes and similar components with relatively small diameter interior passages and those which include throughout their length a number of bent or curved portions, is especially difficult, primarily as the result of the difficulty of inserting conventional tools or other cleaning apparatus into the part and moving it along the full tube or interior passage length. A common technique for cleaning metal parts including the interior of tubes has been the use of so-called degreasing or vapor degreasing agents in which the parts are immersed in or exposed to a quantity of the cleaning liquid or vapor. This approach has been adopted extensively in the metal finishing industry.
Depending upon the ultimate use for the parts, the required cleanliness of the internal surfaces can vary considerably. In the case of gaseous oxygen or hydraulic lines used in aircraft or lines that carry liquid oxygen in missiles, for example, the tubes must be kept extremely clean and this requirement, of course, requires a more intensive cleaning operation. In the past, even when known highly efficient vapor degreasing agents were used, many hydraulic line tubing configurations had to be individually flushed with a solvent liquid in order to achieve the required high degree of cleanliness. As might be predicted, this resulted in a labor intensive and relatively expensive cleaning operation.
In addition to cleaning, proof pressure testing is used to verify the mechanical integrity of a fabricated structure. In typical pressure testing, the structure is filled with a type of fluid, either liquid (typically water) or gas (typically nitrogen), and pressurized to one and a half times the maximum operating pressure that the part is designed to operate with. The pressure is held for a period of time and then the pressure is released. The pressure cycle may be repeated multiple times as required to prove the structural integrity of the structure.
A typical pressure test system consists of a blast cell rated to contain the burst energy of the part being tested, a pump or accumulator to supply the required pressure, regulators and pressure gauges to regulate and measure the supplied pressure, relief valves to protect the system in the event of over pressurization, and various valves to direct and vent off pressure.
The processes of cleaning the various parts and pressure testing the various parts are both laborious and time consuming. In fact, in the mass production of tubular structures, cleaning and pressure testing are often the bottleneck in production schedules due to the need to set up special equipment for each task and the need to wait for equipment availability before each new part or set of parts may be cleaned or tested.
It is desired to provide a system and apparatus that would alleviate some of the problems associated with cleaning and pressure testing tubular structures. Particularly, it is desired to provide a system and apparatus that would reduce production time required to complete cleaning and pressure testing. Further, it is desired to provide a system and apparatus that would simplify the process steps required to clean and pressure test the tubular structures.
SUMMARY OF THE INVENTION
The invention is an apparatus and method capable of cleaning the inside of hollow tube structures, welded assemblies, pump housings, and manifolds (collectively “tubular structures” or simply “parts”) and pressure testing the hollow tubular structures without the need to reconfigure, reposition, or relocate the tubular structures between the cleaning and testing phases. As such, the cleaning and testing phases may be streamlined so as to reduce overall production time.
The invented apparatus generally comprises a feed portion and an outlet portion. The feed portion of the apparatus is connectable to an inlet end of at least one tubular structure and provides fluid into the at least one tubular structure during operation of the apparatus. The feed portion of the apparatus comprises a feed valve network having an inlet and outlet wherein the inlet is selectively operable to provide communication with either a cleaning fluid supply pump, a rinse water pump, or a pressurization pump, and the outlet of the feed valve network is in fluid communication with a feed header having a feed header interface engageable with the at least one inlet end of the tubular structure.
The outlet portion of the apparatus is connectable to an outlet end of the at least one tubular structure and permits fluid to exit the at least one tubular structure during at least one phase of operation of the apparatus. The outlet portion of the apparatus comprises a drain header having a drain header interface that is engageable with an outlet end of the at least one tubular structure and is in fluid communication with an outlet valve network that is selectively closed or open.
The interfaces of the feed and drain headers are engageable to opposing ends of the at least one tube structure such that the inside of the at least one tubular structure is in fluid communication with both headers during operation of the apparatus. The interface seals the tube up to high-pressures for use in pressure testing. A typical pressure test would test the tube at up to 22,000 psi, so the interface would provide a seal up to that pressure during use. An exemplary interface is part interface no. F-250-C, available from Autoclave Engineers, Inc., Erie, Pa.
In operation, one or multiple production parts are cleaned and pressure tested by engaging an inlet of the at least one tubular structure to the interface of the feed header, engaging an outlet end of the at least one tubular structures to an input interface of the drain manifold, and maintaining engagement of the first and second ends of the at least one tubular structure with the respective manifolds while sequentially flowing a cleaning fluid through the inner diameter of the part, pressurizing a static fluid within the part, and releasing fluid from the part.
The flow of cleaning fluid through the tubular structures cleans any oil, solvents, or debris from the inside of the parts. Pressurizing a fluid within the parts to above the rated service pressure of the parts provides assurance that the parts are mechanically sound and suitable for its intended purpose. The ability to both clean and pressure test the tube while the tube is affixed to a single apparatus allows both operations to be accomplished with less setup time, wait time, and capital expense relative to conventional techniques that utilize multiple machines to accomplish those functions.
BRIEF DESCRIPTION OF THE DRAWINGS
Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
FIG. 1 is a schematic diagram showing one embodiment of the invented apparatus;
FIG. 2 is a schematic diagram showing an alternative embodiment of a portion of the apparatus designed for use with a purge fluid and purge gas;
FIG. 3 is a schematic diagram showing another alternative embodiment of the apparatus capable of fluid recycle; and,
FIG. 4 is a schematic diagram showing the embodiment of FIG. 1 , but demonstrates the implementation of the apparatus with an automated controller.
DETAILED DESCRIPTION OF THE INVENTION
The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
Referring to FIG. 1 , according to one embodiment, the apparatus generally comprises a cleaning fluid supply pump 24 and a pressurization pump 54 that are alternatively placed in communication with a feed header 32 by operation of valves 30 a , 30 b of a feed valve network 30 . Supply lines to the cleaning pump 24 are valved such that the cleaning pump may receive a feed of cleaning solution from a cleaning solution reservoir 20 or a rinsing solution reservoir 22 where the rinsing solution is typically deionized (DI) water. The pressurization pump 54 receives a feed from the rinsing solution reservoir 22 .
Fluid is supplied, under pressure, from either of the pumps 24 , 54 through the feed valve network 30 to the feed header 32 . The feed header 32 has at least one but advanageously multiple feed header interfaces 34 engageable to the inlet end of at least one tubular structure 100 such that the inside of the at least one tubular structure is placed in fluid communication with the feed header 32 .
A drain header 42 has at least one but advantageously multiple drain header interfaces 44 engageable to the outlet end of the at least one tubular structure 100 such that the inside of the at least one tube is temporarily placed in fluid communication with the drain header 42 . The drain header 42 has an outlet in communication with an outlet valve network 60 . The outlet valve network 60 comprises two main high-pressure valves. Flow through valve 62 provides communication from the drain header 42 to a fluid catch basin. The catch basin may be the same for each fluid used during cleaning of the tubes, or a separate catch basin may be used for each particular fluid used, for instance a cleaning solution basin 80 and a rinsing solution basin 82 . Drain valve 64 provides a second pathway to a catch basin, for instance the rinsing solution catch basin 82 , or simply to an external drain.
A pressure gauge 70 is advantageously in line with the fluid flow of the system and located between the outlet of the drain header 42 , the flow through valve 62 , and the drain valve 64 . The gauge 70 is used to measure test pressure of the fluid during the pressure testing phase of the apparatus.
A number of analytical instruments are advantageously placed in line with fluid flow between the flow through valve 62 and the catch basins 80 , 82 for use during the cleaning phase of the operation. For instance, a particle counter 72 may be used to monitor the presence of particles within the effluent stream of cleaning solution or rinsing solution flowing out of the tube. A non-volatile residue (NVR) analyzer 74 may be used to monitor the presence of chemical coatings, degreasing agents, or other materials being washed from the inside of the tube. Also, a flow meter 76 is advantageously used to monitor the flow rate of cleaning solution or rinsing solution flowing through the tubular structure during the cleaning phase.
Still referring to the embodiment of FIG. 1 , the apparatus has two primary operating phases, a cleaning phase and pressure testing phase. In the cleaning phase, the cleaning pump 24 is placed in fluid communication with the feed header 32 by opening valve 30 a and closing valve 30 b . The feed to the cleaning pump 24 is initially provided from the cleaning solution reservoir 20 by opening valve 23 a and closing valve 23 b . The cleaning solution is advantageously heated, such as to a temperature of between 140° F. and 180° F. Cleaning solution is pumped by pump 24 through the feed header 32 and into and through the at least one tubular structure 100 . Cleaning solution continues to flow through the tubular structure 100 , through the drain header 42 , and through the outlet valve network 60 where valve 64 is set in the closed position and valve 62 is open to allow continuous fluid flow through a particle counter 72 , NVR analyzer 74 , and flow meter 76 , if any. Finally, the cleaning fluid is allowed to flow out into the appropriate catch basin. The catch basin may include an oil separator or oil skimmer to allow longer use between solution changes.
As the second step in the cleaning phase, the feed fluid to the cleaning pump 24 is changed to a rinse fluid, such as DI water, by closing valve 23 a and opening valve 23 b to the rinsing fluid reservoir 22 . The cleaning phase continues as above except that the rinsing fluid may be diverted to a separate rinsing fluid catch basin after passing through the apparatus.
After the inside of the tube 100 has been determined to be acceptably clean, as described below, both the flow through valve 62 and the drain valve 64 are closed while rinsing fluid remains in the tube 100 . To begin the pressure testing phase of the operation, valve 30 a is closed and valve 30 b is opened to place the pressurization pump 54 in communication with the feed header 32 . The pressurization pump 54 is activated and draws a feed from the rinsing fluid reservoir 22 . Since the apparatus is no longer set up in a flow through configuration, the pressurization pump 54 will only draw a small amount of rinsing fluid from the reservoir while pressurizing the fluid within the tube. Pressurization of fluid within the tube 100 is measured by the pressure gauge 70 , and may also be roughly determined by knowing the pump speed of the pressurization pump 54 . Use of rinsing fluid as the pressurization fluid provides an overall reduction in fluid that must be recycled or disposed of because the apparatus and tubes need not be filled with a separate pressurization fluid for pressure testing as required in traditional hydrostatic-type testing methods.
The one or more tubular structure 100 are pressurized to an extent in accordance with manufacturers' specifications or other specifications designed to ensure the suitability of the tubular structure for their intended purpose. Typically, parts designed for use in critical applications will be tested at pressures of 1.5× the design operating pressure. Typically, pressure will be placed and held on the parts for five repetitions of one to five minutes for each pressurization cycle. The system may incorporate a timer that can control drain valve 64 to relieve pressure and to pressurize the test item to the required pressure. A relief valve or other safety pressure relieving devise should be installed downstream of feed header 32 to protect the system in the event of accidental over pressurization.
After pressure testing is complete, the fluid may be drained from the tubes and portions of the apparatus by opening drain valve 64 . The pressure tested fluid may be collected in a catch basin or sent to an external drain.
The cleaning pump 24 of the apparatus is any pump capable of propelling a volume of fluid through the attached tubes 100 that might act to dislodge particulates within the tube and to wash away any unwanted coatings or residues within the tube. Typically, a pump is used with the capacity to provide flowrates of 400 US gallons/minute at 50 PSI. An exemplary pump motor would provide 20 HP as 3600 RPM. A 10 micron filter may be attached to the outlet of the pump to filter out any particulates in either the cleaning fluid or the rinsing fluid. Further, exemplary pumps might be selected from air driven pumps such as those made by Haskell International or a commercially available electric motor driven pump such as the Motor Speed Series Internal Gear Pumps offered by Viking Pump, Inc., Cedar Falls, Iowa.
The pressurization pump 54 of the apparatus is any pump or device capable of increasing the pressure of the fluid filled tube, and interceding portions of the apparatus, to the desired test pressure of the tube being tested. An accumulator capable of providing the required pressure may be used in lieu of a pressurization pump. Typical required pressures range from 500-20,000 PSIG. An exemplary pump is Haskell International (Burbank, Calif.) Air Driven Liquid Pump Model 8HP, capable of providing pressures up to 22,000 PSI.
Each of the main pressure control valves of the apparatus, particularly valves 30 a , 30 b , 62 , and 64 , are subject to pressure during the pressure testing phase of the operation. The valves are preferably solenoid operated high-pressure valves that are normally opened so that system pressure will be relieved in the event of power loss. Such valves are commercially available from numerous providers.
The interfaces of the feed and drain headers are capable of temporarily connecting the respective ends of tested tube structures to the headers 32 , 42 in such a manner that significant leaking of fluid from the interface does not occur during the cleaning of the pressure testing phase. An exemplary high-pressure interface is Autoclave Engineers, Inc., part number F-250-C.
The cleaning solution used in the apparatus may be any solution capable of dislodging particulates within the tubes being cleaned or of dissolving and carrying away contaminants such as greases, coatings, lubricants, etc. For instance, for tubes having water soluble contaminants, a heated pure water or other aqueous cleaning solution may be used. For tubes having oil soluble contaminents, a solution capable of removing oil based compounds may be used. An exemplary cleaning solution for use with oil soluble contaminants is Turco™ 4215, available from Henkel Surface Technologies Corporation, Madison Heights, Mich.
The rinsing solution is advantageously water or an aqueous solution. As shown in FIG. 1 , the pressurization pump 54 advantageously draws fluid from the rinsing solution reservoir 22 , though, as shown in FIG. 2 , the pressurization pump 54 may instead draw any needed additional fluid from a separate reservoir 56 and the fluid used by the pressurization pump 54 may or may not be the same fluid as the rinsing fluid. The cleaning and rinsing solutions are preferably supplied by the same pump, but the solutions may be provided with separate pumps corresponding to each solution.
Still referring to FIG. 2 , an alternative embodiment of the apparatus is shown in which the use of an additional purge fluid and purge gas are demonstrated. A purge solution and purge gas may be used individually, collectively, or not at all in operation of the apparatus. The use of both purge fluid and purge gas are described herein together for ease of description.
Operation of the alternative embodiment is substantially the same as that of the embodiment of FIG. 1 , with the following exceptions. After the pressurization phase of the operation, valve 30 b is again closed. Purge fluid is flowed through the apparatus and tube by opening valves 23 c and 30 a (all other valves shown in FIG. 2 are closed) and pumping the purge fluid from the purge fluid reservoir 26 through cleaning pump 24 and into the feed header as with cleaning solutions specified above. After purging with the purge fluid, a purge gas is optionally passed through portions of the apparatus and the tube in order to quickly remove any liquid remaining within the tube. The purge gas may be heated to aid in the removal of clean or rinsing solutions. To purge with purge gas, the cleaning pump is isolated by closing valve 30 a and valve 30 c is opened thereby allowing a pressurized purge gas stream to flow through the feed header and tube from a purge gas supply 28 . After flowing through the apparatus, the purge gas may be recaptured or vented to the environment. After the gas purge, valve 30 c is closed and the tube may be removed from the apparatus.
The purge fluid may be a liquid having volatility greater than the rinsing solution such as a VOC solvent. The flow of purge fluid displaces residual rinsing fluid from within the tube. The residual fluid remaining within the tube after the fluid purge either evaporates under environmental conditions, or is easily volatilized by a subsequent gas purge. The purge gas may be any gas that is non-reactive with the other solutions used in this process and which does not readily condense inside the tube under process conditions. Dry gaseous nitrogen is a preferred purge gas. The nitrogen may be heated to aid in the removal of liquids. Nitrogen is advantageous because it is readily available and inexpensive. Helium or compressed air may also be advantageously used.
Referring to FIG. 3 , according to another alternative embodiment of the apparatus, any of the spent cleaning, rinsing, pressurizing, or purge fluids may be recycled by the apparatus rather than being simply collected in catch basins or otherwise disposed of. The fluids may be recycled by a fluid recycle stream 96 , 98 back to the cleaning fluid supply pump 24 or fluid reservoirs 20 , 22 . The fluids may be filtered, cleaned, or otherwise purified by a treatment device 90 , 92 in line with the fluid recycle stream before being reused by the apparatus. It is particularly advantageous to filter the recycled cleaning fluid stream using a filter 90 since this stream is the most likely to contain suspended particulates removed from the inside of previously cleaned parts. Where two or more fluids have mixed during operation of the apparatus, the components of the fluids may be separated as part of the recycling process before reuse.
The degree to which the inside of the tubes must be cleaned will vary with the intended use of the tube. In some situations, it will be known from experimentation or prior knowledge what flow rates and amounts of cleaning and rinsing fluids are required in order to adequately clean the tube. In such circumstances, the apparatus may advantageously provide predetermined, timed flowrates of fluids through the apparatus, either manually controlled or automatically controlled, after which the tube would be deemed to be acceptably clean and fit for service. Alternatively, sensors such as the particle counter 72 or NVR analyzer 74 may be used to determine purity of an effluent stream in order to determine the cleanliness of the interior of the tube being processed. An NVR analyzer tests for carbon based materials that would be incompatible with oxygen and oxidizer systems. An exemplary requirement might be that no particle larger than 100 microns in size be contained in the effluent liquid after cleaning. Cleanliness requirements vary according to the type pf hardware being cleaned and the intended service.
Referring to FIG. 4 , the operation of the apparatus in general is advantageously automated by use of a controller in operative communication with the major components of the apparatus. In particular, the controller is capable of receiving inputs from the pressure gauge 70 , particle counter 72 , NVR analyzer 74 and flow meter 76 to determine the status of the cleaning and/or pressurization processes. The controller may engage/disengage the valves 23 a , 23 b , 24 , 30 a , 30 b , 62 , and 64 , and engage, disengage, or vary the speed of pumps 24 , 54 to alter the operation of the apparatus in the manner generally described above.
The apparatus and method are particularly useful for simultaneously cleaning and pressure testing multiple production parts. By providing the feed and drain headers with multiple interfaces, a large number of production parts may be connected between the headers and simultaneously cleaned/tested in accordance with the invention. The ability to clean and pressure test a large number of production parts without having to reconfigure or reattach the production parts within a cleaning or testing apparatus provides significant time savings relative to traditional cleaning and testing methods.
The invented apparatus may be installed in a fixed location or the apparatus may be situated on a mobile frame so as to be movable throughout a test area or manufacturing facility. If assembled on a mobile cart, the reservoirs of fluid described above may be located on the cart or, alternatively, the fluid supplies may be external to, but connectable with, the cart.
Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings.
Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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An apparatus and method for cleaning and pressure testing tube structures comprising a cleaning fluid supply pump and a pressurization pump alternately in fluid communication with a feed header having a feed header interface engageable to an end of at least one tube structure and a drain header having a drain header interface engageable to an opposing end of the at least one tube structure and an outlet valved so as to be selectively closed or opened depending on mode of operation of the apparatus. The apparatus and associated method cleans and pressure tests a tube by engaging a tube between the feed header interface and the drain header interface and maintaining said engagement while sequentially flowing a cleaning fluid through the inner diameter of the hollow tube, pressurizing a static fluid within the hollow tube, and releasing fluid from the tube.
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STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates to a precision optical fiber winding device and more particularly to a winding machine which permits precise control of reel drag, traversing speed, mandrel rotation speed, fiber tension and fiber lay angle.
(2) Description of the Prior Art
Certain interferometric optical hydrophones are based upon the phenomena that an optical fiber, when elongated, will alter the characteristics of the light transmitted in proportion thereto. A compliant, cylindrical mandrel such as a nylon rod or the like, when circumferentially wrapped with optical fiber, can take advantage of this phenomenon. This wrapped elastomeric mandrel, when exposed to an acoustic pressure, changes its length and, due to Poisson Effects, diameter. The optical fiber, being prestretched by tightly wrapping it around the mandrel, follows these diameter changes and thus elongates or contracts the optical path length in proportion to the acoustic signal. By way of example, a more complete description of a typical fiber optic hydrophone is set forth in U.S. Pat. No. 4,238,856.
At present interferometric hydrophones have mandrels handwrapped with the delicate optical fiber. A significant drawback of the handwrapped hydrophone is the lack of repeatable performance between one hydrophone and the next. This is because once mandrel material has been chosen, hydrophone performance depends strongly on two constructional parameters. First, the amount of initial fiber elongation present after the winding process dictates how easily the fiber will continue to elongate as the mandrel diameter increases or shrinks with diameter reduction. This fiber prestretch is directly controlled by the amount of back tension applied as the fiber is wound onto the mandrel. Handwrapping the fiber does not allow sufficient tension control during this initial fiber elongation. The second constructional parameter governing hydrophone performance is the distribution pattern of the fiber along the length of the mandrel. This fiber density is entirely dependent upon the lay angle of the fiber as it is wound onto the mandrel. Handwrapping does not permit the angular control necessary for consistent performance from hydrophone to hydrophone.
SUMMARY OF THE INVENTION
Accordingly, it is a general purpose and object of the present invention to provide an interferometric fiber optic hydrophone winding machine able to consistently wind delicate optical fibers onto compliant hydrophone mandrels without any degradation of the fiber properties. Another object is that the winding machine be able to vary two important parameters which strongly influence optical hydrophone performance, i.e., fiber lay angle and fiber pretension, thereby permitting the winding machine to serve as a research tool in optimal hydrophone design. A further object is that such a winding machine be able to employ single mode or multimode optical fiber. A still further object is that the machine be capable of producing a plurality of hydrophones having identical performance characteristics.
These objects are accomplished with the present invention by providing an interferometric fiber optic mandrel hydrophone winding machine comprising a rigid baseplate having mounted thereon hydrophone mandrel mounting means, optical fiber dispensing means attached to an adjustable traversing mechanism, electric motor means for rotating the mandrel and driving the traversing mechanism, and control panel means for controlling the winding operation and displaying optical fiber length and tension status. The optical fiber dispensing means includes a fiber reel stand, attached to the traversing mechanism, a journal mounted fiber reel, an idler roll and a lead roll, all bearing mounted thereon. Fiber tension is controlled by adjusting the drag on the reel shaft while a tension assembly attached to a force gage permits digital readout of fiber tension at the control panel. A microswitch operated pulse counter device operating in conjunction with the idler roll monitors the total fiber length already wrapped on the mandrel. By controllably varying mandrel rotation speed, reel stand traversing speed and direction, and reel drag, compliant hydrophone mandrels can thus have optical fibers wrapped therearound having preselected fiber lay angles and fiber tensions. This either permits a plurality of hydrophone variants to be produced for research programs or if desired allows production of large quantities of identical hydrophones.
A more complete understanding of the invention and many of the attendant advantages thereto will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a front view of a fiber optic hydrophone winding machine built according to the teachings of the present invention.
FIG. 2 is a top view of the winding machine of FIG. 1.
FIG. 3 is a sectional view of the device shown in FIG. 2 taken along line 3--3 thereof.
FIG. 4 is a sectional view of the device shown in FIG. 1 taken along line 4--4 thereof.
FIG. 5 is a cross-sectional view of the mandrel gripping device with mandrel inserted taken along line 5--5 of FIG. 2.
FIG. 6 illustrates the cam actuated micro switch which feeds the meters counter, viewed along line 6--6 of FIG. 2.
FIG. 7 is a block diagram of the electrical control system of the present invention.
FIG. 8 is a circuit diagram of the divide-by-six functional block of FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 there is shown a front view of an interferometric optical hydrophone winding machine 10 comprising a rigid horizontal base plate 12 having first and second rigid vertical side plates 14 and 16 spaced a preselected distance apart and fixedly attached thereto. Side 14 and 16 are each braced by a plurality of rigid gussets 18 affixed so as to maintain 90° alignment with respect to plate 12 while remaining essentially parallel and coaxial to each other. Plates 12, 14 and 16 may be of any strong, lightweight material although aluminum is preferred. In addition to alignment considerations, such plate mounting of machine 10 also provides for machine portability without requiring disassembly. A long threaded shaft 20 passes through threaded support 21 which is fixedly attached to vertical plate 14 having the axis thereof parallel to plate 12. Shaft 20 has attached thereto a handle 22 and is used to center one end of compliant hydrophone mandrel 24. The other end of mandrel 24 is gripped by a collet housed within a bore in shaft 26, the collet being compressed by the knurled compression nut 28. A reel 30 is mounted atop an adjustable traversing mechanism 32. Reel 30 has a preselected length of optical fiber 34 wrapped therearound. Traversing mechanism 32 is coupled to shaft 26, via a timing belt 36 housed beneath belt guard 38 which may be aluminum or the like. An electric motor 40 is geared down and clutch coupled to shaft 26 which holds mandrel 24.
Machine 10 is operated using control panel 42. Power is supplied to machine 10 through main power switch 44. An emergency stop button 46 permits disengagement of electrically engaged clutch 48 at any time. Jog button 50, a momentary contact switch, allows the machine operator to incrementally rotate mandrel 24 to an appropriate starting position. An upper digital counter 52 is a preset type such as an Electronic Counters and Controls Inc., (ECCI) Model MU115A-1. The desired number of meters is set using a series of thumbwheels 52a. Display 52b shows the total number of meters of fiber that has been wound onto mandrel 24. Upon reaching the desired preset fiber length, counter 52 deactivates a relay coil disengaging drive shaft clutch 48. Button 52c is a reset device which zero's out display 52b. Lower counter 54, which may be an ECCI Model MU105A-1 or the like, totalizes and displays the number of revolutions of drive shaft 26, and hence mandrel 24, which is used as a check on the "meters" display 52b. A potentiometer 56 is used to regulate the mandrel rotational speed over a preselected range, e.g., from 0.4 to 12 revolutions per minute. Potentiometer 56 may be part of panel 42 or may be fixedly attached to the side of panel 42 within a separate box 57 such as a Boston Gear Ratiopax or the like.
Variable speed motor 40, controlled by motor run switch 58, attaches to the rear face of electrically operated clutch 48 through a suitable reduction gear box 60 having an output shaft 62. A clutch guard 64 fixedly attached to and protruding from belt guard 38, has mounted thereon a proximity switch 66, which provides the count pulse for "totalizer" counter 54 by sensing the number of times indicator 68 passes by.
Optical fiber reel 30 is mounted atop a traversing mechanism 32 which permits changes of optical fiber pitch angles and hence mandrel fiber density. While any rotary to linear motion converter may be used, a preferred variable mechanism is a Uhing Variable Pitch Traverses, Type RG 20/25, available commercially from Amacoil Machinery Inc. where the angle changes are accomplished by setting a control lever 69 at the desired position on dial 70. In such a unit rolling rings, controlled by lever 69, convert the rotational motion of shaft 71 driven by belt 36 into to linear travel parallel to the axis of mandrel 24. Shaft 71 is supported at either end by vertical members 72 fixedly attached to plate 12. A pair of limit stops 73 are moveably mounted on traverse rod 74 which is parallel to shaft 71 and is also supported at each end by members 72. A reversing mechanism 75, located on the underside of traversing mechanism 32, upon encountering a limit stop 73 reverses the direction of traverse of mechanism 32. A third cross member 76, parallel to shafts 71 and 74, further adds strutural support.
Fiber reel 30 is mounted on a reel stand 77 which is fixedly attached to the top of traversing mechanism 32. Stand 77 further comprises a pair of vertical members 77a fixedly attached to horizontal member 77b Fiber 34 is fed from reel 30 the shaft of which rotatably mounts in journals having hinged top sections 78 to provide easy removal. Knurled captive screws 80 with springs 82 are used to provide adjustable drag on the reel shaft and thus act as a braking system for controlling tension in fiber 34. Fiber 34 is fed from reel 30 over an idler roll 84 which is arranged so as to provide the meter count for counter 52 of control panel 42. This meter count is provided by counting pulses from a microswitch 86 fixedly attached to one vertical member 77a. Six electrical pulses from switch 86 are stored in an appropriate circuit before one pulse is sent to counter 52 which increments the count by one meter. Switch 86 is connected to counter 52 via cable 88. The output signals of proximity switch 66 are transmitted by cable 90 to totalizer counter 54. Dead shaft 20 has a live center 92 housed in the working end thereof to assist in holding mandrel 24 steady during the winding operation. The length of threaded shaft 20 is selected to accommodate winding of mandrels of varying length. Motor 40 is supported by motor support stand 94 which is fixedly attached to plate 12.
FIG. 2 shows a plan view of the machine of FIG. 1. From idler roll 84, fiber 34 is fed to a tension assembly 100. Assembly 100 is pivotably mounted on ball bearings at locations 102 and 104. Fiber 34 is fed under a tension roll 106. Roll 106 runs essentially parallel to mandrel 24 and also to a readout roll 108. Rolls 106 and 108 are secured at each end thereof to cross members 110 and 112 respectively thereby forming the rectangular frame which is tension assembly 100. The distance from locations 102 and 104 to rolls 106 and 108 are equal such that a movement of roll 106 causes an equal and opposite movement of roll 108. The tension assembly readout roll 108 is attached to a force gage 114 which provides a digital readout of fiber 34 tension. Knurled captive screws 80 are loosened or tightened to alter this tension. Tension roll 106 is preferably made of aluminum with a finish of teflon impregnated hard coat anodize. This permits lateral motion of fiber 34 with minimal tension changes and/or abrasion of fiber cladding. From tension roll 106, fiber 34 is then fed over lead roll 116 and onto mandrel 24. Lead roll 116 has an annular groove 118 at the midpoint thereof so that fiber 34 is maintained at the same spatial location relative to traversing mechanism 32 when passing onto mandrel 24 thus providing a constant pitch. Both lead roll 116 and idler roll 84 are bearing mounted. Movement of traversing mechanism 32, in the direction shown by the arrow, at a constant traverse rate causes fiber 34 to be wound onto mandrel 24 at a pitch angle θ. Motor support stand 94 is shown to have a circular cross section for the vertical member thereof. This cross section is optional and may be varied.
FIG. 3 shows in cross section the path which fiber 34 traverses during a typical winding operation. Fiber reel 30 plays out fiber 34 which passes over idler roll 84, then under tension roll 106, then over lead roll 116 to and around mandrel 24. Fiber tension is adjusted by tightening or loosening thumb-screws 80 which cause hinges 78 to rotate about pivot points 152 thereby varying the drag on the fiber due to friction imposed on fiber reel shaft 150. The fiber tension so produced causes a load on tension roll 106 which, due to the pivotability of tension assembly 100 about point 102, produces an equal force and opposite movement at roll 108. An analog or digital readout device 114 (although digital is preferred), is mounted on bracket 154, having a vertical actuating linkage 156 extending downward therefrom. Linkage 156 is pivotably connected to horizontal cross member 158 which rests on roll 108 and moves therewith producing proportional vertical movement of linkage 156. Device 114 is calibrated to produce a readout of fiber tension. A typical digital device 114 is a John Chatillion & Sons Model CFG-10.
FIG. 4 shows the drive arrangement between mandrel drive shaft 26 and traversing mechanism shaft 71. Drive belt 36 is driven by primary gear 120 which in turn drives secondary gear 122. A typical gear ratio would be about 21/2 to 1 respectively between gear 120 and gear 122, although this can be varied if desired. Both gears may attach to their respective shafts using any of a variety of well known means such as a key, a spline or the like.
FIG. 5 shows how mandrel 24 is held securely by drive shaft 26. A compliant collet 174, beneath knurled compression nut 28, is slotted at the mandrel end thereof such that a plurality of evenly spaced gripping segments are formed at the tapered end. Upon tightening of nut 28, pressure is exerted in the direction of the shaft 26 bore, thereby forcing the tapered end of collet 174 against the tapered bore of shaft 26 forcing the gripping segments thereof to press axially against mandrel 24 gripping it securely while the slots extend beyond the mandrel end. The pigtail of fiber 34 is passed through one such slot while collet 174 clamps onto the mandrel. The fiber lead is then passed over the end of mandrel 24 and through the shaft bore. From there it is threaded out through a hole and wound onto a takeup reel 170 which is held in place against shaft 26 by set screw 172. A slot 173 may be utilized in one land of spool 170 for ease of winding. This gripping means protects fiber 34 during the winding operation.
Shaft 26 is moveably supported by support 178 which is fixedly attached to plate 16 such that the longitudinal axis thereof is parallel to plate 12. Journal bearings 180 and 182 permit shaft 26 to rotate.
FIG. 6 shows the camming arrangement whereby the circumference of idler roll 84 is used to measure the length of fiber wound on mandrel 24. Normally open micro switch 86, fixedly mounted to suport 77a, has an actuating lever 200 extending therefrom. Idler roll 84 has concentric cylindrical protruding hubs 201 of smaller diameter extending from either end. A tapped hole is provided in one hub 201 lying generally parallel to the longitudinal axis of roll 84 and hub 201 but being offset therefrom so that roll rotation produces an eccentric motion by the head of a screw 202 which is installed in the tapped hole. As idler roll 84 rotates, screw 202 trips lever 200 closing switch 86 once per revolution. Roll 84 is sized such that one revolution equals one sixth of a meter. Surface finish of roll 84 is important as it must be rough enough to permit roll rotation at low fiber contact force while not damaging the fiber buffering or jacketing as the fiber passes thereover. A light sandblasted finish was found to work well.
FIG. 7 shows in block diagram form, the control circuit 300 used to operate machine 10. An AC source provides power concurrently to; variable speed motor 40, totalizer counter 54, meters counter 52 and DC power supply 302. The DC output of supply 302 is controllably used to engage/disengage clutch 48. Placing power switch 44 in the closed position allows motor 40 to run whenever motor run switch 58 is also closed. The speed at which the output shaft of motor 40 revolves is controlled by potentiometer 56. Motor shaft RPMs are monitored by totalizer counter 54 which counts the number of open/closed cycles of proximity switch 66. Meters counter 52 electricaly connects to a divide-by-six counting circuit 304 which transmits a count signal 306 to counter 52 for every six revolutions of idler roll 84 as sensed by cam operated micro switch 86. A reset connection 308 permits divide-by-six circuit 304 to be reset from counter 52 using button 52c. When counter 52 is set using thumbwheels 52a at some desired, non-zero fiber length (in meters) and while the present sensed count from circuit 304 is less than this preset value, coil 310 is activated which, via connection 312, closes DC contact 314 thus engaging clutch 48. DC power to clutch 48 then passes through emergency stop switch 50 which is normally closed. Upon reaching the preset fiber length, counter 52 deactivates coil 310 opening contact 314 thereby stopping the winding operation. It should be noted that clutch 48 is engaged even when motor 40's run switch 58 is open which permits the winding operation to commence upon closing switch 58. Conversely, by setting the meters count to zero and closing motor run switch 58, contact 314 is then open permitting the mandrel to be rotated incrementally by selectively closing normally open jog switch 46.
FIG. 8 shows a detail schematic diagram of divide-by-six circuit 304 which supplies corrected control information to meters counter 52. The raw revolution count information from microswitch 86 is first fed to a switch "de-bounce" circuit 320 comprising two logic NAND gates 320a and 320b cross connected so as to prevent false triggering from entering counter circuitry. This conditioned pulse from de-bounce circuit 320 is next fed to a three-stage synchronous counter 322 comprising three J-K flip-flops 324a, 324b and 326 which simultaneously receive the pulse. Two logic NAND gates, 328a and 328b, are connected such that they perform an AND with the flip-flops. Standard logic techniques are used to count the received pulses. When the sixth pulse is received, the "divide-by-six" output line 306 is activated and feeds meter counter 52. Before a winding operation is begun, the "divide-by-six" circuit must be reset. This command is sent by meter counter reset button 52c and is conditioned by a two-stage transistor/driver circuit 330 such that the command voltage levels are compatible with the TTL counter circuitry.
The advantages of the interferometric fiber optic hydrophone winding machine are as follows: The machine has the ability to provide increased optical fiber care-in-handling. Careful attention has been given to all fiber bends to provide ample, controlled radii in all cases. Constant tension control eliminates any snap loading of the fiber, and during winding, no twists are introduced into the optical waveguide. The surface finish of the rolls prevent damage to the fiber buffering. These safeguards combine to insure minimal fiber degradation for optical hydrophone operation. Another significant advantage of the winding machine is its ability to aid in hydrophone research. The machine can be used to selectively alter the two constructional parameters which most affect hydrophone performance, i.e., lay angle and fiber tension. A handwrapped version would not permit the small, consistent, changes necessary for optimal design. A final enormous advantage of a hydrophone wound on the present machine over its conventional handwrapped counterpart is in repeatability. Machine 10 provides the ability to fabricate multiple hydrophones having substantially identical response characteristics. This is possible because of the precise control of key constructional parameters; i.e., fiber pretension, fiber lay angle and fiber length. Such repeatability is imperative when constructing multiple sensor array systems.
What has thus been described is a hydrophone winding machine comprising a rigid framework, having attached thereto hydrophone mandrel mounting means, optical fiber dispensing means attached to an adjustable traversing mechanism, electric motor means for synchronously rotating the mandrel and driving the traversing mechanism, and control panel means for controlling the winding operation while displaying optical fiber length and tension status. The optical fiber dispensing means further includes a fiber reel stand attached to the traversing mechanism, a journal mounted fiber reel, an idler roll and a lead roll, all bearing mounted thereon. Fiber tension is controlled by adjusting the drag on the reel shaft while a tension assembly attached to a force gage permits digital readout of fiber tension at the control panel. A micro switch/pulse counter device attached to the idler roll monitors the total fiber length already wrapped on the mandrel. By varying mandrel rotation speed, reel stand traversing speed and direction, and reel drag compliant hydrophone mandrels thus can have optical fibers wrapped therearound having preselected fiber lay angles and fiber tensions thereby permitting many hydrophone variants to be produced for research programs and/or allowing production of a quantity of identical hydrophones.
Obviously many modifications and variations of the present invention may become apparent in light of the above teachings. For example: Single mode or multimode fiber may be wound on this machine. Materials used for plates, rolls, shafts, etc may be varied. A second fiber tensioning device may be added at roll 108 without deviating from the teachings of the present invention.
In light of the above, it is therefore understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A machine for winding, in a selected and consistent manner, a fiber optic lament on a compliant elastomeric mandrel, which assembly responds to acoustic waves by producing variations in diameter and light transmission characteristics of the fiber optic means. A motor rotates the mandrel at a selectable speed. A timing belt couples the mandrel rotation to a traversing mechanism supporting an optical fiber carrying reel and is adjustable to variably convert the rotary to linear motion. The shaft supporting the reel has brake means for adjusting the tension on the fiber. The fiber feeds over an idler roll which operates to count the number of meters of fiber wound on the mandrel, and then passes under a tension sensing roll. By varying mandrel rotation speed, traversing speed and reel drag, compliant hydrophone mandrels can have optical fibers wrapped therearound having many different fiber lay angles and fiber tensions, thus permitting production of hydrophones of desired characteristics.
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CROSS-REFERENCE TO RELATED APPLIC
[0001] This application is a continuation of U.S. application Ser. No. 14/049,726, filed Oct. 9, 2013, which is a continuation of International Application No. PCT/US2011/032122, filed Apr. 12, 2011, the entire disclosures of which are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] During the drilling phase of well exploration, it is common to hit pockets of gas and water. When using an air drilling process in a shale formation, shale cuttings, dust, gas and fluid/water create a volatile mixture of hard-to-handle debris; especially when encountering previously fractured formations. Drilling operations and debris disposal account for the majority of the volatility and fire risk during the drilling process. Without limitations, these operations include fluid recovery, gas irrigations and debris disposal.
[0003] As the number of wells drilled in a given area increase, the possibility of encountering a fractured formation within an active drilling operation, increases. This possibility presents the drilling operator with a problem of removing shale cuttings, along with dust, fluid/water and gas. There is no effective way to separate the shale cuttings, mute the dust, by-pass the fluid/water encountered, and control/burn the waste gas in the air portion of the drilling program.
[0004] Air drilling is one method of drilling into shale formations, but it creates large volumes of dust. Unfortunately, the dust cannot be discharged into the environment due to the many governmental regulations related to dust control for shale-gas drilling operations. Thus, such drilling efforts must overcome this problem or face substantial penalties and fines.
[0005] As gas is often encountered during the air drilling operation from a previously fractured formation, a combustible gas cloud may be created and linger near the ground. A similar gas cloud may exist and linger within and/or around the debris disposal pits. These combustible gas clouds create a fire hazard at the drilling site, and downwind therefrom. Accordingly, many additional governmental regulations for shale-gas drilling relate to the handling and processing of debris from such wells in order to avoid a volatile, combustible gas cloud.
[0006] The foregoing issues show there is a need for an apparatus to separate the shale-gas-water mixture into non-volatile components, and provide environmentally safe collection and disposal of the shale debris, fluid and formation gas burned a safe distance from wellbore.
SUMMARY OF THE INVENTION
[0007] In one aspect, the following invention provides for a shale-gas separator. The shale-gas separator comprises a vessel and a jet assembly. The vessel has an intake pipe defined thereon, where the intake pipe is positioned to tangentially communicate a shale-gas-fluid mixture into the vessel. A gas release vent is defined on the vessel, and positioned to communicate gas therefrom. The jet assembly has a side opening connected to a port positioned on the bottom of the vessel. The jet assembly has a first end and a second end defined thereon. A jet is connected to the first end. A jet assembly outlet is secured to the second end.
[0008] In another aspect, a shale-gas separator and clearing apparatus is provided. The shale-gas separator and clearing apparatus comprises a vessel, a jet assembly and internal aerated cushion system (IACS) pipe. The vessel has an intake pipe defined thereon. The intake pipe provides tangential communication of a shale-gas-fluid mixture into the vessel. The vessel has a top and a bottom, where the top and the bottom each have a port disposed therethrough. The jet assembly is secured to the bottom. The jet assembly has a jetted input and a venturi output. The IACS pipe is centrally disposed within the vessel, and extends towards the port in the bottom. The IACS pipe has at least one discharge nozzle defined thereon.
[0009] In yet another aspect, a shale-gas separator dust eliminator is provided. The dust eliminator comprises a sidewall, an inlet and an outlet. There is at least one fluid jet disposed through the sidewall. There is a plurality of baffles positioned within the housing, where a first baffle is positioned beneath the fluid jet and oriented to deflect fluid towards the outlet. There is a second baffle complementarily positioned within the housing between the fluid jet and the outlet, wherein the baffles are positioned to interrupt the flow of fluid through the housing.
[0010] Numerous objects and advantages of the invention will become apparent as the following detailed description of the preferred embodiments is read in conjunction with the drawings, which illustrate such embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 depicts a simplified schematic elevational view of a wellsite in fluid communication with a shale-gas separator.
[0012] FIG. 2 depicts a simplified schematic plan view of a wellsite in fluid communication with a shale-gas separator.
[0013] FIG. 3 depicts a lower left perspective view of a shale-gas separator.
[0014] FIG. 4 depicts right side elevational view of a shale-gas separator.
[0015] FIG. 5 depicts a left side elevational view of a shale-gas separator.
[0016] FIG. 6 depicts a front elevational view of a shale-gas separator.
[0017] FIG. 7 depicts a rear side elevational view of a shale-gas separator.
[0018] FIG. 8 is plan view of a shale-gas separator.
[0019] FIG. 9 is a sectional detail view taken from FIG. 4 along line 9 - 9 , and illustrates a debris shield.
[0020] FIG. 10 is a sectional detail view taken from FIG. 4 along line 10 - 10 , and illustrates an intake pipe having a tangential input and a wear plate.
[0021] FIG. 11 is sectional view taken from FIG. 6 , long line 11 - 11 , and illustrates an internal aerated cushion system (IACS) pipe.
[0022] FIG. 12 depicts a side view of a jet assembly.
[0023] FIG. 13A depicts a side view of a dust eliminator having spiraling baffles.
[0024] FIG. 13B is a sectional view taken from FIG. 13A along line 13 B- 13 B, and illustrates one of the spiraling baffles.
[0025] FIG. 13C is a sectional view taken from FIG. 13A along line 13 C- 13 C, and illustrates another of the spiraling baffles.
[0026] FIG. 13D is an elevational end view of a dust eliminator having spiraling baffles.
[0027] FIG. 14A is a bottom view schematic of slotted outlet muffler with the slot on one side.
[0028] FIG. 14B is a bottom view schematic of an outlet muffler having holes on one side.
[0029] FIG. 15A is a side view schematic of a slotted outlet muffler disposed within a housing.
[0030] FIG. 15B is a sectional view of a slotted outlet muffler disposed within a housing taken from FIG. 15A along lines 15 B- 1 B.
[0031] FIG. 15C depicts a perspective view of an alternative configuration of the collection bin, slotted outlet muffler without a housing and fluid overflow bypass line.
[0032] FIG. 16 depicts a perspective view of a jet assembly and pressurized fluid input lines, and optional valve.
[0033] FIG. 17 depicts a detail view of the vessel and fluid overflow bypass line.
DETAILED DESCRIPTION
[0034] Referring to FIGS. 1-3 , the inventive shale-gas separator is illustrated and generally designated by the numeral 10 . As shown by the drawings and understood by those skilled in the art, shale-gas separator 10 and components thereof are designed to be associated with a well 12 . As discussed herein, shale-gas separator 10 is associated with well 12 , shale formations 14 and drilling strategies. The drilling strategies include air drilling in shale formations. However, the invention is applicable to multiple drilling techniques with cuttings, dust, debris, gas and fluid from wells 12 other than those associated with shale formations 14 .
[0035] Shale-gas separator 10 is in air/fluid communication with well 12 . FIGS. 1 and 2 illustrate shale debris, dust, gas and fluid being communicated to shale-gas separator 10 in pipe 16 . The fluid is typically water, mist, foam, detergent or aerated mud. Shale-gas separator 10 receives the shale-gas-fluid mixture at intake pipe 18 . Intake pipe 18 is secured to and protrudes through wall 20 of vessel 22 . Optional dust eliminator 24 is illustrated as being directly connected to intake pipe 18 . However, dust eliminator 24 may also be positioned in-line with pipe 16 .
[0036] Shale-gas separator 10 , illustrated in FIGS. 1-7 illustrates vessel 22 in fluid communication with intake pipe 18 . As illustrated in FIG. 3 , intake pipe 18 flows into tangential input 26 through the sidewall 20 of vessel 22 and opens within vessel 22 , thereby defining the tangential flow and initiating the cyclonic effect with vessel 22 .
[0037] Vessel 22 is generally circumferential with domed top 28 and conical bottom 30 . Domed top 28 has a port disposed therethrough. The port in domed top 28 functions as gas release vent 32 , which is in fluid communication with flare stack feedline 34 and is capable of communicating gas from vessel 22 to a flare (not shown) placed sufficiently far enough from the well to mitigate any threat of accidental ignition of gas, Although not shown, gas release vent 32 optionally includes one-way valves, splash-guards, and/or back-flow preventers placed in flare stack feedline 34 prior to igniting the flare. Conical bottom 30 has port 36 disposed therethrough. Port 36 is in fluid communication with jet assembly 38 .
[0038] Interiorly disposed between tangential input 26 and gas release vent 32 is debris shield 40 . Debris shield 40 interiorly extends outward from wall 20 and covers about 40 percent to about 75 percent of the inner diameter of vessel 22 . As illustrated in FIGS. 4-9 , debris shield extends across the inner diameter of vessel 22 about 4 feet (about 1.2 meters). Additionally, FIGS. 4 and 5 illustrate debris shield 40 as having downward angle 42 and being oriented towards conical bottom 30 . Downward angle 42 is between about −5° and about −60° below the horizon, and is illustrated in FIGS. 4 and 5 as having an angle of about −15° below the horizon. Downward angle 42 provides for the downward deflection of shale debris and fluid, while allowing the separated gas to escape towards gas release vent 32 . Debris shield 40 has gas vents 44 penetrating therethrough along edges 46 to facilitate gas release.
[0039] In operation, debris shield 40 receives the shale-gas-fluid mixture from intake pipe 18 , and working in concert with the cyclonic effect communicated by intake pipe 18 and tangential input 26 , causes the gas to separate from the shale-gas-fluid mixture. The separated gas rises towards gas release vent 32 where it is communicated from vessel 22 . The shale debris and fluid fall towards conical bottom 30 , where it is received by jet assembly 38 .
[0040] FIG. 10 illustrates wear plate 48 secured to wall 20 and positioned to receive shale-gas-fluid mixture from intake pipe 18 and tangential input 26 . Wear plate 48 may be permanently affixed to wall 20 , or it may be removably affixed. As illustrated, wear plate 48 is interiorly welded to wall 20 . In the alternative, not shown, wear plate 48 is bolted, or otherwise secured to wall 20 . As illustrated, wear plate 48 is between about 18 inches to about 24 inches wide (about 0.46 meters to about 0.61 meters) and covers about one-half of the circumferential interior of wall 20 . As illustrated, wear plate 48 is about 0.5 inches (about 1.3 centimeters) thick. Wear plate 48 begins where tangential input 26 ends within vessel 22 . The longitudinal centerline (not shown) of wear plate 48 is centered on tangential input 26 , Preferably, wear plate 48 and tangential input 26 are blended together to prevent any edges for input flow to impinge upon.
[0041] As illustrated in FIGS. 1 , 3 - 8 , 12 and 16 , jet assembly 38 connects to port 36 of conical bottom 30 at a side opening thereon, also referred to as side receiver 50 . Side receiver 50 has a shape facilitating the flow of debris and fluid into jet assembly 38 . Side receiver 50 surrounds port 36 , thereby providing for unimpeded flow into jet assembly 38 . Jet assembly 38 has first end 52 and second end 54 . First end 52 has jet 56 connected thereto. Referring to FIG. 12 , jet 56 extends into jet assembly 38 along a center axis of jet assembly 38 , and terminates between side receiver 50 and second end 54 , Vacuum gauge 58 is illustrated in FIG. 12 as being positioned on side receiver 50 within jet assembly 38 to measure the drop in pressure or amount of vacuum pulled in inches or kilopascals. In practice, the amount of vacuum pulled by jet assembly 38 is about −10 inches of mercury to about −15 inches of mercury (about −34 kilopascals to about −51 kilopascals).
[0042] Jet 56 is capable of receiving fluid, either liquid or air, which in turn provides the motive force to the shale debris and fluid to exit through second end 54 . Preferably, jet 56 is able to use compressed air, compressed inert gas, pressurized water, pressurized hydraulic fluid, or combinations thereof. Jet assembly 38 also has pressure gauge 60 . Pressure gauge 60 provides feedback on the pressure of air/fluid flowing into jet assembly 38 through jet 56 and to internal aerated cushion system (IACS) pipe 62 .
[0043] Second end 54 communicates the debris and fluid to outlet muffler 64 . FIG. 12 depicts second end 54 as venturi 66 . Jet assembly outlet 68 , illustrated in FIGS. 4-6 , 8 , 12 and 16 , communicates the debris and fluid from second end 54 to collection bin 70 via discharge line 72 . In an alternative embodiment, venturi 66 is part of jet assembly outlet 68 that is secured to second end 54 .
[0044] Jet assembly outlet 66 is secured to discharge line 72 , which is in communication with outlet muffler 64 . As illustrated in FIGS. 2 and 15C , outlet muffler 64 is positioned to discharge shale debris and fluid into collection bin 70 . Outlet muffler 64 has at least one discharge port 74 . As illustrated in FIGS. 2 , 11 A- 12 C, outlet muffler 64 has one to six discharge ports 74 , but any number will provide the desired discharge. FIGS. 2 , 14 A, and 15 A- 15 C illustrate discharge port 74 being a slot. FIG. 14B illustrates three discharge ports 74 as holes. Other shapes and sizes of discharge port 74 are understood to be included. For example, discharge port 74 can be elliptical or square. It is also anticipated that discharge line 72 can directly discharge the shale debris and fluid without outlet muffler 64 ,
[0045] FIGS. 15A and 15B depict outlet muffler 64 with housing 76 surrounding it and being secured thereto. Housing 76 tapers outwardly from top 78 to bottom 80 , as illustrated in FIGS. 2 , 3 , 15 A and 15 B. Also illustrated in FIGS. 2 , 15 A and 15 B, is outlet muffler 64 with discharge port 74 oriented towards bottom 80 , FIG. 15A shows one embodiment of outlet muffler 50 secured to housing 76 . Additionally, outlet muffler cap 82 is illustrated as extending externally to wall 84 of housing 76 . In this embodiment, discharge port 74 is a slot extending across a substantial depth 86 of housing 76 .
[0046] Outlet muffler cap 82 provides impact baffling for debris discharging through outlet muffler 64 . Alternatively, internal baffles (not shown) may be used to divert and slow the debris within outlet muffler 64 . Another alternative is to not use outlet muffler 64 and secure housing 76 directly to elbow 88 . This alternative has internal baffles or wear plates on wall 84 .
[0047] FIG. 15A illustrates housing 76 with sniffer port 89 thereon. Sniffer port 89 provides access for a gas sniffer (not shown) to sample the output from outlet muffler 64 for the presence of gas, In this context, the gas sniffer includes the capability to detect one or more of the gaseous chemicals found in well 12 . In the absence of housing 76 , sniffer port 89 is positioned on outlet muffler 64 .
[0048] Vessel 22 also includes IACS pipe 62 . As illustrated in FIGS. 4-8 and 11 , IACS pipe 62 is elongated and positioned within vessel 22 . IACS pipe 62 is centrally positioned within conical bottom 30 of vessel 22 , and located above port 36 . IACS pipe 62 has at least one nozzle 66 defined thereon. IACS pipe 62 is positioned within vessel 22 to provide pressurized fluid to remove any debris buildup on wall 20 of conical bottom 30 down to port 36 , In use, IACS pipe 62 provides a fluid cushion to mitigate the buildup of gas in jet assembly 38 and vessel 22 .
[0049] The non-limiting example in FIG. 11 depicts IACS pipe 62 having three to five sets of nozzles 90 positioned along longitudinal portion 92 of IACS pipe 62 . Additionally, the non-limiting example depicts another three cleanout nozzles 90 secured to IACS pipe end 94 , and are downwardly oriented. By way of another non-limiting example, if longitudinal portion 92 of IACS pipe 62 is about three (3) feet (about 1 meter) in length, nozzles 90 are spaced along longitudinal portion 92 with spacing of about six (6) inches to about 18 inches (about 0.15 meters to about 0.5 meters). The spacing between cleanout nozzles 90 is determined by the size of vessel 22 . As shown in FIG. 11 , the spacing between nozzles 90 is about twelve (12) inches (about 0.3 meters). There may be a plurality of nozzles 90 circumferentially positioned along longitudinal portion 92 at each spacing. Alternatively, there may be a plurality of nozzles 90 circumferentially and offsettingly positioned along longitudinal portion 92 at operator desired spacing.
[0050] Referring to FIGS. 4-8 and 11 , IACS pipe 62 is secured to and through wall 20 . Although IACS pipe 62 is illustrated as a single line, it may be formed out of several pipe sections, IACS pipe 62 is in fluid communication with pressurized fluid line 96 with line 98 at t-joint 100 . Line 98 has valve 102 disposed between pressurized fluid line 96 and IACS pipe 62 . Valve 102 provides control of the fluid communicated to IACS pipe 62 , and is illustrated as a manually operated valve. However, automating valve 102 is understood to be within the skill of one knowledgeable of the art.
[0051] As illustrated in FIG. 16 , pressurized fluid line 96 communicates pressurized fluid to jet 56 and to IACS pipe 62 through line 98 . Valve 104 is positioned upstream from t-joint 100 and pressure gauge 60 , and controls the fluid communicated to jet 56 . Valve 104 may also be manually or automatically operated. Although, using the same fluid for both jet 56 and IACS pipe 62 is preferred, an alternative is to use separate types of fluid communicated through separate supply lines (not shown). For example, compressed air is communicated to jet assembly 38 and pressurized water is communicated to IACS pipe 62 . Compressed air will be the most common fluid communicated through pressurized fluid line 96 and line 98 due to its availability at the wellsite.
[0052] FIG. 16 also illustrates pressure gauge 60 and vacuum gauge 58 as described above. Preferably, valve 104 is adjusted to set a minimum vacuum condition in jet assembly 38 . One embodiment facilitates achieving the above-mentioned desired vacuum range of about −10 inches of mercury to about −15 inches of mercury (about −34 kilopascals to about −51 kilopascals). In this embodiment, jet 56 operates using fluid having a pressure in the range of about 75 pounds per square inch to about 200 pounds per square inch (about 517 Kilopascals to about 1,379 Kilopascals). Valve 104 is adjustable until vacuum gauge 58 indicates the vacuum is within desired range.
[0053] FIGS. 4-8 illustrate fluid overflow bypass line 106 , or overflow line 106 . Overflow line 106 communicates any excess fluid buildup within vessel 22 away from vessel 22 . As illustrated, intake port 108 is oriented towards conical bottom 30 , is centrally positioned within vessel 22 and below than intake pipe 18 . Preferably, intake port 108 is also positioned above IACS pipe 62 .
[0054] Overflow line 106 is secured to and through wall 20 at point 110 . Preferably, point 110 is below intake pipe 18 . Overflow line 106 is connected to fluid bypass discharge line 112 , or bypass line 112 . Bypass line 112 discharges to any receptacle capable of receiving the fluid, with one example shown in FIG. 15C . Preferably, bypass line 112 discharges to another device (not shown) capable of separating any gas from the fluid.
[0055] To provide additional access to vessel 22 , at least one manway 114 and at least one cleanout/observation hatch 116 are utilized and disposed through wall 36 . Manway 114 is disposed through wall 20 above conical bottom 30 . Cleanout/observation hatch 116 is disposed through wall 20 of conical bottom 30 . Manway 114 and cleanout/observation hatch 116 are sized to provide complete or partial access to the interior of vessel 22 . As shown, manway 114 is about 24 inches (about 0.6 meters), and cleanout/observation hatch 116 is about 10 inches (about 0.25 meters).
[0056] As illustrated in FIGS. 1-8 , 10 and 13 A-D dust eliminator 24 has inlet 118 , outlet 120 , fluid jet 122 , and a plurality of baffles. As illustrated, the plurality of baffles include first spiral baffle 124 and second spiral baffle 126 . Fluid jet 122 is disposed through sidewall 128 of dust eliminator 24 near inlet 118 . First spiral baffle 124 and second spiral baffle 126 are positioned from about inlet 118 to about outlet 120 . Second spiral baffle 126 is complementarity positioned within dust eliminator relative to first spiral baffle 124 . Fluid jet 94 is positioned near inlet 118 above first spiral baffle 124 and second spiral baffle 126 . First spiral baffle 124 and second spiral baffle 126 deflect the fluid, typically water, being propelled from fluid jet 122 towards outlet 120 . First spiral baffle 124 and second spiral baffle 126 interrupt an axial flow of fluid and debris through the dust eliminator, thereby inducing a spiraling flow of the fluid and debris through dust eliminator 24 . This spiraling flow action causes the dust and fluid to mix, thereby reducing dust.
[0057] An alternative for first spiral baffle 124 and second spiral baffle 126 is to use offsetting baffles (not shown) that are alternating and obliquely positioned. In this case, the first baffle will be obliquely positioned below fluid jet 122 and capable of deflecting the fluid towards outlet 120 . The subsequent baffles alternate and provide points of impact for the fluid and the debris of shale-gas. The fluid impacts interrupt flow of fluid through the dust eliminator 24 . In this setup, there are at least two baffles and preferably three or more baffles.
[0058] Referring to FIGS. 1-8 , shale-gas separator 10 is shown as being carried by skid 130 . Preferably, skid 130 is transportable across a standard U.S. highway.
[0059] In an embodiment illustrating the use of shale-gas separator 10 , a typical well 12 using shale-gas separator 10 discharges the shale-gas debris through pipe 16 to the optional dust eliminator 24 , where a fluid, such as water, is injected therein and encounters the debris, thereby reducing and/or eliminating any dust. The shale-gas debris may be shale-gas-fluid debris. Exiting from the optional dust eliminator 24 , the debris is communicated to vessel 22 where it is cyclonically communicated therein through intake pipe 18 and tangential input 26 .
[0060] The debris cyclonically spins around within vessel 22 . In a non-limiting example, vessel 22 has a diameter of about 72 inches (about 1.83 meters). In this same non-limiting example, debris shield 40 has 15-degree downward angle 42 and covers about 66 percent of the interior of vessel 22 , which is about four (4) feet (about 1.2 meters). Debris shield 40 restricts and deflects solids and fluid downwardly, away from gas release vent 32 . The released gas is communicated upwardly to gas release vent 32 , whereby it is further communicated to flare stack feedline 34 and burned at a flare positioned a safe distance from the well 12 .
[0061] The solid debris and fluid fall downwardly into conical bottom 30 and through port 36 where the solids and fluid enter jet assembly 38 . Jet 56 , using air or fluid, propels the solids and fluid through jet assembly 38 to venturi 66 . As the solids and fluid flow through venturi 66 , they are propelled to outlet muffler 64 . Outlet muffler 64 discharges the solids and fluid into collection bin 70 .
[0062] If jet assembly is blocked or clogged, IACS pipe 62 is positioned to provide high-pressure fluid that is expelled through cleanout nozzles 90 within conical bottom 30 . The high-pressure fluid is commonly air due to the availability at wellsites. The high-pressure fluid creates a cushion or barrier to keep gas from being communicated to jet assembly 38 . The placement of IACS pipe 62 provides for maximum or additional force of pressurized fluid to further motivate the solids out of conical bottom 30 of vessel 22 . Additionally, IACS pipe 62 provides fluid to remove debris build up on the interior of wall 20 of vessel 22 . For this non-limiting example, the supply of fluid is from the same source of fluid provided to jet 56 . However, separate sources of fluid for IACS pipe 62 and jet 56 are equally acceptable as is the same source. Additionally, for this non-limiting example IACS pipe 62 is about 2 inches (about 5 centimeters) in diameter.
[0063] Jet assembly 38 has an additional clean out port, or cleanout plug 131 . Clean out plug 131 is illustrated in FIG. 16 as being oppositely positioned side receiver 50 . In the event jet assembly 38 becomes too clogged to clean it out with pressurized air or fluid, plug 131 can be removed for manual cleaning.
[0064] Referring to FIG. 16 , valve 132 is illustrated as being positioned between second end 54 and outlet muffler 64 . Valve 132 is optional and provides a means to prevent all flow from vessel 22 through jet assembly 38 . In this instance, all flow can be forced through overflow line 106 . As illustrated in FIG. 16 , valve 132 is a knife valve, but any valve capable of preventing flow will work. In one embodiment, valve 132 is air actuated. As shown in FIGS. 3 and 16 , valve 132 is manually operated.
[0065] Overflow line 106 , functioning as a bypass, provides for a means to passively remove excess fluid, which is typically water, accumulating within vessel 22 , As the fluid accumulates, it begins to enter intake port 108 until it reaches first turn 134 . At that time, the fluid begins to flow out of overflow line 106 and into discharge line 112 , where it is deposited into an approved receptacle. As described in this non-limiting example, overflow line 106 and discharge line 112 are each about 6 inches (about 0.15 meters) in diameter.
[0066] Referring to FIGS. 2-8 and 17 , external valve 136 is utilized to open and close overflow line 106 to control fluid communication from overflow line 106 to bypass line 112 . External valve 136 may be automated, or it may be manual. The manual system of external valve 136 is illustrated with handle 138 to open and close it. In the manual mode, an internal indicator float (not shown) and float signal 140 , as shown in FIG. 17 , are used to notify an operator to open the external valve 136 . The same float and signal 140 are automatically integrated with an automated system. Signal 140 can be audible, visual, electronic, or a combination thereof.
[0067] FIG. 17 depicts optional vessel pressure gauge 142 . Vessel pressure gauge 142 provides the operator with feedback on the current pressure within vessel 22 .
[0068] Other embodiments of the current invention will be apparent to those skilled in the art from a consideration of this specification or practice of the invention disclosed herein. Thus, the foregoing specification is considered merely exemplary of the current invention with the true scope thereof being defined by the following claims.
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This invention relates to the separation of shale, gas and fluid at a shale-gas well. The shale debris and water from a shale-gas well is tangentially communicated to a vessel where the cyclonic effect within the vessel facilitates the separation of the gas from the shale debris. The separated shale debris and fluid falls to a jet assembly whereby it encounters a jet communicating a fluid therethrough. A venturi provides a motive force to the shale debris and fluid sufficient to propel it into a collection bin. The shale-gas separator incorporates a fluid bypass overflow line to prevent a buildup of fluid within the vessel. The shale-gas separator also incorporates an internal aerated cushion system (IACS) pipe for further motivating the shale debris and into the jet assembly, to ensure the walls of the vessel are clean, and to provide an air cushion restricting gas migration to the jet assembly.
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This is a continuation of application Ser. No. 08/116,740 filed on Sep. 7, 1993 now U.S. Pat. No. 5,425,158 which is a continuation in part of application Ser. No. 950,272 filed on Sep. 24, 1992 now U.S. Pat. No. 5,253,392 which is a continuation in part of Ser. No. 612,558 filed Nov. 13, 1990 now U.S. Pat. No. 5,199,134, issued on Apr. 6, 1993.
BACKGROUND OF THE INVENTION
The invention relates to a continuous, fully integrated system and method for producing nonwoven webs consisting of bleached cotton fibers.
Bleached cotton fibers have been used in many nonwoven fabric applications for cleanliness and absorbency such as wipes, premoistened towelettes, absorbent pads, etc. The purified, absorbent fibers are particularly advantageous in hospital and medical applications such as disposable sheets, blankets, gowns, and bandages, and, particularly, because of their biodegradability. Typically the bleached cotton fibers are made into a nonwoven web and then fabricated for the particular end use.
The typical process has included many separated processing steps. Typically, raw cotton fibers are bleached at a remote bleachery using a large vat. The bleached fibers are dried and pressed into bales. The bales of bleached cotton fibers are then transported to a textile mill at another location where they are processed further by a nonwoven carding system into nonwoven webs in a conventional manner. Bleaching processes have not been a part of nonwoven textile processing lines. As a result, the textile process has been fairly inefficient incurring transportation costs, and inefficiency through piecemeal processing.
Various textile process lines for woven and nonwoven fabrics are known and have been proposed in the past. Various processes and systems are known for opening, cleaning, and blending fibers, for example, U.S. Pat. No. 2,718,671. Various processes and systems for opening fiber bales, and opening and cleaning the fiber before being carded into a web for woven or nonwoven applications are known, for example, as shown in U.S. Pat. No. 4,535,511.
It is known to make webs formed from synthetic fibers more integral by hydroentanglement techniques. Various hydroentanglement techniques and apparatus for producing integral webs having various patterns are shown in U.S. Pat. Nos. 3,494,821; 3,486,168; 3,485,706; 3,508,308; and 3,493,462.
Because of the increased demand for the bleached cotton fiber, for both woven and nonwoven products, it has become necessary to use lower grades of cotton. This has rendered the prior bleaching and textile processes unsatisfactory because they do not satisfactorily process the lower grade of cotton. Accordingly, an important object of the present invention is to provide a system and method for producing bleached cotton, nonwoven webs in a single processing line under one roof.
Another object of the invention is to provide a continuous fiber preparation process capable of converting low grade, dirty, short stable cotton fibers into a clean blended fiber web.
Another important object of the invention is to provide an efficient textile process system and method which begins with the opening of raw cotton fibers from bales and ends with the production of nonwoven webs ready to enter a cotton bleaching process in a continuous system.
Another object of the invention is to provide a continuous cleaning cotton system which dries the cotton fibers prior to cleaning so as to more efficiently and effectively remove trash and dirt particles.
Another object of the invention is to provide a continuous cotton cleaning system capable of adapting between extremely dirty cotton and mildly dirty cotton.
Another object of the invention is to provide a textile processing system and method wherein low grade raw cotton fibers may be processed and bleached and the bleached fibers may be subjected to further processing and production of a nonwoven web and prepared for further textile processing.
Another object of the invention is to provide a cotton processing system capable of producing cleaned and bleached cotton at an extremely high yield.
Another object of the invention is to provide a cotton processing system which reduces the cost per pound of processing clean and bleached cotton.
Another object of the invention is to produce surgical grade cleaned and bleached cotton at a rate of at least three to four thousand pounds per hour.
Another object of the invention is to provide a system which fully cleans and blends low grade cotton for the formation of cotton webs to be bleached.
SUMMARY OF THE INVENTION
A continuous fiber processing system for producing a bleached and blended cotton fiber web beginning with bale opening means for opening bales of cotton fibers and delivering the fibers to a plurality of fiber feed lines each of which includes a first fiber opening means for individualizing and cleaning the fibers to produce cleaned opened fibers. From the opening means the fibers move to a fiber preparation station which includes a fiber heating unit and a metal removing unit for collecting the opened fibers and preparing them for blending, cleaning and web forming. Conveyor means deliver the fibers from the preparation station to a precleaning station. The precleaning station cools, cleans and reheats the fibers for presentation to the primary cleaning and web forming station. The primary cleaning and web forming station further cleans, blends and forms the fibers into a web. The fiber web is delivered to a cross-blending station which prepares the web for delivery to the bleaching station.
The pre-cleaning station includes a horizontal cleaning machine which allows the fibers to cool and also inclined cleaning machines.
The primary cleaning and web forming station includes a stick and large trash removing machine, inclined cleaning machines, micro dust removing machines, double battery comber machines and in line comber machines.
Switching means are provided which allow the precleaning and conditioning station to be by passed.
The heating means include vacuum chambers which introduce the fibers into the transport system which conveys the heated fibers to the pre-cleaning and conditioning station and to the primary cleaning and web forming station. The fibers are heated to between one and six million BTU's.
Bale forming devices are arranged to receive and bale removed dirt and lint.
The primary cleaning and web forming station includes a web divider which separates the web to feed simultaneously the double battery combing machines.
The bleaching station further stabilizes the web and delivers it to a continuous flow bleaching system which bleaches the fibers forming the web producing a web of bleached cotton fibers. From the bleaching system, the web is fed into a dryer system for drying. From the dryer system the now dried bleached web goes to a slitter which slits same into a plurality of web strips or slivers. The slivers are fed to a plurality of carding machines which further blend and clean the fibers and also forms them into a loose web. The loose webs are delivered to a common conveyor means in stacked overlaying fashion forming a stacked web. The common conveyor delivers the stacked bleached web to a second web stabilizing means in the form of a hydroentangling system which produces a stable web of entangled fibers. The stable web is passed to a dryer mechanism and from there to roll forming means wherein it is a rolled web for use in further fiber processes.
To obtain additional blending web cross-lapping means may be arranged to receive the non-woven webs from the carding machines. This arrangement forms a cross-lapped web having a plurality of web layers.
The first web forming means preferably consist of comber machines which produce a blended web prior to bleaching.
The first dryer system comprises a foam dryer for receiving and treating the bleached web from the fiber bleaching means and a web drying oven for receiving the web from the foam drying means. Also, there may be included apparatus for applying an additive to the bleached cotton fibers before they are dried as they exit the fiber bleaching means. Additionally, means for dying the bleached and hydroentangled web a desired color may be provided.
An alternative arrangement comprises a fiber processing system which includes bale openers connected to deliver opened fibers to a fiber preparation station as in the primary embodiment.
A routing system is connected with the fiber preparation station and is controlled to deliver the fibers through a myriad of routes to a fine cleaning station.
The routing system may be connected to deliver the prepared fibers to a primary cleaning station or to only a portion of the primary cleaning station. The fibers may or may not be routed to be dried before being sent to the primary cleaning station. Also, the fibers may or may not be routed through a stick and leaf remaining chamber prior to being sent to the primary cleaning chamber.
From the primary cleaning station, the fibers are fed into an auger conveyor which is connected to a plurality of inclined feed stations of a plurality of carding machines. The auger conveyor includes a re-circulating system which allow for any excess of fibers to be re-circulated through the auger conveyor.
Suction take-off means remove the carded fibers, still in fiber form, from the carding machine and deliver them to a conveyor which is connected with further processing mechanisms of the type utilized with the primary embodiment.
DESCRIPTION OF THE DRAWINGS
The construction designed to carry out the invention will hereinafter be described, together with other features thereof.
The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:
FIG. 1 is a schematic view illustrating a textile processing system and method for producing a non-woven web of cleaned cotton, prepared for delivery to a bleaching operation in a single and continuous processing line; and
FIG. 2 is a schematic view illustrating a waste collecting and baling arrangement.
FIG. 3 is a sectional side view of the preheating chamber.
FIG. 4 is a sectional end view of the preheating chamber taken from the left side of FIG. 3.
FIG. 5 is a schematic view illustrating an alternative arrangement for a pre-bleaching cotton opening, cleaning and blending processing system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in more detail to the drawings, a system and method for producing a nonwoven web of cleaned and bleached cotton fibers will be described. The system begins with a delivery line which is connected with at least two bale openers 10 which may be any suitable and known type such as a HF6012 hopper feeder manufactured by Hollingsworth, Inc. of Greenville, S.C. Bale openers 10 are each capable of opening up to four bales per hour. Fibers from bale openers 10 are discharged onto a mechanical conveyor 12 and delivered to a fiber preparation station A which includes a preheating chamber 18 which removes moisture from the fibers and readies them for particle and dust removal. The fiber preparation station A also includes a metal removing unit 14 which cleans and removes metal and begins the process of opening and further individualizing the heated fibers. Any suitable metal removing unit may be used such as those manufactured by Continental, Hollingsworth or Lumas. Fibers are conveyed from metal remover 14 into y-valve 16 which controls the additional cleaning and web forming processes from between an intensive cleaning process and a super intensive cleaning process.
Heated air is generated at a heat source 20 and delivered through conduit 22 to heating unit 18 with an air flow which may range between 5,000 and 15,000 CFM, however an air flow of 10,000 CFM is preferred. The air is heated to between 1 and 6 million BTU's with air heated to 4 million BTU being preferred.
FIGS. 3 and 4 show in detail the structure of heating chamber 18. The opened cotton fibers 25 are fed by conveyor belt 30 into vacuum unit 24'. The vacuum unit consists of a pair of sides 32 which are solid, a front wall 34 which has a feed opening 36 and a rear wall 38. A fiber exit opening 40 is formed at the lower end of wall 38. Conveyor belt 30 is of a width substantially equal to the width of vacuum chamber 24.
A vacuum chamber forming paddle wheel 42 is rotably driven about axis 44. Paddle wheel 42 includes a plurality of equally spaced paddles 46 each equipped with a resilient flapper 48 at its end. Paddles 46 are provided at their edges with a seal 46' and are of a width substantially equal that of vacuum unit 24'.
Mounted adjacent vacuum unit 24' is a mixing and cleaning chamber 48. Mixing and cleaning chamber 48 includes a connection for conduit 22 which emits the heated air into the chamber. Vanes 50, 51 control the passage of air through chamber 48 and out the exit conduit 24. The lower portion of chamber 48 contains a trash collecting sump 52 which connects with a trash collector not shown.
Pre-heating chamber 18 receives the opened cotton fibers 25 from opening machines 10 by conveyor 30. As the fibers enter unit 24' paddle wheel 42 which is rotating in the direction of and at the same speed as conveyor belt 30 engages with the conveyor belt. The opened fibers are separated into individual bundles by the paddles 46 as paddle wheel 42 continues to move toward exit opening 40. The paddles 46, through the engagement of seals 46' with side walls 32 and the engagement of flapper 48 with conveyor belt 30 form moving vacuum chambers, which prevent the escape of the heated air and which carry the fibers and deliver them into mixing and cleaning chamber 48 through opening 40. One of the moving chambers is shown at 26 and is formed between paddles 46".
The heated air passes through conduit opening 22 with the flow following the arrows as indicated in FIG. 3. As the air passes under lower vane 51, it engages with the fibers entering through opening 40. Paddles 46 prevent the air from exiting chamber 26 through opening 36. As the heated air engages, dries, and lifts the fibers which are being delivered through opening 40, large trash particles drop out into sump 52. The fibers become entrained in the air flow and are transported out of chamber 48 through the opening connecting with conduit 24.
Vanes 50 and 51 are pivotal about axis 53 to move between extreme open and closed positions. When vane 50 is positioned in its extreme left most position, it prevents substantially all of the air flow across the upper part of chamber 48 between openings 22 and 24. When vane 50 is in this position vane 51 must be positioned in its extreme right position. This allows the air to flow through the opening formed between the end of vane 51 and the end of conveyor belt 30. Vanes 50 and 51 are adjusted relative to each other to allow air of sufficient volume to pass below vane 51 and engage with the fibers to heat, clean and convey them. When vane 50 is moved to the right, a portion of the incoming air passes over the upper end of the vane and directly out conduit 24 as shown by the arrows in FIG. 3. This requires that the opening between vane 51 and conveyor belt 30 be made smaller so that the air moves through the opening with sufficient force.
Conduit 24 conveys the heated fibers into the metal removing station 14. From this station the fibers pass to y valve 16.
If it is necessary that a super intensive cleaning operation be conducted, valve 16 directs the heated fibers carried by the heated air into conduit 60 which delivers them to a pre-cleaning operation B. The pre-cleaning station includes a horizontal cleaner 62 into which the fibers are delivered by conduit 60. In line with and adjacent to the horizontal cleaning machine 62 are a plurality of inclined cleaners 64. Both horizontal cleaner 62 and inclined cleaners 64 deliver the processed fibers to drops 65 which direct them to the next processing station. It is preferred that three in line inclined cleaning machines 64 which are inner connected via drops 65 and fed from a horizontal cleaner 62 function to clean, condition and blend the fibers. This arrangement allows the fibers to cool. Therefore, upon leaving the last inclined cleaning machine 64, the fibers are again passed through a heating station 66 which is similar to heating station 18.
Heat source 68 delivers heated air through conduit 70 into heating station 66 where it further heats, blends, cleans and conveys the fibers into and through conduit 74. Conduit 74 terminates with y valve 76.
Primary cleaning and web forming station C receives the heated, conditioned and cleaned fibers through valve 76. Primary cleaning and web forming station C begins the fiber preparation process with stick and large trash removing machine 78 which again cleans the fibers of large particles. From cleaning machine 78 the fibers are delivered to a comber machine 80 which cleans the fibers and forms them into a batt. The fiber batt is delivered to the first of a series of in line inclined cleaners 82 which break up the fiber batt and further blend and clean the fibers. To assist in keeping the fibers separated for cleaning, each of the inclined cleaners 82 delivers the fibers into a fiber drop 83 which allow fiber free fall before delivery to the next machine. Following the inclined cleaning machines is a fine trash removal machine 84 followed by a micro dust removing machine 86.
The fiber batt upon leaving the micro dust remover 86 is passed through a splitter 90 which divides the web into two parts. Adjacent to splitter 90 is a double battery comber 88. The divided webs are delivered into double battery comber 88 where they are combed and formed into webs. The webs are delivered onto conveyor 91 which stacks them in vertical fashion on conveyor 92. Conveyor 92 delivers the stacked web into the first of the in line combers 96 where the fibers are again combed and formed into a single web.
The web is passed from the last of comber machines 96 to y valve 100. This y valve is connected in one direction with a condenser 101 which condenses the web and delivers it to a baler 102 which forms a bale of the fibers for storage before further processing.
Alternatively, y valve 100 connects with conduit 104 which delivers the fiber web to further processing machinery.
Should the fibers require only intensive cleaning valves 16 and 76 are controlled to direct the heated fibers leaving the fiber preparation station A through conduit 75 and directly into the primary cleaning and web forming station C.
Each of the cleaning and combing machines of the system is of known construction and is readily available from the various machine manufacturers such as American Treutzschler, Inc. of Charlotte, N.C.; Continental Eagle Corp of Prattville, Ala.; Consolidated Engineering of Kennesaw, Ga.; Hollingsworth on Wheels of Greenville, S.C. and Leemar Corp of Columbus, Ga. The machine structures form no part of the instant invention.
Conduit 104 connects with a switch box 106 which divides the web between the cross blenders 108 or it may act to switch the web back and forth in a selected sequence between the cross blenders 108. The number of blenders 108 is determined by the volume of fibers being fed. Cross blenders 108 may be any suitable fiber blenders such as LCB lay down cross blenders manufactured by Hollingsworth, Inc. The cross blenders blend the fibers while providing some fiber opening, and act as a reserve to feed bleach feeding lines 108a, 108b. The fibers coming out of the bleach feeding lines are conveyed to flow distributor 110 which acts to equalize the fiber flow and to deliver a constant uniform fiber flow to chute feeder 110. Chute feeder 110 may be of any suitable design such as that disclosed in U.S. Pat. No. 4,657,444. The fibers pass into chute feeder 112 at its upper end and are condensed into a uniform fiber mat by means of air and mechanical movements. A fiber web is delivered from chute feeder 112 to hydroentangling unit 114. Hydroentangling unit 114 acts to entangle and interlock the fibers of the web together to form a stable web of highly entangled fibers capable of retaining its integrity as it passes through bleaching unit D. Plural blenders are used because the bleaching unit has a capacity of at least 4000 pounds per hour, and each blender has a capacity of about 2500 pounds per hour. Hydroentangling unit 114 may act on the top, the bottom, or both the top and bottom of each web W. Hydroentangling unit 114 has a capacity in excess of 4000 pounds per hour, thereby allowing the plural cross blenders 108 and bleaching unit D to operate at or near capacity. Switch box 106 switches the fibers between lines 106a, 106b.
The web moves through the bleaching unit via a plurality of bleaching chambers I, II, III, IV, and V via a plurality of rolls (not shown) and is immersed in various bleaching agents. The bleaching agents in the various chambers may be one or a combination of alkali impregnation, alkali steam reaction, alkali reuse, bleach impugn, bleach steam, or bleach venue. A suitable bleaching unit D is a continuous flow bleaching unit manufactured by Greenville Machinery of Greenville, S.C. The bleaching unit bleaches the fibers as they continuously flow through the bleaching unit in web form. A bleached fiber web W leaves bleaching unit D and passes into dryer system E. Dryer system E may include foam dryer 116 which applies a flame or mildew retardant to the fibers while still wet. The web may then pass to a gas dryer 118 which can be a conventional gas fired textile oven operating at necessary speed and temperature to accommodate 4000 pounds per hour of fiber web. Dryer 118 may completely dry web, in which case the web passes directly to slitter 120. Optionally, web W may be partially dried and passed to a second foam dryer 116 which also dyes the web a solid color. From dryer 116, web W passes into a second gas dryer 118 where drying is completed. Dried web W passes now to slitter 120 which slits the web into a plurality of web strips or slivers 5, 6, 7, 8. Slivers or web strips 5, 6, 7, 8 are each delivered by delivery lines to a fine clean cleaning station F comprising a plurality of carding machine 122 by. There are four card machines 122 shown; however, the number is increased or decreased depending upon the fiber pounds per hour delivered from slitter 120. Also, the number of slitters 120 may be increased if necessary. Each card 122 delivers a fiber web to mechanical conveyor 124 where the carded fibers are lapped or stacked so as to again further blend and clean the bleached fibers. The carded webs formed from web strips 5, 6, 7, 8 are now formed into bleached and stacked web W'. It is noted that the carding process performed by carding machines 122 removes trash, micro dust, and fibers which are too short. Cards 122 perform the final opening and cleaning operation for the fibers prior to their being delivered for further product processing. The carded webs are doffed by air from conveyor 124 and carried to an additional card 125 which delivers the fibers to cross lapped machine 126. The bleached cross lapped cotton web W' is then fed to a hydroentanglement unit G which intermingles and interlocks the fibers together in an integral web W" of bleached cotton fibers. After drying by dryers 116 and 118, web W" is formed into a roll 113 on take-off mechanism H and is in condition to be handled for further applications or to be fabricated into various end products.
A suitable hydroentanglement unit is manufactured by Honeycomb Systems of Maine. As the web enters the hydroentanglement unit, it encounters a series of very fine water jet units that pierce the carded web and cause the fibers to be intermingled and interlocked. This action holds the web together. Hydroentanglement is a rather unique process which provides softness and the drapeability to the web, and a generally lint free web. The finished product is dirt, dust, and lint free, and therefore, can be used in a lot of advantageous applications, such as with instruments or electronics, in hospitals, and other non-woven markets.
The processed and carded web of opened cleaned bleached fibers W' may be directed through Y valve 127 to bale press 139. A condenser 130 assembles the opened bleached fibers to be compressed into a bale. These bleached fibers can be sold in bale form.
An alternative arrangement for preparing cotton fibers for further treatment is shown in FIG. 5. In this arrangement openers 10 again open and separate cotton fibers from bales and deliver these fibers into a chute feed 12 which delivers them to a fiber preparation unit A. The number of openers 10 is totally dependent upon needs of the remainder of the system and the capacity of each opener.
From fiber preparation area A, the fibers are conveyed by hot air through a conduit which connects with a Y valve 140. A conduit 142 leading from valve 140 connects with a primary cleaning area I.
Primary cleaning area I consist of a condenser 144 which condenses the heated fibers and delivers them into the first of a series of at least three inclined cleaners 146 which act to blend and separate the condensed fibers allowing dust, dirt and foreign objects to be drawn away. Following this series of inclined cleaners 146 another condenser 148 is arranged to again condense the fibers before feeding them into a final inclined cleaner 150. Inclined cleaner 150 delivers the cleaned fibers into an even feed machine 152 which evenly delivers the fibers to a condenser 154.
A fine cleaning section J which includes a fiber feed apparatus comprising an auger conveyor or screw conveyor 156 is arranged to receive the condensed opened and cleaned fibers from condenser 154. Auger conveyor 156 is of usual construction consisting of an elongated tube or casing in which rotates an elongated screw. Arranged along the length of and connected with auger convey 156 are a series of carding stations 159, to be hereinafter described in detail.
The cleaned fibers are delivered into the auger feed from condenser 154 and are moved along the length thereof in the direction of the arrow towards overflow bin 161. Shute feed systems 160 are connected with auger conveyor 156 and are adapted to receive the opened and cleaned cotton fibers through openings in the auger casing. Should the volume of cleaned and opened fibers exceed the capacity of shute feeds 160, auger 156 simply pushes these fibers out of its opposite end and into overflow bin 161. An air current removes the excess fibers from the overflow and carries them through conduit 164' back to overflow separator 166 which recirculates the fibers back into condenser 154 where they are recirculated through auger conveyor 156.
Carding stations 159 consist of a shoot feed 160 which receives fibers from auger conveyor 156 and delivers them into carding machines 158. It should be noted that each carding machine can process up to 1600 lbs per hour and that the number of carding stations 159 in the system is variable dependant upon the capacity of the further processing system.
The carding machines 158 receive opened and air born fibers from the chute feed 160, and card and align the fibers to remove particles and to allow micro dust to fall away. The carded product is drawn away from carding machines 158 by pneumatic suction members 162 which remove the carded fibers from the carding machines and deliver them into conduit 164 as loose fibers. Conduit 164 is connected with Y valve 100 which as earlier described is connected with conduit 104 which delivers the fibers to a further processing systems such as one having stations D, E, F, and G shown in FIG. 1. Valve 100 is also connected with condenser 101 which delivers the fibers to a baler such as 102 of FIG. 1.
Between preparation station A and five cleaning station J are many variable routes through which the heated and opened fibers may be passed. The route selection is made in dependence upon the quality, to include cleanness, of the baled cotton and the intended end use for the processed cotton fibers. A very high grade of clean cotton fibers clearly do not require an intensity of cleaning as do fibers from lower grade and less clean bales.
The fibers leaving preparation station A move through valve 140 which is normally connected with conduits 142 as previously described. Should either additional or less cleaning be desirable, valve 140 is opened to connect with conduit 168.
Valves 170 arranged on each side of drying chamber 172 receive fibers through conduit 168 and delivers them to or around the drying chamber via conduit 174.
Conduit 178 connects with conduit 182 via valve 176 which is arranged adjacent to but beyond valves 170 and is also connected with conduit 178 and via valve 180. Valve 176 also is connected with valve 184. Valve 184 in one position is connected with stick and leaf removing and opening chamber 188 and in its other position with conduit 186.
Chamber 188 delivers fibers into conduit 182 which is connected to conduit 190 by valve 188', to conduit 178 by valve 180 and to conduit 142 by valve 181.
Conduit 190 is connected with even feed 150 of primary cleaning station I by valve 192 and with conduit 186 by valve 194. Conduit 186 is also connected with condenser 148 at 149 of primary cleaning station I.
Fibers leaving preparation station A may be sent through a myriad of cleaning combinations because of the network of conduits and valves as described above. This gives the cleaning system a maximum of flexibility to handle cotton fibers of a wide range of staple lengths and degree of cleanness and to produce a product cleaned to the degree desired.
A few examples of fiber routes after leaving preparation station A will now be described. The fibers normally leave station A and pass to primary cleaning unit A via conduit 142. Extra cleaning may be provided by passing the fibers first through drying chamber 172, stick and leaf cleaner 188 and then to primary cleaning unit I via conduits 182, 142 using valves 188', 180, and 181. Only a portion of primary cleaning unit I may be used by selecting to deliver the fibers through conduit 190, 186 and to primary cleaner I at 149. Even less of the primary cleaning unit may be used by moving the fibers through conduit 190 and directing them into even feed 150 by valve 192.
It is noted that no matter the degree of primary cleaning selected, the fibers are always fed from the primary cleaning station I to the fine cleaning station J.
Again, the various fiber processing machines are of themselves old and may be purchased from various manufacturers as earlier noted.
Turning now to FIG. 2, a waste receiving and baling system 140 is shown. This baling system is designed to receive the waste fibers, dust and dirt from the various sumps associated with the many processing and cleaning stations A, B, C, D, E, F, I and J.
Waste baling station 140 is provided with a conduit 142 which receives waste from the various cleaning stations, delivers it to an inclined cleaner 144. A trash removing fan 146 is connected with conduit 140 to remove heavy trash prior to delivery to cleaner 144. A dust removal section 148 draws air born fibers and dust from the cleaners as the fibers are delivered to a press on baler 150. The baled trash fibers have a use in industrial cleaning.
While preferred embodiments of the invention have been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.
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A continuous textile processing system and method are disclosed for producing a non-woven web containing bleached cotton fibers in a single line system which includes a supply of fibers delivered from a bale opening device, a plurality of fiber delivery lines transport the fibers through a fiber preparation process and then through a fiber cleaning process where the fibers are individualized, opened, aligned and cleaned. A selective delivery system which is capable of moving the fibers through a multiple of stations during the precleaning process is provided. From the precleaning processes the fibers are processed into a fiber web and fed to a web stabilizing and bleaching apparatus which forms a stable bleached web. The bleached web is then passed through a drier unit. The dried bleached web is slit into a plurality of web strips or slivers which are fed to carding machines. The carding machines reform the fibers into a web which is hydroentangled and dried. The web is then rolled and readied for other processing. The final non-woven web, consisting of bleached cotton fibers, may be made into highly purified and absorbent wipes, pads, and other articles for medical, industrial, or domestic use.
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BACKGROUND OF THE INVENTION
[0001] Peanut butter is widely enjoyed and finds a variety of uses. The most common use of peanut butter is in preparing sandwiches. Product characteristics which are responsible for peanut butter's wide acceptance and popularity are its flavor, its good nutritional properties and its suitability for consumption alone or in combination with a variety of other foods.
[0002] While peanut butter is much appreciated as a food, individuals assigned to clean eating utensils often feel differently. Peanut butter tends to adhere to knives, spoons and the like. Removal of peanut butter from those objects is a nuisance at best; any member found to have left peanut butter on a utensil during an after hours snack may well be ostracized within his household.
[0003] Recently, new forms of peanut butter products have been marketed. These include squeezable peanut butter in the form of sticks and tubes. The sticks afford a nutritious snack, especially for children. Both forms provide a convenient way to eat peanut butter while avoiding the chore of cleaning peanut butter from a utensil.
[0004] Peanut butter has also been marketed in admixture with other ingredients such as chocolate. Unfortunately, these products have tended not to afford consumers the distinct and enjoyable sensations afforded by each of the ingredients individually.
[0005] A variety of peanut butter products have been reported in the popular and the patent literatures.
[0006] An article entitled “RESERVISTS BRING THEIR BOSSES ALONG ON TRAINING; CIVILIANS RIDE HUMMERS AND HELICOPTERS AND SNACK ON MRES” in the Nov. 4, 2001 issue of the St. Louis Dispatch describes someone squeezing peanut butter from a tube onto a cracker.
[0007] In the Oct. 17, 2001 edition of the Straits Times (Singapore), an article with a headline entitled “Radios Being Dropped to woo Afghan Hearts” describes a drawing showing how tubes of peanut butter should be squeezed.
[0008] An article in the Congressional Quarterly DBA Governing Magazine dated September, 2001 accompanied by the headline: “A STICKY STATE OF AFFAIRS” mentions that California prisons pack plastic peanut butter and jelly “squeezes” in lunch bags for prisoners who have off-site job.
[0009] The Pantagraph of Aug. 12, 2001, in a headline entitled “Scout records events of national conference” mentions that in 1997, the Scouts had crackers, squeeze cheese, squeeze peanut butter, squeeze jelly, and trail mix.
[0010] CNN THE SPIN ROOM 22:30 of May 14, 2001 reported that a company called P.J.'s Squares, has sent to the White House a couple of cases of little plastic squeezey things, like you might get mustard in or mayonnaise, but these are full of peanut butter and jelly.
[0011] Newsletter Database™, Copyright 2001 Marketing Intelligence Service Ltd., Product Alert of Mar. 26, 2001 discloses “Squeezers,” available from Portion Pac, Inc., located in Mason, Ohio. The 2.12 oz. pouches of Peanut Butter & Concord Grape Jelly Combo and Peanut Butter & Strawberry Jam Combo are presented in boxes that state, “Nutritious and fun—Grab and go—Easy lunches—Hiking, biking, camping, sporting events—No cutlery needed.” Squeezers is said to be a registered trademark of Thermo Pac, Inc.
[0012] The West County Times of Sep. 10, 2000 in an article about scouts mentions lunching on crackers with squeezable peanut butter and jelly.
[0013] An article in The Washington Post on Aug. 30, 2000, p F01 entitled EYE ON THE AISLES; Jump for Jerky by Carole Sugarman mentions that “last September” a Los Angeles company named Visionary Brands rolled out Peanut Squeeze—peanut butter in an easy-to-squirt plastic bottle.
[0014] The Enertia Trail Foods catalogue on the Internet at least as early as Sep. 16, 2002 shows a “Peanut Butter Squeezers” product in a mayonnaise-type pouch. On page 11, a “Peanut Butter/Jelly Combo Squeezers” product is mentioned.
[0015] Wong et al. U.S. Pat. No. 6,623,783 is directed to a fluid suspension of sugar and oil which is useful in making nut spreads having high levels of sugar. It is said that having the sugar in the form of a fluid suspension with the oil allows the sugar to be easily mixed with the nut solids containing mixture. The combining of the sugar and oil and the nut solids-containing mixture can be made continuous such as by co-blending the two streams in a static or in-line mixer or series of mixers. The water soluble solids in the fluid suspension such as the sugar, salt and the like preferably have a relatively fine particle size. Chocolate may be blended into the Wong et al. nut solids mixture. Many flavorants are mentioned and it is said that these can be delivered from flavored or flaked bits. Wong et al. prefer cocoa solids enrobed or encapsulated by sugar, which are said to impart a more milk chocolate-like flavor and avoid imparting a bitter aftertaste to the nut spreads. The nut spreads are said to be prepared by combining the fluid suspension and the nut solids-containing mixture so as to form a substantially homogeneous blend. Intense mixing such as high shear mixing is said not to be required. In Example 2, apple flakes are added via an ingredient feeder.
[0016] Germick et al. US Patent Application Publication No. 2003/0009987 discloses a food product, preferably a food ingredient, in the form of a dye, pigment or similar colorant in a random pattern in a refrigerated, thixotropic, food material, preferably a cultured dairy product and most preferably refrigerated yogurt held in a flexible wall pouch. The second food ingredient is said to remain in the irregular and random pattern for the intended shelf life of the product. The food ingredient is produced by supplying the food ingredient through a supply tube extending through an injection tube and into a fill pipe and a fill tube.
[0017] Jerry Boy PB N′ Go peanut butter is said to come in five flavors in both creamy and crunch. Flavors include Cinnamon Surprise, Munchy Crunchy, Jalapeno Kick, Caramel-Carmel Crunch and Dreamy Creamy. The products are described at http:/www.clorders.com/jerryboy.htm.
[0018] A product has been sold in the United States under the name Jif® Smooth Sensations, which includes blended peanut butter and chocolate.
[0019] A product, Doubly Delicious, has been sold in the United States under the Skippy® brand which includes peanut butter and distinct chocolate pieces.
[0020] Despite all of the attention which has been directed to peanut butter products, and the use of peanut butter combined with other components, there is a need for peanut- and other nut butter products where the nut butter is combined with one or more other components in such a way that consumers can readily perceive the presence of both, including their individual favorable organoleptic sensations. There is further a need for readily applied peanut butter products admixed with other, separately perceivable, desirable edible components, such as jelly and chocolate.
SUMMARY OF THE INVENTION
[0021] The present invention is directed to a process for making a variegated nut spread and to the spread which can be made by the process. It has been discovered that a variegated nut spread can be made by (a) pumping a nut spread into a container such as a single serve tube; (b) before or after step (a), pumping in a separate stream of an inclusion to form a variegated nut spread; and (c) closing said container without homogenizing said nut spread and inclusions. The process of the invention permits the preparation of a nut spread which comprises discrete, separately perceivable inclusions such as a chocolate syrup. By forming the inclusions as discrete pieces or streams, the consumer is better able fully to enjoy the separate organoleptic impression of the inclusion in addition to that of the base nut spread. Otherwise, typically an “average” impression which combines the impressions of both but which may well lack the organoleptic appeal of either, may be obtained.
[0022] The inclusion can be in the form of a liquid or semi-solid, such as a structured stripe, or as particulates. If liquids or semi-solids, the inclusions are preferably added using a simple piston filler such as a Dangan filler available from Dangan-North America of Marina, Calif. If particulate, the inclusions may be added via an enrober. Any particulates are preferably less than ⅜″ in size.
[0023] The invention is also directed to a nut spread, especially combined with a tube, having discrete, separately perceivable inclusions such as chocolate syrup and chocolate morsels, which have not been homogenized. The product is made by combining finely milled ground roasted peanut slurry with additional flavorings (sweetener, salt, etc.) and stabilizing ingredients. The inclusions may be provided in a liquid stream pumped into the tube at 20-40 wt. % or by solids in an enrober.
[0024] In accordance with a preferred feature of the invention, the product of the invention is contained within a tube, e.g., a single serve tube. Especially preferred is the use of squeezable tubes, with or without an applicator cap having a dispensing orifice.
[0025] The nut butter can be a peanut butter under the FDA standard of identity or some other nut spread such as a nut cream. If desired, it can be formulated to be particularly squeezable, yet creamy, and/or it can be formulated to be low in carbohydrates, fat or other ingredients.
[0026] In accordance with the invention, the nut spread is combined with the additional, discrete food component, an inclusion, which is desirably eaten with peanut butter, such as a filling or a particulate. The nut spread and additional food component are combined in such a way that the presence of the additional component is discernable as a separate component, visually or by taste. The inclusion may, for example, add solids, texture and/or flavor. Examples of inclusions include fruit flavored variegates, banana, marshmallow filling, chocolate, bacon bits, etc.
[0027] The nut spreads used in the invention include stabilizer, but in limited amounts. Levels of from 0.5 wt. % through 1.75 wt. % are preferred. The stabilizer is preferably a fully or partially hydrogenated vegetable oil. The inclusion of modest amounts of stabilizer facilitates formulation of a nut spread which is squeezable and has good mouth feel but does not flow uncontrollably.
[0028] For a more complete understanding of the above and other features and advantages of the invention, reference should be made to the following detailed description of preferred embodiments and to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
[0029] FIG. 1 is a front elevational view of a tube of peanut butter and additional edible component in accordance with the present invention.
[0030] FIG. 2 is a front elevational view of the tube of FIG. 1 during filling and prior to sealing of its top end.
DETAILED DESCRIPTION OF THE INVENTION
[0031] By “homogenization” herein is meant mixing together such that the product appears substantially uniform to the naked eye.
[0032] The squeezable peanut or other nut butter or spread which may be used in the invention may include high melting (145°-155° F.) vegetable oil stabilizers of palm, cottonseed and similar vegetable oil origins at a level of from 0.5 to 10 percent, preferably from 1 to 5%, preferably from 1 to 1.75%. The stabilizer tends to reduce liquid oil separation and to improve the viscosity of the product.
[0033] The preferred base nut spreads into which the inclusions are pumped fully comply with the FDA standard of identity for peanut butter as defined in 21 CFR (Apr. 1, 2000 edition) Section 164.150, namely they contain ground shelled and roasted peanut ingredients of at least 90 wt. % and a maximum fat content for the finished food of not greater than 55% when determined as prescribed in “Official Methods of Analysts of the Association of Official Analytical Chemists,” 13th edition, (1980) section 27.006(a) under “Crude Fat-Official First Action, Direct Method. These also require that the standardized product contain no more than 10 percent of optional seasoning and stabilizing ingredients such as salt, nutritive sweeteners and hydrogenated vegetable oils and emulsifiers such as mono- and diglycerides. The percent by weight of peanuts can range from 90 to 95% and higher for standard peanut butters. An appropriate peanut butter for use in the present invention is sold under the Skippy® brand.
[0034] The peanut ingredients may be blanched peanuts in which the germ may or may not be included, and unblanched peanuts, including the skins and germ.
[0035] Appropriate seasonings and stabilizing ingredients include the following and combinations thereof; salt, sugar, liquid sugar, dextrose, honey, fructose, corn syrup, medium invert and invert sugars, maple syrup, molasses, liquid or powdered, peanut oil, particularly high flavor oil extracted from roasted peanuts, vegetable oils, fractionated vegetable oils and partially hydrogenated vegetable oils, including soybean, palm, coconut, cottonseed, corn, rapeseed, canola and peanut oils, saturated and unsaturated mono- and diglycerides and lecithin, polyglycerol esters and other food emulsifiers. It is preferred that the seasonings and stabilizing ingredients added to the peanuts do not exceed the 10% limit imposed by the Standards of Identity for peanut butter. In particular, the seasonings and stabilizers preferably constitute from 0.5 to 10%.
[0036] If needed, liquid molasses or dried powdered molasses may be added to improve the color of the final product. A suitable powdered molasses is MC-71, which is granulated so that 90% will pass though #100 U.S. standard sieve, supplied by Sethness Co., Chicago, Ill. 60647.
[0037] The mixture of peanuts, seasonings and stabilizers is ground into a fine paste for example via the use of milling equipment which is standard in the peanut butter industry, such as a Bauer and/or an Urshel mill. The milled peanut butter paste may be collected in a standard feed or supply tank fitted with a vacuum system to de-aerate the milled paste from any entrapped or entrained atmospheric air. It may also be de-aerated prior to milling.
[0038] Generally, the composition of the invention will include peanut oil. Optionally as supplement and to boost further the flavor intensity, a high flavor peanut oil may be used in this invention. The high flavor peanut oil is obtained by the extraction of oils from dark roasted peanut. As example of a high flavor peanut oil suitable for use herein is the high flavor peanut oil extracted from dark roasted peanuts supplied by Food Materials Corp., Chicago, Ill. 60618. The high flavored peanut oil may be added at levels of 0.5 to 3.0%. Also, dark roasted peanut paste may be used.
[0039] The further edible component(s) will generally be ingredients which are not within the Standard of Identity for peanut butter mentioned above. As indicated, further edible components used as inclusions in the nut spreads will generally be fillings or particulates. Fillings can be defined as sweet or savory food mixtures used to fill pastry, cake or sandwiches. For the peanut butter and other nut butters and spreads of the invention, the further edible components which may be added include fruit flavored variegate (aw<0.62) (filling), chocolate (filling), chocolate and/or bacon bits (particulates) and marshmallow filling.
[0040] A more comprehensive list of examples of fillings/filling components includes: fruit, chocolate, jams/jellies, apricot, cherry, blueberry, guava, lemon, mango, raspberry, strawberry, papaya, marshmallow and banana. Often fillings will include a gel material such as a pectin. Gum bases, such as guar, are common.
[0041] The filling will generally be low in water and/or high in sugar. Fillings generally impart flavor/and or solids and/or texture to the food.
[0042] The fruit filling variegate may be any flavor, such as grape or strawberry fruit filling variegate. An example of a suitable fruit filling variegate is a grape filling available from Haarmann & Reimer. The ingredient statement for the Haarmann & Reimer grape filling is as follows:
[0043] Dextrose, Sugar, Corn Syrup, Water, Fructose, Glycerine, Modified Corn Starch, Grape Juice Concentrate, Natural Flavors, Apple Powder, Citric Acid, Salt, Soybean Lecithin, Propylene Glycol, Gellan Gum, Sodium Benzoate, Potassium Sorbate, Sodium Citrate, Red 40, Blue 1.
[0044] The further edible components may also be particulates, such as graham, puffed rice and chocolate morsels. Particulates may impart texture and/or flavor and/or solids to the food.
[0045] For some further edible components which may be mixed with the nut spread, it is important to consider the water activities of the further edible component and the nut butter. For instance, to promote compatibility, a variegate such as grape fruit filling, which is to be in direct contact with the peanut butter in a given packaging format has the following desirable characteristics:
The water activity must be at or below 0.62 The difference in water activity between the filling and the peanut butter must not be more than 0.3 units (to reduce osmotic pressure differences)
[0048] It is a good rule of thumb for all combinations of peanut spread and further edible component that the difference in water activity between the further edible component and the spread must not be more than 0.3 units (to reduce osmotic pressure differences)
[0049] Appropriate selection of water activity can favorably impact shelf stability by minimizing microbiological growth and leaching of water between the components.
[0050] For longer term stability, the filling should:
Be a low pH (<4.5) Contain mold inhibiting preservative (Potassium Sorbate or Benzoate)
[0053] The further edible components, e.g., filling, may be used at levels of, say, 15-50 wt. % of the combined nut spread and filling. The further edible components may be combined in patterns. The nut butter or nut spread component, e.g. peanut butter, and the further edible component, e.g., fruit flavored variegate or other filling are mixed in discrete portions discernable to the consumer.
[0054] Preferred containers are Low Density Polyethylene (LDPE) tubes, which may be obtained from American Packaging. It may include an EVOH copolymer barrier layer. While a plastic tube is preferred, it may also be metallic, e.g., tin, aluminum, etc. Preferably the tubes are flushed with nitrogen prior to filling to prevent/minimize oxidation and oil separation. A safety seal or other consumer protection device can be employed. Suitable tubes are disclosed in, e.g., Eichelberger et al. U.S. patent application Ser. No. 10/244,284, the disclosure of which is hereby incorporated by reference.
[0055] As seen in FIG. 1 , tube 10 , made of low density polyethylene (LDPE), has been filled with peanut butter 12 and chocolate filling 14 , in accordance with the invention. Tube 10 can be formed using a flat sheet of LDPE, which is then folded along fold line 16 . The flat sheet may be cut along superposed side margins 18 , 20 and top and bottom margins 22 and 24 . A heat seal 26 may be imposed adjacent and parallel to bottom margin 22 and along side margins 18 , 20 at 28 . As seen in FIG. 2 , the peanut spread 36 and the further edible component 38 are then pumped into the open tube through the top prior to sealing the top margin, using, e.g., side by side Dangan fillers 32 , 34 . The top margin 24 may then be heat sealed at 30 . Fillers 32 , 34 are shown schematically and not to scale.
[0056] Product filling can be continuous where the equipment “squeegees” the product and seals the top, or it can be intermittent.
[0057] The consumer consumes the product by opening the end seal and squeezing the contents of tube 10 .
[0058] Squeezable food products of the invention, e.g. a nut butter, may be prepared using the following procedure (the Preparation Procedure):
a) ground roasted full fat nuts are heated to a temperature above the melting point of the given stabilizer, for example to 145° F., especially 155-160° F. or above; b) the ingredients are added to the heated slurry in accordance with the formulation and thoroughly mixed; c) the peanut mixture is cooled to 125° F. and then fed into the primary milling operation Urschel Mill 10 at a rate to ensure particle size distribution of 90%<=40 microns, 50%<=13 microns and 10%<=3 microns with a mean diameter of 15-20 microns. The mill is model MG 1700 having a 206 head. The mixture emerges from the Urschel Mill at 165-170° F.; d) the milled composition is deaerated using Versater 12 or vacuum kettle and cooled to approximately 130° F. in the Rotator; e) the milled composition is deaerated, cooled to 155-160° F. before filling and filled at 85-90° F. filled at 850 to 95° F. into tubes; f) The liquid or semi-liquid inclusions are pumped into the tubes at 20-40% by a filler pump; g) The tube is closed by heat sealing the top of the tube without homogenization of the inclusions and the peanut butter; and h) the resulting peanut butter is a soft squeezable product having visibly and organoleptically distinct inclusions in addition to the peanut butter.
[0067] If, alternatively, the inclusion is a particulate, it may be pumped to the tube simultaneously with the peanut stream.
[0068] Alternative vacuuming and milling such as homogenizers, Colloid mills and Fryma mills are acceptable provided that the criteria in (e) have been obtained.
EXAMPLE
Prophetic
[0069] A peanut butter having the following ingredients is prepared.
Ingredient Level % Peanut oil 5.0 Roasted peanuts 86.3 Stabilizer (hardened rapeseed oil blended with 1.0 cottonseed oil and hydrogenated soybean oil Sucrose 6.2 Salt 1.5 Total % 100.000
[0070] The product is prepared (using the procedure described above) by milling under vacuum and then filling tubes with the peanut butter. The product is combined with 35 wt. % chocolate syrup using a Dangan piston filler and without homogenization due to mixing components prior to filler. A peanut butter having visible chocolate randomly distributed throughout the nut butter is obtained. The chocolate flavor is readily discerned separate and apart from the peanut butter flavor.
[0071] Unless otherwise explicitly indicated, or clearly required by context, percentages in this application are by weight.
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In a first embodiment, the invention is directed to a process for making a variegated nut spread comprising (a) forming an enclosure from a film, b) pumping a nut spread into the enclosure; and (c) before, during, or after step (b), pumping in a separate stream of an inclusion to form a variegated nut spread; and (d) sealing the enclosure to form a container without homogenizing the nut spread and inclusions. The inclusion is generally another food component which is desirably eaten with peanut butter, such as fruit filling variegate, banana, marshmallow filling, chocolate, bacon bits, etc. The invention is also directed to a nut spread, comprising discrete inclusions selected from the group consisting of chocolate syrup, fruit and mixtures thereof. The inclusions in the nut butter of the inventions are discrete so that consumers can experience simultaneously organoleptic properties both of the inclusions and the nut butter.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of Great Britain patent application serial number GB 0306774.1, filed Mar. 25, 2003, and Great Britain patent application serial number GB 0312278.5, filed May 29, 2003, which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to tubing expansion. In particular, but not exclusively, the invention relates to diametric expansion of tubing downhole.
[0004] 2. Description of the Related Art
[0005] One of the most significant recent developments in the oil and gas exploration and production industry has been the introduction of technology which allows for expansion of extended sections of tubing downhole. The tubing may take different forms, including but not restricted to: expandable casing, liner, sandscreen, straddles, packers and hangers. A variety of expansion methods have been proposed, including use of expansion cones or mandrels which are forced through the tubing. One difficulty which has been experienced with cone expansion is the high level of friction and wear between the surface of the cone and the inner surface of the tubing to be expanded.
[0006] It is among the objectives of embodiments of the present invention to obviate or mitigate this difficulty.
SUMMARY OF THE INVENTION
[0007] According to the present invention there is provided a method of expanding tubing, the method comprising:
[0008] locating an expansion device in tubing to be expanded;
[0009] vibrating at least one of the tubing and the expansion device; and
[0010] translating the expansion device relative to the tubing.
[0011] The vibration of at least one of the tubing and the expansion device preferably acts to reduce friction between the tubing and the device.
[0012] In conventional tubing expansion operations an expansion device which slides relative to the tubing to be expanded, such as a cone or mandrel, will tend to progress through the tubing incrementally in a series of small steps. From a static condition, the load on the cone is increased until the load is sufficient to drive the cone through the tubing. In addition to the forces required to expand the tubing diametrically, it is also necessary to overcome the static friction between the contacting surfaces of the cone and the tubing before the cone will move relative to the tubing. Once static friction has been overcome, frictional resistance to movement typically decreases sharply due to the lower dynamic friction between the contacting surfaces, such that the initial movement of the cone will tend to be relatively rapid. As the cone moves forward rapidly relative to the tubing, the driving force being applied to the cone will tend to fall, the inertia of the cone-driving arrangement being such that the cone-driving arrangement will typically fail to keep pace with the cone. Thus, after the initial rapid movement, the cone will tend to stall as the driving force decreases. The driving force applied to the cone then increases once more, moving the cone forward again once static friction between the cone and tube is overcome. For brevity, this form of movement will hereinafter be referred to as “stick-slip”.
[0013] With the present invention, the vibration of one or both of the expansion device and the tubing is intended such that there will be little or no static friction experienced between the contacting surfaces, and the conventional stick-slip progression of the expansion device relative to the tubing should be avoided. The driving force necessary to drive the expansion device through the tubing should therefore remain relatively constant, as the frictional forces remain at a relatively constant, and relatively low, level.
[0014] Furthermore, the reduction in friction between the expansion device and the tubing should tend to decrease the wear experienced by the expansion device, which in conventional expansion operations may place limits on the length of tubing which can be expanded in a single expansion operation.
[0015] Of course, in downhole applications, the vibration may also serve to assist in reducing the occurrence of differential sticking between the tubing and the surrounding bore wall.
[0016] The frequency and amplitude of vibration may be selected to suit each particular application. Furthermore, the direction of vibration may be selected as appropriate: for example, the vibration may be random, multi-directional, axial, transverse or rotational. In one embodiment of the invention the vibration is substantially perpendicular to the surface of the expansion device, and in another embodiment the vibration takes the form of torsional oscillations.
[0017] Where the expansion device is vibrated, all or a major portion of the device may be subject to vibration. Alternatively, only a selected portion of the device may be subject to vibration, for example only a surface portion of the device, or only a selected area of the surface of the device, may be subject to vibration. Portions of the expansion device may also experience different degrees or forms of vibration.
[0018] If the tubing is vibrated, all or a substantial portion of the tubing may be vibrated. Alternatively, only a selected portion of the tubing may be vibrated. For example, only a portion of the tubing at or adjacent the expansion device may be vibrated, or only a surface portion of the tubing may be vibrated.
[0019] The vibration of the expansion device or tubing may induce physical movement of the device or tubing. Alternatively, or in addition, the vibration of the device or tubing may induce contraction and expansion of all or a portion of the device or the tubing. For example, the vibration may take the form of one or more waves traveling through the device or tubing.
[0020] The vibration of the expansion device or tubing may induce physical movement of the device or tubing. Alternatively, or in addition, the vibration of the device or tubing may induce contraction and expansion of all or a portion of the device or the tubing. For example, the vibration may take the form of one or more waves traveling through the device or tubing.
[0021] The vibration may be induced or created locally relative to the expansion device or the tubing being expanded, or may be created remotely, for example a wave form oscillation may be created remote from the expansion device location, and then travel along or through the tubing wall, or travel to the expansion location via another medium.
[0022] The vibration may be created by any appropriate means, including: an oscillating or otherwise moving mass; creating a varying or cyclic restriction to fluid flowing through the expansion device or tubing; an electromagnetic oscillator; varying the pressure of fluid operatively associated with the device or tubing; creating pressure pulses in a fluid; or injecting gas or liquid or a mixture of both into fluid operatively associated with the device or tubing.
[0023] The source of vibration or oscillation may be directly or indirectly coupled to one or both of the expansion device and the tubing.
[0024] The vibration may be of a constant, varying or substantially random nature, that is the amplitude, direction, frequency and form of the vibration may be constant, varying or random.
[0025] The vibration or oscillation may be of high frequency, for example ultrasonic. Such vibration may not be apparent as physical movement, as the vibration may be at a molecular or macromolecular level, or at least at a level below that of readily detectable physical movement of the device or tubing. Such vibration may be induced electromagnetically, for example by a varying electromagnetic field, or a varying or alternating current or voltage. Alternatively, or in addition, the vibration or oscillation may be of relatively low frequency, for example in the range of 1 to 100 Hz. If desired, the vibration may comprise a plurality of different components, for example a low frequency component and a high frequency component.
[0026] The vibration may be selected to coincide with a natural frequency of the expansion device or the tubing, or another element of apparatus. Alternatively, the vibration may be selected to avoid such natural frequency or frequencies.
[0027] The expansion device may be translated relative to the tubing by any appropriate means. The device may be mounted on a support which allows the device to be pushed, pulled or otherwise driven through the tubing. The support may extend from a downhole location to surface, where a pushing, pulling or torsional force may be applied. Alternatively, the expansion device may be coupled to a tractor or other driving arrangement located downhole. Alternatively, or in addition, fluid pressure may be utilised to move the device relative to the tubing.
[0028] The expansion device may take any appropriate form and may utilise any appropriate expansion mechanism, or a combination of different expansion mechanisms. An expansion cone or mandrel may be utilised with an expansion surface adapted for sliding or rolling contact with the tubing wall. The cone may be adapted for axial movement relative to the tubing, but may also be adapted for rotation. Alternatively, or in addition, a rotary expander may be utilised, that is a device which is rotated within the tubing with at least one expansion member, typically a roller, moving around the surface of the tubing and creating localised compressive yield in the tubing wall, the resulting reduction in wall thickness leading to an increase in tubing diameter.
[0029] The expansion device may define a fixed diameter, or a variable diameter. The device may be compliant, that is the device has a degree of flexibility to permit the device to, for example, negotiate sections of the tubing which cannot be expanded to a desired larger diameter or form. Alternatively, the expansion device may define a fixed diameter and may be non-compliant. In certain embodiments, the expansion device may feature both fixed and compliant elements.
[0030] References herein to expansion are primarily intended to relate to diametric expansion achieved by thinning of tubing wall. However, embodiments of the invention may also relate to tubing which is expanded by reforming a tubing wall, for example by straightening or smoothing a corrugated tubing wall, or other expansion mechanisms.
[0031] In other embodiments of the invention the expansion process may be supplemented by the application of an elevated fluid pressure, and in particular a varying fluid pressure, to the tubing.
[0032] The varying fluid pressure preferably acts across the wall of the tubing. The variation in pressure may be achieved by any appropriate means, and one or both of the fluid pressure within the tubing and the fluid pressure externally of the tubing may be varied. A body of varying volume may be located in a volume of fluid operatively associated with the tubing. Alternatively, or in addition, the volume of a body of fluid operatively associated with the tubing may be varied by movement of a wall portion defining a boundary of the volume, which wall portion may be operatively associated with an oscillator or a percussive or hammer device. In other embodiments a pressurised fluid source may be provided, and the fluid may be supplied at varying pressure from the source or the manner in which the fluid is delivered to the tubing from the source may be such as to vary the fluid pressure. An increase in pressure within the tubing may be accompanied by a reduction in pressure externally of the tubing, or a reduction of pressure externally of the tubing may occur independently of any variations in the internal pressure, which may remain substantially constant.
[0033] In one embodiment, in a downhole application, the fluid pressure externally of the tubing may be maintained at a relatively low level by providing a relatively low density fluid externally of the tubing. Thus, the hydrostatic pressure produced by the column of fluid above the tubing will be relatively low. This may be achieved by injecting gas or low density fluid into fluid surrounding the tubing. Alternatively, or in addition, a volume of fluid externally of the tubing may be at least partially isolated from the head of fluid above the tubing, for example by means of a seal or seals between the tubing and a surrounding bore or tubing wall, or by providing pumping means above the tubing.
[0034] Alternatively, or in addition, the fluid pressure internally of the tubing may be maintained at a relatively high level by providing a relatively high density fluid internally of the tubing.
[0035] Tubing expansion operations are typically carried out using conventional, readily available fluids, such as seawater or completion brine, which may have a specific gravity (SG) of approximately 1.025. However, the SG of fluids used in downhole operations of course varies depending on, for example, the choice of base fluid and the presence of weight materials or other additives, and may range from 0.85 to 2.2. Thus, references herein to high and low density fluids should be related primarily to fluids utilised in conventional tubing expansion operations and other downhole operations where the fluid is selected with reference primarily to other requirements, including availability and ease of handling. Accordingly, by way of example, with reference to expansion operations which, using conventional expansion techniques, would be carried out in the presence of completion brine, a high density fluid may be one having an SG in excess of around 1.025 and a low density fluid may be one having an SG less than around 1.025. In other cases, the density of a fluid present within tubing to be expanded may be considered to be relatively high if the fluid has been selected with reference to the lower density of the fluid in the annulus surrounding the tubing. Similarly, the density of a fluid in the annulus may be considered to be relatively low if the density is lower than the density of the fluid present within the tubing to be expanded. Of course the invention is not limited to use with liquids, and in some cases one or both of the fluids, particularly where a lower density fluid is required, may be a gas such as natural gas or air, or a multiphase fluid.
[0036] The portion of tubing to be expanded may be isolated from ambient fluid by one or more appropriate seals, and a varying pressure differential may be maintained across each seal. However, in accordance with a further aspect of the invention a degree of leakage past the seals may be permissible, and in some cases may even be desirable, particularly if means for providing or creating a cycling fluid pressure is being utilised; if the frequency or rate of pressure variation is sufficiently high, a degree of leakage, and the corresponding pressure decay, will not adversely affect the expansion process and may assist in providing the desired pressure cycling when combined with an appropriate source of pressure. In particular, the method may include the step of producing a pressure pulse, and thus an elevated fluid pressure, which then reduces or decays, as leakage occurs across the seal. Furthermore, the ability to utilise “leaky” seals tends to facilitate use of the expansion method, as there are difficulties involved in providing a fully effective seal in many environments: when expanding tubing downhole, the tubing will often not be perfectly cylindrical, and the tubing diameter may be variable; the tubing surface is unlikely to be perfectly smooth, and may include profiles; the ambient fluid in the tubing may contain particulates and contaminants; and in preferred embodiments the seal will move relative to the tubing as the tubing is expanded, which movement would of course result in wear to one or both of the seal and the tubing, and which movement would have to overcome friction, which could be considerable if a leak-free seal was provided or required. Also, the leakage of fluid around and over the seal will provide lubrication, facilitating relative movement between the seal and the tubing.
[0037] The seal may take any appropriate form, but is preferably in the form of a labyrinth seal. Typically, the seal comprises a plurality of seal members, each seal member adapted to maintain a proportion of the total pressure differential across the seal. The number of seal members may be selected depending upon a number of considerations, including the form of the seal members, tubing form and condition, ambient conditions, the pressure differential to be maintained, tubing diameter, and the frequency or rate of variation of the fluid pressure. Of course such a seal configuration may also be suitable for use in situations where the fluid pressure is substantially constant, or is maintained above at least a minimum level, provided of course that means is provided for maintaining the expansion pressure at the desired level, despite leakage past the seal. Thus, perhaps five, ten, fifteen or more seal members may be provided, as appropriate. The number of seal members may be selected to provide for redundancy, such that failure or damage of one or more seal members will not adversely affect the expansion process.
[0038] The fluid pressure may be maintained at a base pressure, for example at 70% of the yield pressure of the wall of the tubing, upon which base pressure additional pressure pulses or spikes are superimposed, taking the fluid pressure to or in excess of 100% of the yield pressure, to induce plastic deformation of the tubing.
[0039] The mechanical expansion or reforming device, such as an expansion cone, mandrel or die, or a rotary expansion device, may exert only a small expansion force, and may merely serve to stabilise the expansion process and assist in achieving a desired expanded form, for example achieving a desired expanded diameter and avoiding ovality. Alternatively, or in addition, the mechanical expansion or reforming device may serve to retain expansion induced by the elevated fluid pressure. In one embodiment, a shallow angle cone may be advanced through the expanding tubing, the cone preferably being advanced in concert with the periods of elevated pressure. The cone angle may be selected depending upon the particular application, but for downhole tubulars of conventional form it has been found that an 11 degree cone angle results in a cone which retains expansion, that is the cone may be advanced into the tubing expanded by the elevated pressure, and is then retained in the advanced position as the tubing contracts on decay of the fluid pressure below the tubing wall yield pressure. It is anticipated that by cycling the fluid pressure at a rate of around 5 Hertz the cone will advance at a rate of approximately 6 to 8 feet per minute. Of course the rate or frequency of fluid pressure variation may be selected to suit local conditions and equipment. Such advancement may be achieved by providing separate mechanical drive means but may be conveniently achieved by virtue of the pressure differential over a seal coupled to the cone; as the pressure peaks, causing expansion of the tubing, the axial differential pressure acting force across the seal will also peak. Where the cone is located between seals, in particular a leading seal and a trailing seal, the leading seal may be mounted on the cone or otherwise coupled to the cone such that any pressure differential across the seal will tend to urge the cone forward. The trailing seal may be located at some point behind the cone, such that the cone is located within an isolated fluid volume between the seals. The trailing seal may be fixable or securable relative to the tubing or may be floating. The trailing seal may be retained in position mechanically or, alternatively or additionally, by fluid pressure, for example by a column of fluid above the seal, which column may be pressurised by appropriate pumps on surface. The variations in pressure are preferably applied to the isolated fluid volume between the seals, and may be created by a pulse generator located within the isolated volume, or by supplying elevated pressure fluid or pressure pulses from a source externally of the isolated volume. In other embodiments, variations in pressure may also be applied to one or both of the fluid volumes above and below the isolated volume.
[0040] Of course the presence of fluid will facilitate movement of any expansion device present relative to the tubing, in particular by serving as a lubricant between the contacting surfaces of the expansion device and the tubing. The fluid may be selected for its lubricating properties. This is particularly the case in embodiments where the fluid surrounding the expansion device is at least partially isolated from the ambient fluid, and as such a smaller volume of fluid selected for its particular properties may be provided. Leakage past isolating seals may be accommodated by providing a larger initial volume, or by supplying further fluid to the volume. Of course the fluid may be selected with properties other than lubrication in mind, for example the fluid may comprise or include a relatively viscous element, for example a grease, to minimize the rate of leakage and pressure decay. Downhole expansion may be accomplished either top down or bottom up, that is expansion process moves downwardly or upwardly through the tubing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] These and other aspects of the present invention will now be described, by way of example, with reference to the accompanying drawing, which a schematic illustration of a tubing expansion operation, in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0042] The figure illustrates a subterranean bore 10 , such as may be drilled to gain access to a subsurface hydrocarbon reservoir. After drilling, the bore 10 may be lined with metal tubing, sometimes known as liner or casing. In the illustrated embodiment, a section of expandable casing 12 has been run into the bore 10 , and once located in the bore 10 the casing 12 is expanded from a smaller first diameter D 1 to a larger second diameter D 2 .
[0043] The expansion is achieved by means of driving an expansion cone 14 down through the casing 12 , the cone 14 being mounted on a string of drill pipe 16 which extends to surface. The force necessary to drive the cone 14 through the casing 12 while expanding the casing 12 is considerable: the force must be sufficient to deform the casing 12 and also to overcome the friction between the contacting surfaces of the cone 14 and the casing 12 . In conventional cone expansion operations the level of friction experienced is such that the cone 14 will tend to progress with an inefficient stick-slip movement, due in part to the differences in static and dynamic friction experienced by the cone 14 as it is moved through the casing 12 . However, in the present invention, this difficulty is substantially avoided due to the vibration of the cone 14 by means of an oscillator 18 mounted to the cone 14 . In use, the oscillator 18 , which is powered from surface via an appropriate control line, produces oscillations at ultrasonic frequencies, which vibrations or oscillations are transferred to the cone 14 . This high frequency of vibration of the cone 14 is such that there is substantially constant relative movement between the contacting surfaces of the cone 14 and the casing 12 , such that there is no static friction experienced between the contacting surfaces. Thus, the level of friction between the cone 14 and the casing is relatively low, allowing the cone 14 to progress through the casing 12 at a relatively constant rate, in response to a relatively constant applied force.
[0044] It will be apparent to those of skill in the art that the above-described embodiment is merely exemplary of the present invention, and that various modifications and improvements may be made thereto without departing from the scope of the present invention.
[0045] In other embodiments, the casing 12 rather than the cone 14 may be vibrated, and the manner in which the vibration or oscillation is created may be varied. For example, fluid may be pumped through the drill pipe 16 and the fluid flow path may be interrupted or varied to induce vibration. Alternatively, a stream of gas may be injected into the fluid surrounding the cone 14 , causing vibration of one or both of the cone 14 and the casing 12 .
[0046] In other embodiments of the invention translation of the cone 14 through the casing may be achieved at least in part by application of a fluid pressure, which fluid pressure may also assist in expanding the casing 12 . The fluid pressure may be varied such as to vibrate one or both of the cone 14 or casing, or to assist in the expansion of the casing, as described in greater detail in our patent application GB 0306774.1 entitled “Hydraulically Assisted Tubing Expansion”, the disclosure of which is incorporated herein by reference.
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A method of expanding tubing comprises locating an expansion device in tubing to be expanded, vibrating one or both of the tubing and the expansion device, and translating the expansion device relative to the tubing, the vibration acting to reduce friction between the tubing and the device.
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[0001] This application claims priority to provisional application No. 60/917,769, filed May 14, 2007, which is incorporated by reference herein, in its entirety, for all purposes.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates generally to Ethernet communication and, more particularly, to a system and method for enabling operation of an Ethernet device over an extended distance.
[0004] 2. Introduction
[0005] Incumbent local exchange carriers (ILEC) and competitive local exchange carriers (CLECS) are seeking to capitalize on the growing market for broadband Internet connections to the home. One example of an ILEC Internet service is a digital subscriber line (DSL) service, which provides a broadband connection over a conventional copper twisted pair. Recent ILEC offerings have enhanced the bandwidth of connections to the home using fiber optic technology. Hybrid solutions also exist where fiber optic solutions are combined with copper twisted pairs from a curbside or other remote terminal. These ILEC offerings are seeking to compete with cable providers that provide broadband connections using their existing coaxial cable TV infrastructure.
[0006] Regardless of the method of connection to the customer, the connections terminate on customer premise equipment (CPE). Examples of CPEs include a DSL or cable modem. In general, the CPE is responsible for performing media conversion, switching, security, provisioning, etc.
[0007] One of the major markets of competition for ILEC and CLECS are multiple dwelling units (MDUs) such as apartment complexes, office buildings, high-rise complexes, etc. This MDU market has vast potential due to the density of the customer base. In servicing such a market, it is important that the delivery of services to CPEs in individual customer premises be accomplished in a cost-effective manner. What is needed therefore is a service transport mechanism such as Ethernet that increases the cost effectiveness of a service provider in meeting the particular needs of the MDU market.
SUMMARY
[0008] A system and/or method for enabling operation of an Ethernet device over an extended distance, substantially as shown in and/or described in connection with at least one of the figures, as set forth more completely in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0010] FIG. 1 illustrates an example of a system that services a MDU complex.
[0011] FIG. 2 illustrates an embodiment of a system that services a MDU complex.
[0012] FIG. 3 illustrates an embodiment of a VOIP CPE.
[0013] FIG. 4 illustrates CPE functionality in a VOIP device.
[0014] FIG. 5 illustrates a connection of a VOIP CPE using a conversion device.
[0015] FIG. 6 illustrates an embodiment of a conversion device.
DETAILED DESCRIPTION
[0016] Various embodiments of the invention are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the invention.
[0017] Unlike suburban residential markets, the MDU market can benefit greatly from economies of scale. FIG. 1 illustrates an example system architecture for provisioning service to multiple customer premises in an MDU. In this illustrated example, the MDU service is supported by central office 110 (or other hub location). Although not shown, central office 110 is itself connected with other central offices and hubs through a broader communications network. In one embodiment, central office 110 is connected to MDU 120 via a high bandwidth connection between line terminal (LT) 112 in central office 110 and network unit (NU) 121 in MDU 120 . In one scenario, NU 121 is located in a basement of MDU 120 . In various implementations, link 114 can be embodied as a copper link, fiber optic link, etc. Moreover, in one embodiment, LT 112 is positioned as a remote terminal in a location that is remote from central office 110 .
[0018] NU 121 in MDU 120 can be configured to perform a media conversion. For example, NU 121 can perform a media conversion from fiber optic cabling to copper cabling. In the illustrated example, NU 121 can support multiple CPEs in MDU 120 via a plurality of links 122 . In a typical high-rise building, the plurality of links can extend from the basement to customer premises 131 - 134 on various floors in MDU 120 .
[0019] In one configuration, the connection between NU 121 and individual CPEs is via a copper connection. In various embodiments, this copper connection can be based on standard Ethernet, DSL, or the like. In various implementations, the copper DSL connection can be Ethernet (e.g., 2BASE-TL and 10PASS-TS) or non-Ethernet based.
[0020] As illustrated, NU 121 also incorporates switching functionality that aggregates a plurality of links into a single uplink. NU 121 can also effect various network policies. For example, NU 121 can enforce various bandwidth limitations in accordance with service provisioning under a particular service level agreement (SLA).
[0021] In general, a CPE can be configured to perform media conversion, switching, security, provisioning, etc. As such, a CPE such as a DSL modem can be used to support multiple devices within a single customer premises. For example, a DSL modem can support such devices as a VOIP phone, a computer, a wireless access point, a television, etc. As illustrated in FIG. 1 , NU 121 can have a DSL connection to CPE 142 in customer premises 134 . CPE 142 in turn supports various customer devices. As illustrated, CPE 142 supports VOIP phone 146 via Ethernet connection 144 .
[0022] One of the disadvantages of the provisioning example of FIG. 1 is the expense of supporting the various links from NU 121 to each customer premises 131 - 134 . In a typical MDU, these links can extend well over 100 meters, thus creating a need for CPE components such as DSL modems. CPEs represent the most significant component of the expense in supporting the links from NU 121 to customer premises 131 - 134 .
[0023] FIG. 2 illustrates a system architecture that enables a reduction of such costs. In the illustrated example, a high-bandwidth connection such as fiber-optic link 214 is supported by LT 212 in central office 210 and NU 221 in MDU 220 . Unlike the previous system architecture, links from NU 221 to customer premises 231 - 234 are not supported by conventional CPEs. Rather, the conventional CPE such as a DSL modem is eliminated from the system architecture. Instead, the links from NU 221 to customer premises 231 - 234 can be based on an Ethernet CPE device such as VOIP phone 242 in customer premises 234 .
[0024] In this arrangement, a VOIP phone can be configured to function as a VOIP CPE. As illustrated in FIG. 2 , VOIP CPE 242 can therefore be used to support multiple customer devices (CDs) 246 in customer premises 234 . Examples of such CDs are personal computers, wireless access points, televisions, HD receivers, etc. These CDs can be coupled to VOIP CPE 242 via a separate link (e.g., Ethernet).
[0025] In the system architecture of FIG. 2 , each VOIP CPE can be coupled to NU 221 via a wall socket that supports an Ethernet-type connection. As noted, one example of MDU 220 is a high-rise building. As would be appreciated, a link from NU 221 to a customer premises near the top of the high-rise building would require a link length that is far greater than 100 meters. Conventional Ethernet connections only support link spans up to 100 meters. Accordingly, conventional Ethernet connections cannot be used to support the lengthy link spans from NU 221 to customer premises 231 - 234 .
[0026] For this reason, the connection between NU 221 and a customer premises can be based on a broad reach Ethernet connection that can handle link spans as long as 500 meters and beyond. An example of such a broad reach Ethernet transceiver is Broadcom's BroadR-Reach™ transceivers.
[0027] The broad reach connection enables frames to be carried natively in Ethernet. This is advantageous because NU 221 can be based on a conventional enterprise switch box not a DSL box, and a frame format conversion such as that performed by a DSL modem at the CPE would not be required. Moreover, the switch chips inside NU 221 are standard devices that can enjoy high volume efficiencies. In general, broad reach Ethernet extends the physical transmission capabilities of Ethernet but preserves the PCS, RS, MAC and above as native Ethernet. Broad reach Ethernet is also backwards compatible with standard Ethernet.
[0028] In general, the VOIP CPE can be built with functionality similar to personal computers. For example, a VOIP CPE can have a central processing unit (CPU), a switch, router, and software/firmware that can define its configuration and functionality. In one embodiment, the VOIP CPE is embedded with CPE functionality such as encryption, authentication, provisioning, packet inspection, router, network address translation, USB support, prioritization, audio/video bridging, etc. This embedded functionality would enable the VOIP CPE to operate in a capacity similar to a conventional CPE.
[0029] FIG. 3 illustrates an example of a VOIP CPE. As would be appreciated, various bus/bridge architectures (e.g., north/south bridge architectures) can be used to connect the various components in the system. As illustrated, VOIP CPE can include conventional components such as CPU 311 , system memory 312 , and power 313 . As the VOIP CPE can be embodied as a VOIP phone, support for VOIP traffic is also included. Here, the VOIP CPE would include display 314 , codec 315 , and keypad 316 . Display 314 can be embodied as an LCD screen for dialing and other call control/notification functions. Codec 315 supports the conversion of an audio signal from/to a digital bitstream in the downstream/upstream directions. As such, codec 315 can be coupled to an amplifier that supports a speaker and microphone for VOIP communication. Finally, keypad 316 enables the user input of dialing instructions. In combination, display 314 , codec 315 , and keypad 316 would support the VOIP function of the VOIP CPE.
[0030] As noted, a VOIP CPE can support multiple CDs such as wireless access points, televisions, computers, HD receivers, etc. In FIG. 3 , this support is enabled by switch 319 , router 318 , and network address translation (NAT) 317 functionality. In combination, switch 319 , router 318 , and NAT 317 enable the VOIP device to operate as a CPE for one or more CDs. FIG. 4 illustrates an example of such CPE functionality. As illustrated, VOIP CPE 400 includes WAN port 412 for connection to an NU/SW, one or more LAN ports 414 for connection to one or more CDs, and internal port 418 . In one embodiment, WAN port 412 and LAN ports 414 are Ethernet ports. In general, WAN port 412 , LAN port(s) 414 and internal port 418 support full duplex links such that traffic can be coming from either direction at the same time. Traffic can also be switched to two ports simultaneously. For example, internal port 418 can add traffic to WAN port 412 (e.g., VOIP traffic) and LAN port(s) 414 , or receive traffic from either or both of WAN port 412 and LAN port(s) 414 . WAN port 412 , LAN port(s) 414 , and internal port 418 are coupled together via switch 416 . In routing traffic from WAN port 412 to LAN port(s) 414 , VOIP CPE 400 would support a CPE switching functionality for the customer premises.
[0031] VOIP CPE can be designed to support some form of authentication, privacy and security. Authentication would indicate to the network that the VOIP CPE is a valid network device that can receive communication. By validating exactly what services (e.g., IPTV, VOIP, data, etc.) are allowed to the VOIP CPE, the system can ensure that services are not stolen. Privacy/security can be enabled by encryption (e.g., MACSec), which would ensure that transmitted data (e.g., voice data) cannot be monitored by third parties. In general, authentication, privacy and security can be used to prevent unauthorized devices from accessing the link at other points.
[0032] As described above, the VOIP CPE can be designed with a physical layer device (PHY) that supports broad reach Ethernet. In one embodiment, the VOIP CPE is configured with a standard Ethernet PHY. This configuration would be suitable for those applications where links less than 100 meters were used. This configuration can also be used for those applications where links are greater than 100 meters.
[0033] In accordance with the present invention, a VOIP CPE with a standard Ethernet PHY can be coupled to a broad reach Ethernet connection via a conversion device that converts standard Ethernet to broad reach Ethernet. FIG. 5 illustrates such an embodiment, where VOIP CPE 530 having a standard Ethernet PHY is coupled to NU 520 via conversion device 5 10 . Here, NU 520 supports a broad reach Ethernet link that terminates on a broad reach PHY in conversion device 5 10 . Conversion device 510 then converts the broad reach Ethernet link to a standard Ethernet link for delivery to VOIP CPE 530 . In one embodiment, conversion device 510 is a dongle that is designed for insertion into VOIP CPE 530 . In another embodiment, conversion device 510 can be coupled to VOIP CPE 530 via an Ethernet cable.
[0034] An advantage of using an Ethernet link (conventional or broad reach) between an NU and CPE is the elimination of reliance on local loop technologies such as DSL. This feature leads to simpler NU and CPE designs that leverage high volume Ethernet components. Specifically, the support of broad reach Ethernet communication by the VOIP CPE either directly or through a conversion device obviates the need for DSL support by both the NU and CPE. This greatly reduces the complexity and cost of the NU.
[0035] FIG. 6 illustrates an embodiment of a conversion device, which operates as a media converter. As illustrated, conversion device 600 includes broad reach Ethernet PHY 610 and standard Ethernet PHY 620 operating back to back. Here, broad reach Ethernet PHY 610 is coupled to the NU, while standard Ethernet PHY 620 is coupled to the WAN port of the CPE. Conversion device 600 can also include buffering and/or control logic 630 in between broad reach Ethernet PHY 610 and standard Ethernet PHY 620 . In one embodiment, conversion device can also include internal port 640 for management purposes.
[0036] In one embodiment, the conversion device can be used to abstract the VOIP CPE from knowing the particular type of physical WAN connection. The VOIP CPE can therefore be designed with a standard Ethernet WAN port, while relying on the conversion device to meet the particular application need. Thus, the VOIP CPE having a standard Ethernet WAN port can be coupled to a conversion device that converts standard DSL, Ethernet-based DSL (e.g., 2BASE-TL and 10PASS-TS), etc. to a standard Ethernet connection.
[0037] These and other aspects of the present invention will become apparent to those skilled in the art by a review of the preceding detailed description. Although a number of salient features of the present invention have been described above, the invention is capable of other embodiments and of being practiced and carried out in various ways that would be apparent to one of ordinary skill in the art after reading the disclosed invention, therefore the above description should not be considered to be exclusive of these other embodiments. Also, it is to be understood that the phraseology and terminology employed herein are for the purposes of description and should not be regarded as limiting.
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A system and method for enabling operation of an Ethernet device over an extended distance. In a multiple dwelling unit (MDU) a customer premises equipment (CPE) can be coupled to a network unit via a broad reach Ethernet link that is greater than 100 meters (e.g., 500 meters). In this example, a CPE having a conventional Ethernet port can be operated over the broad reach Ethernet link using a converter device.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to pending U.S. Patent Application Ser. No. 60/508,177 (Attorney Docket Number PC—P006V, filed Oct. 2, 2003 by Robert F. Schmidt, et al. and entitled “Manipulator System for Servicing a Hydraulic Choke.”
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an apparatus for use in servicing hardware used in the drilling and production of fluids from petroleum wells. More particularly, the present invention relates to a field servicing apparatus for lifting, manipulating, and handling the heavy components of hydraulic choke valves.
[0004] 2. Description of the Related Art
[0005] Hydraulic choke devices are commonly used in the oilfield when drilling or treating wells. Herein, the term “hydraulic choke” is taken to refer to a device typically used as a pressure reducing valve with a variety of fluids, such as drilling mud, salt water, oil, gas, and other chemicals that are injected into or withdrawn from a well. “Hydraulic” does not herein refer to the choke actuation means. The service conditions for hydraulic chokes are typically severe, so that the units require frequent field servicing in order to minimize drilling or production downtime. Since the primary components of the choke system, namely the choke valve itself and its associated actuator, are very heavy and field working conditions are often difficult for handling the choke valve, an auxiliary manipulation means is needed to ease choke servicing.
[0006] Manipulator devices are use for simplifying the servicing of blowout preventers. However, easy-to-use manipulators for hydraulic choke valves have not been available previously.
[0007] Kunkle, U.S. Pat. No. 4,460,154, discloses a pair of telescoping tubes supported in a fixed relationship to a valve. One tube provides a mounting location for a linear actuator, while the other tube is stationary.
[0008] Hewitt, U.S. Pat. No. 4,961,538, discloses a valve operation system wherein a linear actuator is provided with a rod in a housing. The system components are held in place by a mounting plate that may be secured to a number of different valves through a valve stem adaptor.
[0009] Hewitt, in U.S. Pat. No. 4,611,617, discloses an apparatus mountable on an irrigation pipe for use in controlling valves within the pipe. The apparatus includes a mounting bracket attachable to the valve mechanism and mounting plates for various components of a drive mechanism, including an electric motor, a gear box, a main gear, and a drive chain.
[0010] None of these references disclose equipment that will simplify the lifting and manipulation of the heavy components of a choke valve. Power Chokes of Cypress, Texas has used a primitive manipulator for choke valves based on horizontally telescoping support tubes, wherein one tube is mounted to the body of the choke valve and the other tube has its end attached to the separable actuator of the choke valve. The first tube is able to pivot about a nominally vertical axis to permit adjusting the actuator alignment relative to the choke valve. However, this apparatus requires that the tubes remain in the horizontal plane so that high side loads do not cause inadvertent misalignment. Further stick-slip motion of this Power Chokes actuator made manipulation difficult.
[0011] A need exists for a simple to install, robust field service device for hydraulic choke valves which is insensitive to stick-slip behavior and misalignment.
SUMMARY OF THE INVENTION
[0012] The invention contemplates a choke valve manipulator device comprising: a frame; a mounting means for attaching a choke valve to the frame; and a rotation means for rotating the choke valve about an axis of a horizontal plane; whereby the manipulator device supports the weight of the choke valve and eases access to the choke valve components whenever the choke valve is serviced.
[0013] The invention further contemplates a choke manipulator device comprising: a frame; a mounting means for attaching a choke valve to the frame; and a tilt means for tilting the choke valve in a vertical plane; whereby the manipulator device supports the weight of the choke valve and eases access to the choke valve components whenever the choke valve is serviced.
[0014] Additionally, the invention contemplates a choke manipulator device comprising: a frame having an elongated track; a choke valve attachment structure positioned on an underside of the track; a reciprocable trolley, wherein the trolley moves along a length of the track; a trolley actuator in communication with the trolley, the trolley actuator causing the trolley to move along the length of the track; and a choke actuator attachment mechanism positioned on an underside of the trolley; whereby when the trolley is moved the choke actuator attachment is moved in the same direction.
[0015] Further, the invention contemplates a choke manipulator device comprising: a frame having an elongated track including two parallel mirror image channels; a choke valve attachment structure positioned on an underside of the track, the choke valve attachment structure rotatable about an axis of a horizontal plane; a reciprocable trolley having a plurality of mounted rollers, the rollers maintaining the trolley with the track; a trolley actuator in communication with the trolley, the trolley actuator causing the trolley to selectably reciprocate along a length of the track; and a choke actuator attachment mechanism positioned on an underside of the trolley; whereby whenever the trolley actuator moves the trolley the choke actuator attachment mechanism moves in the same direction as the trolley.
[0016] In addition, the invention contemplates a method for servicing a choke valve system, said method comprising the steps of: (i) positioning a choke valve manipulation device close to the choke valve system to be serviced, the choke valve manipulation device comprising: a frame having an elongated track, a choke valve attachment structure positioned on an underside of the track, a reciprocable trolley, wherein the trolley moves along a length of the track, a trolley actuator in communication with the trolley, the trolley actuator causing the trolley to move along the length of the track, and a choke actuator attachment mechanism positioned on an underside of the trolley; (ii) attaching a choke valve to the choke valve attachment structure; (iii) aligning the choke actuator attachment mechanism with a choke actuator connected to the choke valve; (iv) attaching the choke actuator to the choke actuator attachment mechanism; (v) disconnecting the choke actuator from the choke valve; (vi) activating the trolley actuator to cause the trolley to move away from the choke valve to separate the choke valve from the choke actuator; and (v) evaluating an interior component of the choke valve system for replacement or repair.
[0017] The foregoing has outlined rather broadly several aspects of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed might be readily utilized as a basis for modifying or redesigning the structures for carrying out the same purposes as the invention. It should be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0019] FIG. 1 is a profile view of the first manipulator embodiment assembled onto a choke valve assembly;
[0020] FIG. 2 is an oblique view from above and to the side of the first manipulator embodiment corresponding to FIG. 1 ;
[0021] FIG. 3 is a longitudinal centerline cross-sectional view of the first embodiment of the manipulator assembly corresponding to FIG. 1 ;
[0022] FIG. 4 is an oblique view of the trolley subassembly of the first embodiment from above and to the side;
[0023] FIG. 5 is a side profile view of the trolley subassembly of FIG. 4 ;
[0024] FIG. 6 is a plan view of the trolley subassembly of FIG. 4 ;
[0025] FIG. 7 is a longitudinal centerline cross-sectional view of the first embodiment of the manipulator assembly corresponding to FIG. 1 and showing the choke actuator separated from the choke valve body and supported by the trolley;
[0026] FIG. 8 is an oblique view from the rear quarter of the second manipulator embodiment assembled onto a choke valve assembly;
[0027] FIG. 9 is a profile view of the second manipulator embodiment shown in FIG. 8 assembled onto a choke valve assembly;
[0028] FIG. 10 is an oblique exploded view of the second manipulator embodiment wherein the relatively rotatable components are displaced from each other for exposure of their working mechanisms;
[0029] FIG. 11 is an oblique view of the trolley of the second manipulator embodiment; and
[0030] FIG. 12 is a profile view of the second manipulator embodiment shown in FIG. 9 , with the trolley and the disconnected actuator displaced from the choke in the axial direction.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The present invention provides a device for manipulating choke valve components during field service. The described manipulator is easily installed in the field and permits the easy and safe disassembly and reassembly of the choke valve components.
[0032] Referring now to the drawings, and initially to FIG. 1 , it is pointed out that like reference characters designate like or similar parts throughout the drawings. The Figures, or drawings, are not intended to be to scale. For example, purely for the sake of greater clarity in the drawings, wall thickness and spacing are not dimensioned as they actually exist in the assembled embodiment.
[0033] Typical materials of construction of the choke valve manipulator are high strength low alloy steel or mild steel. In the case of plain bearings, bronze or a lubricious plastic such as Delrin™ or Teflon™, is generally used. FIGS. 1 to 7 illustrate a first embodiment 10 of a choke valve manipulator system.
[0034] FIG. 1 shows the choke valve manipulator system 10 assembled to the choke valve 201 and an adjoined electrically/manually powered actuator 203 . The trolley subassembly 39 of the manipulator system 10 is shown in more detail in FIGS. 4, 5 , and 6 . FIG. 7 shows the manipulator of the first embodiment supporting the choke actuator, where the actuator 203 has been separated from the choke valve body 201 .
[0035] Referring to FIGS. 1 to 3 , the basic manipulator assembly 10 is shown in, respectively, profile, oblique, and longitudinal vertical cross-sectional views. The major components of the manipulator assembly include the track 11 , the trolley subassembly 39 composed of a first trolley 40 and second trolley 60 , and the supporting means for the manipulator including members 90 , 91 , and 92 .
[0036] The track 11 is composed of two horizontal mirror image channels. The righthand channel 12 and the lefthand channel 13 have an extended linear section with a distal 90° arcuate curved end segment and vertical webs. To strengthen the track 11 in order to support the heavy loadings on the track, vertical flat plate stiffeners 14 are welded to the upper surface of each of the channels 12 and 13 in line with their webs. The stiffeners 14 are coped on their lower sides to conform to the upper surfaces of channels 12 and 13 , while the upper corner of the stiffeners at the straight end of the track 11 has a large chamfer. The stiffeners 14 add both strength and rigidity to the track assembly 11 .
[0037] The channels 12 and 13 are spaced apart parallel with their flanges projecting inwardly. Multiple angle crossmembers 16 are placed on top of the upper flanges and welded horizontally and perpendicularly to those upper flanges of the channels 12 and 13 in order to tie the channels together. For example, three crossmembers 16 are used in the track 11 as illustrated in FIGS. 2 and 3 . One crossmember 16 is positioned adjacent to the start of the arcuate portion of the channels 12 and 13 , another crossmember 16 is adjacent to the righthand end of the straight portion of the track 11 , and a third crossmember 16 is spaced a short distance inwardly away from the second crossmember.
[0038] The vertical flange of each angle crossmember 16 has a central horizontal hole at approximately midheight to accommodate the trolley actuator screw 24 . Additionally, on each side of the central hole at the same height and equispaced from the central hole is located a mounting hole for the attachment of a plain bearing 17 . Plain bearing 17 is typically a rectangular prismatic block with a central horizontal hole for journaling the actuator screw 24 . Whenever the bearing 17 has its central hole aligned with that of a crossmember 16 , the mounting holes match the mounting holes of the angle crossmembers 16 . Bearing retainer screws 18 and bearing retainer nuts 19 are used with the mounting holes of the crossmembers 16 and the bearings 17 to coaxially attach the bearings 17 to the crossmembers 16 .
[0039] The trolley actuator screw 24 is a long right circular cylindrical rod with a male threaded central section, a short reduced diameter first end having a male thread at its distal end, and an elongated reduced diameter shank 26 at the other end. The extreme end of the shank 26 has a flat offset from the cylindrical screw axis so that the actuator screw handwheel 38 can be attached. The diameters of the said first end of the screw 24 and its shank 26 are the same and are a slip fit to the bearings 17 .
[0040] The trolley actuator screw 24 is mounted in the set of bearings 17 so that the first end of the screw 24 is supported in the bearing 17 near the arcuate end of the track 11 and the shank 26 at the opposite end of the screw 24 is supported in the other two bearings 17 . The actuator screw 24 is retained in place by actuator screw retainer nut 25 that is attached to the thread at the first end of the actuator screw 24 .
[0041] A rectangular prismatic driven nut 30 has a central horizontal through hole 31 which is drilled and tapped with a female thread mateable with the male thread of the trolley actuator screw 24 . The driven nut 30 is threadedly engaged with the screw 24 between the first and third bearings 17 of the track 11 . A horizontal drilled and tapped hole with its axis intersecting the axis of threaded hole 31 is located on each of the lateral sides of driven nut 30 . The drilled and tapped lateral holes in driven nut 30 are used to attach the driven nut 30 to the trolley subassembly 39 and to prevent the rotation of driven nut 30 . A conventional handwheel 38 is attached to the actuator screw 24 adjacent the straight end of the track 11 by means of the flat on the shank 26 of the screw.
[0042] The trolley actuator screw 24 is axially fixed with the nut 25 , yet turning the handwheel 38 will rotate the screw 24 . As the handwheel 38 rotates the actuator screw 24 , the nonrotating driven nut 30 is selectably caused to reciprocate along the threaded axis of the screw 24 .
[0043] The trolley subassembly 39 , shown in detail in FIGS. 4 to 6 , consists of a first trolley 40 and a second trolley 60 , which are linked to pivot about a central horizontal axis 70 . The trolley assembly 39 is mounted to reciprocate within track 11 between the inwardly facing flanges of the track. The trolley assembly 39 can be caused to enter the arcuate end of the track 11 and is limited in its travel by a travel stop bar 34 . The travel stop bar 34 is a threaded right circular cylindrical rod which extends from righthand channel 12 across the track 11 to lefthand channel 13 . The travel stop bar 34 is mounted horizontally and extends through coaxial corresponding transverse holes located near the upper arcuate end of channels 12 and 13 . The travel stop bar 34 is retained in position by a travel stop bar nut 35 on each of its external ends.
[0044] The first trolley 40 is configured to support the choke actuator 203 under the track 11 . The second trolley 60 contributes vertical support to the first trolley 40 and, because it is attached to the driven nut 30 , serves to transmit horizontal positioning loads to the first trolley 40 .
[0045] First trolley 40 consists of a backbone plate body 41 with mounted vertical restraint rollers 44 and horizontal restraint rollers 45 to maintain and control the position of the trolley 40 within the guiding track 11 . The first trolley body 41 is a thick horizontal plate having a generally rectangular outline with a reduced width central “waist” and lightening holes. Transverse horizontally drilled and tapped holes are located slightly below midheight near the four corners of the body 41 . Each of these holes serves to mount a horizontal support roller 44 on a shaft provided by a roller mounting screw 46 .
[0046] A rectangular prismatic flat crossbar 42 is transversely mounted underneath body 41 at about midlength of the body. The crossbar 42 is attached to the body 41 by hex screws 47 engaged into drilled and tapped holes in the body. The crossbar 42 mounts a vertical restraint roller 45 on each side of the body 41 . A vertical restraint roller 45 is mounted at each end of the upper side of the crossbar 42 by a vertical roller mounting screw 46 that passes through a drilled and tapped hole in the crossbar 42 .
[0047] Dependent plates 43 are Y-shaped with the arms of the Y up and clearance holes at the upper tips of the Y and a pair of bolt holes at the bottom. The central notch of the Y permits the plates 43 to clear the crossbar 42 . The holes at the upper end of the Y are positioned to be a slip fit to the horizontal roller mounting screws 46 and are positioned thereon. At the left end of the first trolley 40 as shown in the figures, each dependent plate 43 is spaced away from the body 41 by a short right circular cylindrical tubular second cylindrical spacer 49 , which is concentrically mounted on a horizontal roller mounting screw 46 . At the right end, each dependent plate is spaced away from the body 41 by an intertrolley connector link having the same thickness as the cylindrical spacer 49 . Each horizontal roller mounting screw 46 at the right end of the body 41 passes through, from its hex head end, a vertical support roller 44 , a dependent plate 43 , and an intertrolley connector link 62 . The coaxial righthand horizontal roller mounting screws 46 on body 41 provide a horizontal rotational axis for flexing in the vertical plane of the trolley assembly 39 .
[0048] A large crossbar 50 , used to support the choke actuator 203 , is a thick rectangular prismatic plate mounted horizontally at the bottom ends of the Y of the spaced apart parallel dependent plates 43 by mounting screws 52 engaged in the bottom holes of the plates 43 and drilled and tapped horizontal holes in crossbar 50 . Crossbar 50 has on its center vertical transverse plane two symmetrically spaced apart vertical hanger screw holes 51 which correspond to similar drilled and tapped holes in bosses 206 on the upper surface of the choke valve actuator 203 . Hanger screw holes 51 mount downwardly extending actuator hanger screws 94 for attaching to the actuator.
[0049] The second trolley 60 is very similar to first trolley 40 in construction, but with the following differences. The body 61 of second trolley 60 is similar to that of the body 41 except for a short rectangular horizontal prismatic protrusion on its righthand end centerline. The protrusion has opposed horizontal coaxial drilled and tapped holes for mounting a pair of link attachment screws 65 . Additionally, spaced toward the center of body 61 from the lefthand mounting holes for the horizontal axis vertical support rollers 44 and their roller mounting screws 46 is another pair of opposed horizontal coaxial drilled and tapped holes for mounting a pair of link attachment screws 65 .
[0050] The first and second trolleys are linked together with a horizontal intertrolley connection link 62 . The intertrolley connection link 62 is rigidly mounted to the body 61 on each lefthand lateral side by a link attachment screw 65 and a roller mounting screw 46 . The intertrolley connection link 62 is a vertical rectangular flat plate which is horizontally elongated to extend leftward beyond body 61 and has three horizontal through holes. The leftmost through hole is journaled on a righthand horizontal roller mounting screw 46 of trolley 40 and the middle hole is a slip fit onto the lefthand horizontal roller mounting screw 46 of trolley 60 . The righthand hole is a slip fit for a link attachment screw 65 as described above. This arrangement of the horizontal intertrolley connection link 62 permits the first and second trolleys to pivot about horizontal axis 70 that is coaxial with the horizontal axis of the righthand vertical support rollers 44 of trolley 40 . The lefthand vertical support roller screw 46 of second trolley 60 has a second cylindrical spacer 49 located between the roller 44 and link 62 . The righthand vertical support roller screws 46 spaces the roller 44 outwardly from body 61 by a first cylindrical spacer 48 that is similar to the second spacer 49 , but longer.
[0051] A rectangular elongate attachment link 66 having a horizontal through hole at each end is positioned in the vertical plane and lapped onto each side of the rightward protrusion of body 61 , where it is journaled at one end by a screw 65 . The other end of each attachment link 66 is journaled on a second screw 65 that is mounted in one of the horizontal transverse holes in driven nut 30 . This arrangement permits the relative alignment of second trolley 60 to vary with regards to the axis of actuator screw 24 as the track 11 departs from being parallel to screw 24 .
[0052] A support structure, as shown in FIG. 7 , is provided to rigidly mount the track 11 with its trolley assembly 39 to the choke valve 201 . Symmetrically positioned and transversely mounted by welding to channels 12 and 13 underneath track 11 at their righthand ends are a pair of channel crossmembers 90 . The webs of channels 90 are vertical and parallel and their flanges face inwardly in an opposed fashion. Parallel to and symmetrically spaced apart from the longitudinal centerline of track 11 are elongate rectangular choke mounting bars 91 , which are attached by welding symmetrically to the outer ends of the lower flanges of crossmembers 90 . The distal ends of the bars 91 have vertical holes mounting downwardly extending choke mounting screws 92 . The hole pattern in the bars 91 corresponds to an array of drilled and tapped mounting holes in the upper surface of choke valve 201 .
[0053] An alternative embodiment of the choke manipulator 300 is shown in FIGS. 8 to 12 . the choke manipulator 300 can be both rotated in the horizontal plane and reciprocated toward and away from the choke valve body 201 . Referring to FIGS. 8 to 10 , the basic manipulator assembly 300 is shown in an oblique, side profile, and oblique exploded views. The major components of the manipulator assembly include track 311 , the trolley assembly 340 , and the supporting means for the manipulator 300 , which consists of members rotator base 359 and choke mounted base 363 . The actuator 203 is supported by an actuator hanger 367 , which is dependent from the trolley 340 and is rotatable about a vertical axis.
[0054] The track 311 is composed of horizontal mirror image righthand and lefthand straight channels, 312 and 313 respectively, which have vertical webs. Vertical stiffeners for the track 311 are not shown in this case, but could be included readily in a manner similar to that used with plates 14 on the track 11 of the first manipulator embodiment 10 . The channels 312 and 313 are spaced apart parallel with their flanges projecting inwardly. A generally rectangular transverse plate 315 is coped to fit between the flanges of channels 312 and 313 and welded at the outer end of the track 311 to rigidize the track and provide an end stop.
[0055] Multiple angle crossmembers 16 are placed on top of the upper flanges and welded horizontally and perpendicularly to those upper flanges of the channels 12 and 13 to tie the channels together to form a track. For example as shown in FIGS. 9 and 10 , two crossmembers 16 are used. One crossmember 16 is placed adjacent the lefthand end of the channels 312 and 313 and another crossmember 16 is placed at the righthand end of the channels.
[0056] The vertical flange of each angle crossmember 16 has a central horizontal hole at approximately midheight to accommodate the actuator screw 324 . Additionally, on each side of the central hole at the same height and equispaced from the central hole is located a mounting hole for the attachment of a plain bearing 17 . Plain bearing 17 is a rectangular prismatic block with a central horizontal hole for journaling the actuator screw 324 and mounting holes matching those of the angle crossmembers 16 when the bearing has its central hole aligned with that of the crossmembers. Bearing retainer screws 18 and bearing retainer nuts 19 are used with the mounting holes of the crossmembers 16 and the bearings 17 to coaxially attach the bearings to the crossmembers.
[0057] Actuator screw 324 is a long right circular cylindrical rod with a male threaded central section, a short reduced diameter first (lefthand) end having a male thread at its distal end, and a short reduced diameter shank 326 at its second end. The extreme end of the shank 326 has a flat offset from the cylindrical screw axis so that shaft coupling 328 can be attached. The diameters of the first end of the screw 324 and the shank 326 are generally about the same and are a slip fit to the bearings 17 . The screw 324 is mounted in the set of bearings 17 so that the first end of the screw is supported in the bearing near the outer end of the track 311 , while the shank 326 of the screw is supported in the other bearing 17 . Actuator screw 324 is retained in place by actuator screw retainer nut 25 being attached to the thread at the first end of the actuator screw 324 .
[0058] A rectangular prismatic driven nut 330 has a central horizontal through hole 331 which is drilled and tapped with a female thread mateable with the male thread of actuator screw 324 . The driven nut 330 is threadedly engaged with the screw 324 between the bearings 17 of the track 311 . Horizontal through holes with their axes parallel to and laterally offset from the axis of threaded hole 331 are located in driven nut 330 . The drilled and tapped holes in driven nut 330 are used to prevent its rotation.
[0059] A conventional handwheel 38 is attached to the worm gear reduction gear box 380 by means of a second coupling 328 so that the axis of the handwheel projects horizontally transverse to the axis of the track 311 . The output shaft of the reduction gearbox 380 projects horizontally parallel to and in the direction of the longitudinal axis of track 311 . Reduction worm gear box 380 is attached to actuator screw 324 adjacent the inner end of the track 311 by means of the coupling 328 on the adjacent second end of the actuator screw.
[0060] Although the nut 25 axially fixes the screw 324 , the screw 324 can be rotated by handwheel 38 acting through gearbox 380 so that nonrotating driven nut 330 can be selectably caused to reciprocate along the axis of the screw. Gearbox 380 is mounted on bracket angle 381 , which is transversely mounted by welding at the extreme righthand end of track 311 by its vertical downwardly projecting flange and with its long flange horizontal and projecting to the right. The horizontal flange of bracket angle 381 is drilled for mounting gearbox 380 by means of multiple screw and nut pairs 382 . The horizontal flange of bracket angle 381 is at approximately the same height as the upper flange of the channels 312 and 313 .
[0061] The trolley subassembly 340 , shown in detail in FIG. 11 , is very similar to the first trolley 40 of the first embodiment 10 of the present invention and uses most of the same components. The trolley subassembly 340 is mounted to reciprocate within track 311 between the inwardly facing flanges of the track. Trolley 340 is configured to support the actuator 203 of the choke under the track 311 . Trolley 340 consists of a backbone plate body 41 mounting horizontal 45 and vertical 44 restraint rollers to maintain and control the position of trolley 340 within the guiding track 311 . First trolley body 41 is a thick horizontal plate having a generally rectangular outline with a reduced width central “waist” and lightening holes.
[0062] Transverse horizontally drilled and tapped holes are located slightly below midheight near the four corners of the body 41 and each serves to mount a vertical support roller 44 on a shaft provided by a roller mounting screw 46 . A rectangular prismatic flat crossbar 42 is transversely mounted underneath the body 41 at about midlength of the body 41 . Two hex screws 47 engaged into drilled and tapped holes in the body 41 support the crossbar 42 . In a drilled and tapped hole in the crossbar on the upper side of each of the upper outer tips of the crossbar 42 , a vertical roller is mounted on the crossbar 42 by a mounting screw 46 that also supports a coaxial horizontal support roller 45 .
[0063] Dependent plates 43 are Y-shaped with the arms of the Y up and clearance holes at the upper tips of the Y and a pair of bolt holes at the bottom. The central notch of the Y permits the plates 43 to clear the crossbar 42 . The holes at the upper end of the Y are positioned to be a slip fit to the horizontal roller mounting screws 46 and are positioned thereon. At both the left end and right end of trolley 340 , the dependent plate 43 is typically spaced away from the body 41 by a short right circular cylindrical tubular second cylindrical spacer 49 , which is concentrically mounted on a horizontal roller mounting screw 46 as shown in FIG. 6 .
[0064] The actuator support crossbar 350 is a thick rectangular prismatic plate. The crossbar 350 is mounted horizontally at the bottom ends of the Y of the spaced apart parallel dependent plates 43 by means of mounting screws 52 engaged in the bottom holes of the plates 43 and drilled and tapped horizontal holes in crossbar 350 . Crossbar 350 has on its center a vertical hanger screw hole 351 . The hanger screw hole 351 mounts downwardly extending actuator hanger 367 for attaching to the choke actuator 203 .
[0065] Transverse vertical attachment link 356 is a rectangular plate with a pair of through holes at its lower end symmetrically spaced apart from the plate vertical longitudinal midplane. A clearance through hole for the actuator screw 324 is located near the upper end of plate 356 on the vertical longitudinal midplane. Laterally offset equally to each side of the clearance hole in plate 356 are two through holes that are aligned with the bolt holes in driven nut 330 and with which the driven nut is attached to plate 356 using screw 18 and nut 19 . In addition, the transverse face of the trolley body 41 has two horizontal drilled and tapped holes at midheight of the body plate 41 and equispaced from the longitudinal centerplane of the body 41 . The spacing of these holes in body 41 is the same as that of the lower holes in plate 356 and link attachment screws 357 are engaged through these holes to attach link plate 356 to the body 41 of trolley 340 .
[0066] Rotator base 359 , shown in FIG. 12 , is attached to the bottom side of track 311 at its righthand end and serves to provide a rotatable support between the track assembly 311 and the choke valve 201 . As seen in FIGS. 8 to 10 , the rotator base 359 has a rotator upper plate 360 , worm gear 361 , rotator keeper nut 362 , rotator keeper washer 396 , rotator top bearing 397 , and rotator bottom bearing 398 .
[0067] The rotator upper plate 360 is a thick horizontal plate with one circular end and the other end squared. On the centerline of the circular portion of plate 360 and extending downwardly from the lower surface of the plate is worm gear 361 . Worm gear 361 has a large diameter worm gear located on an upper cylindrical portion and a downwardly extending concentric reduced diameter right circular cylindrical lower hub joined to it by a transverse shoulder. The lower end of the hub of worm gear 361 has an upwardly extending drilled and tapped hole on its axis that is engagable by rotator keeper screw 362 .
[0068] The rotator top bearing 397 is a transversely flanged thin walled right circular cylindrical tube having a bore which has a close slip fit to the lower hub of the worm gear 361 and a flange diameter the same as that of the toothed portion of worm gear 361 . The bearing 397 is generally made of a lubricious plastic or a bearing bronze. The rotator bottom bearing 398 has the same outer diameter as the flange of bearing 397 and the same inner diameter as bearing 397 . Rotator bottom bearing 398 is a thin annular ring typically made of the same material as that of the rotator top bearing 397 .
[0069] The thick right circular cylindrical washer 396 has the same outer diameter as lower bearing 398 and a central clearance hole for accommodating rotator keeper screw 362 . Rotator top bearing 397 is mounted on the hub of worm gear 361 with its flange abutting the downward facing shoulder of the gear. The lower bearing 398 is mounted on the upper surface of washer 396 and both are clamped to the lower end of the worm gear 361 by screw 362 . The spacing between the flange of bearing 397 and the upper face of bearing 398 is slightly more than the thickness of the plate 365 .
[0070] The rotator assembly 359 is assembled by the welding of the worm gear 361 to the rotator upper plate 360 . The upper surface of the rotator upper plate 360 is welded to the bottom of the righthand end of the track assembly 311 so that the horizontal track centerline intersects the vertical centerline of the rotator assembly and the track extends in the direction of the squared end of the rotator upper plate 360 .
[0071] The choke mounted base subassembly 363 has a horizontal rectangular upper pivot plate 365 , two transverse riser plates 364 , and two choke mounting bars 366 . This subassembly mounts a handwheel driven worm 383 which is engaged to the worm gear 361 of the rotator base 359 . Thick upper pivot plate 365 has a large circular through hole to journal bearing 397 of the rotator base 359 . The lower side of the flange of bearing 397 and upper side of bearing 398 then can be supported on the upper and lower surfaces of the upper pivot plate 365 , respectively.
[0072] A pattern of small vertical drilled and tapped holes is offset to one side of the pivot plate from the large through hole in the central portion of the plate. This hole pattern is for mounting the pillow blocks 385 . The rectangular transverse riser plates 364 are attached to the lower transverse face of plate 365 by welding. A first riser plate 364 is attached to plate 365 with its outer transverse face flush with the transverse lefthand face of the plate 365 . The second riser plate 364 is positioned parallel to the first symmetrically about the large center through hole, so that it is inward to the left from the righthand transverse edge of plate 365 .
[0073] The choke mounting bars 366 are rectangular cross-section bars with symmetrically placed vertical through holes at their ends for accommodating choke attachment screws 392 . The choke mounting bars 366 are welded horizontally transverse to and below the riser plates 364 at the outer ends of the riser plates 364 . When assembled, the hole pattern in the choke mounting bars 366 corresponds to an identical pattern of drilled and tapped holes on the upper side of the body of choke valve 201 so that screws 392 can be used to attach the choke mounted base 363 to the choke.
[0074] A helically toothed worm 383 is concentrically mounted on an elongate cylindrical worm shaft 384 and supported by two bearing pillow blocks 385 . One pillow block is positioned adjacent a first end of the shaft 384 , while the other pillow block is set back from the second end of the shaft. The second end of the shaft 384 has a flat provided whereby another handwheel 38 can be mounted at the second end for selectably driving the shaft. The height of the pillow blocks 385 is such that, when the pillow blocks 385 are mounted onto the upper surface of plate 365 by screws 386 , the worm 383 is properly positioned vertically with respect to worm gear 361 of the rotator base 359 . The transverse positioning relative to the centerline of worm gear 361 of the mounting holes for the pillow blocks 385 on plate 365 is such that the worm 383 and the worm gear 361 are suitably meshed. The worm shaft 384 extends laterally sufficiently beyond the side of choke mounted base 363 that its handwheel 38 is freely accessible and the rotator base 359 is able to rotate through a large arc.
[0075] The actuator hanger 367 has a stepped vertical shaft with a large transverse flange 370 at its lower end. The upper end of hanger 367 has a male thread, below which is a concentric cylindrical shank. A transverse flange joins the lower end of the round cylindrical shank to the relatively larger diameter main round cylindrical body of the actuator hanger 367 . Two diametrically opposite vertical holes are drilled in the flange 370 at the lower end of hanger 367 so that screws 94 can be used to engage the threaded holes in the bosses 206 of the choke actuator 203 . Hanger washer 368 is a round disk washer with a central hole to accommodate the threaded section and the shank of hanger 367 . The outer diameter of the washer 368 is generally the same as the diameter of the main cylindrical body of hanger 367 .
[0076] Two thin flat annular bearing washers 369 are generally fabricated from a lubricious plastic or bearing bronze. The outer diameter of the bearings 369 correspond to both the outer diameter of hanger washer 368 and of the main round cylindrical body of the actuator hanger 367 . The threaded portion and shank of actuator hanger 367 are assembled into the hanger screw hole 351 of the trolley 340 with a bearing 369 on each side of the actuator support crossbar 350 and the lower bearing abutting the transverse shoulder of the hanger, washer 368 on top of the upper bearing 369 , and hanger nut 371 and hanger jam nut 372 engaged with the thread of hanger 367 to retain the bearings 369 and washer 368 in place. The nuts 371 and 372 are not made up so tightly that the hanger 367 cannot be readily rotated.
[0000] Operation of the Invention
[0077] The arrangements shown in the drawings of this document can be varied somewhat from what is shown herein without departing from the spirit of the present invention. Likewise, the operational sequence can be varied somewhat from what is described herein without departing from the spirit of the invention.
[0078] The operation of the first embodiment 10 of the present invention is as follows. The manipulator 10 is mounted to drilled and tapped holes in the upper surface of the choke valve 201 by means of screws 92 engaged through the vertical holes in the ends of the choke mounting bars 91 . The track 11 is then positioned so that it extends outwardly on the actuator 203 side of the choke 201 and is aligned with the axis of the choke. The arrangement of the trolley assembly 39 is such that the lower surface of its actuator support crossbar 50 is coplanar with the top surfaces of the bosses 206 of the choke actuator 203 .
[0079] The handwheel 38 is rotated, thereby causing driven nut 30 and trolley assembly 39 to move along track 11 until the holes 51 in the actuator support crossbar 50 are aligned with the corresponding holes in the bosses 206 of the choke actuator 203 . Screws 94 are then engaged with the choke actuator by means of the holes in the bosses 206 so that the trolley assembly 39 , the track 11 , the track support members 90 and 91 , and the rigidly mounted choke 201 are supporting the choke actuator 203 . At this point, the attachment nut 204 , which connects the choke actuator 203 and the internal valve components of the choke valve 201 to the choke valve body at its lefthand neck, is disconnected.
[0080] The handwheel 38 is then rotated so that the trolley assembly 39 and its attached actuator 203 and the internals of the choke valve 201 are withdrawn axially from choke body cavity. If it is desired to service these withdrawn components horizontally, then the trolley 39 is not moved onto the arcuate portion of the track 11 . However, if it is desired to rotate the actuator 203 so that components do not readily drop out of the actuator housing during service, the trolley can be shifted sufficiently so that the first trolley 40 moves well up into the arcuate portion of the track, thereby tilting the lefthand, cover end of the actuator upwardly. The trolley assembly 39 is prevented from excessive outward travel by travel stop bar 34 . The reassembly of the choke system uses a reverse procedure to the disassembly described above.
[0081] The operation of the second embodiment 300 of the present invention is as follows. The manipulator 300 is mounted to drilled and tapped holes in the upper surface of the choke valve 201 by means of screws 392 engaged through the vertical holes in the ends of the choke mounting bars 366 . The track 311 is then positioned so that it extends outwardly on the actuator 203 side of the choke 201 and aligned with the axis of the choke. The arrangement of the trolley assembly 340 is such that the lower surface of its actuator support crossbar 350 is coplanar with the top surfaces of the bosses 206 of the choke actuator 203 .
[0082] The first handwheel 38 is rotated causing driven nut 330 and trolley assembly 40 to be driven through gearbox 380 and the actuator screw 324 and to move along track 311 until the holes in the flange 370 of the actuator hanger 367 are aligned with the corresponding holes in the bosses 206 of the choke actuator 203 . Screws 94 are then engaged with the actuator 203 by means of the holes in the bosses 206 so that the trolley assembly 340 , the track 311 , the rotator base 359 , the choke mounted base 363 , and the rigidly mounted choke 201 are supporting the actuator 203 . At this point, the attachment nut 204 , which connects the actuator 203 and the internal valve components of the choke valve 201 to the choke valve body at its lefthand neck, is disconnected.
[0083] The first handwheel 38 is then again rotated so that the trolley assembly 340 and its attached actuator 203 and the internals of the choke valve 201 are withdrawn axially from choke body cavity. If it is desired to rotate the choke actuator 203 in the horizontal plane so that components are more readily accessible, the actuator hanger 367 can be directly rotated.
[0084] Alternatively, the second handwheel 38 can actuate the worm 383 to drive worm gear 361 and rotate rotator base 359 and its attached track 311 . Both rotational methods can be used together to achieve a desired alignment. Choke reassembly uses a reverse procedure of the disassembly described above.
[0085] Advantages of the Invention
[0086] The first embodiment 10 of the present invention permits servicing of the choke valve 201 and the choke actuator 203 at the height of the choke valve axis, which is normally an easier working position than at ground level. Additionally, it is very advantageous to be able to tilt the actuator upwardly so that its internal components are not so easily dropped during servicing.
[0087] The second embodiment 300 of the present invention permits the actuator 203 and the internals of the choke valve 201 to be swiveled in the horizontal plane so that they can be placed in a more conveniently accessible position. This is an important advantage when the choke is located in the middle of a complex flow manifold where conventional access would be problematic.
[0088] A common advantage to both embodiments 10 and 300 of the present invention is the reduced susceptibility to stick-slip movement of the trolley supporting the actuator 203 and the choke valve 201 components. This improvement is due to the screw drive and the gear drive arrangements for the manipulators, since these operational means are much smoother, stiffer, and more forceful than manually urging the suspended choke system components to new positions.
[0089] A further important advantage is that the mechanical advantage of the screw and/or gear drives of the present manipulators permits controlled movement of the suspended components of the choke even when the movements are not in a very level position. A common advantage for both types of manipulator is that is markedly eases the assembly and disassembly and servicing of the typically heavy components of the choke valve, leading to reduced strain and injury in service personnel and to reduced choke valve system component damage due to dropped or impacted components.
[0090] These and other advantages will be obvious to those skilled in the art. Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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The present invention relates to an apparatus for use in field servicing a choke valve system. The apparatus is used for lifting, manipulating, and handling the heavy components of hydraulic choke valves. The apparatus includes an elongated track, a choke valve support structure, a trolley that selectably reciprocates along a length of the trolley, and an attachment mechanism for attaching a choke actuator to the trolley.
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FIELD OF THE INVENTION
This invention relates to mixtures of fluorinated hydrocarbons and more specifically relates to azeotropic or azeotrope-like compositions comprising 1,1,1,2,3,4,4,5,5,5-decafluoropentane (HFC-43-10mee, or CF 3 CHFCHFCF 2 CF 3 ) and trans-1,2-dichloroethylene, cis-1,2-dichloroethylene, or 1,1-dichloroethane. Such compositions are useful as cleaning agents, expansion agents for polyolefins and polyurethanes, refrigerants, aerosol propellants, heat transfer media, gaseous dielectrics, fire extinguishing agents, power cycle working fluids, polymerization media, particulate removal fluids, carrier fluids, buffing abrasive agents, and displacement drying agents.
BACKGROUND OF THE INVENTION
Fluorinated hydrocarbons have many uses, one of which is as a cleaning agent or solvent. Cleaning agents are used, for example, to clean electronic circuit boards. Electronic components are soldered to circuit boards by coating the entire circuit side of the board with flux and thereafter passing the flux-coated board over preheaters and through molten solder. The flux cleans the conductive metal parts and promotes solder fusion, but leave residues on the circuit boards that must be removed with a cleaning agent.
Preferably, cleaning agents should have a low boiling point, nonflammability, low toxicity, and high solvency power so that flux and flux-residues can be removed without damaging the substrate being cleaned. Further, it is desirable that the cleaning agents be azeotropic or azeotrope-like so that they do not tend to fractionate upon boiling or evaporation. This behavior is desirable because if the cleaning agent were not azeotropic or azeotrope-like, the more volatile components of the cleaning agent would preferentially evaporate, and would result in a cleaning agent with a changed composition that may become flammable and that may have less-desirable solvency properties, such as lower rosin flux solvency and lower inertness toward the electrical components being cleaned. Theazeotropic character is also desirable in vapor degreasing operations because the cleaning agent is generally redistilled and employed for final rinse cleaning.
Fluorinated hydrocarbons are also useful as blowing agents in the manufacture of close-cell polyurethane, phenolic and thermoplastic foams. Insulating foams depend on the use of blowing agents not only to foam the polymer, but more importantly for the low vapor thermal conductivity of the blowing agents, which is an important characteristic for insulation value.
Fluorinated hydrocarbons may also be used as refrigerants. In refrigeration applications, a refrigerant is often lost through leaks during operation through shaft seals, hose connections, solder joints, and broken lines. In addition, the refrigerant may be released to the atmosphere during maintenance procedures on refrigeration equipment. Accordingly, it is desirable to use refrigerants that are pure fluids or azeotropes as refrigerants. Some nonazeotropic blends of refrigerants may also be used, but they have the disadvantage of changing composition when a portion of the refrigerant charge is leaked or discharged to the atmosphere. Should these blends contain a flammable component, they could also become flammable due to the change in composition that occurs during the leakage of vapor from refrigeration equipment. Refrigerant equipment operation could also be adversely affected due to this change in composition and vapor pressure that results from fractionation.
Aerosol products employ both individual halocarbons and halocarbon blends as propellant vapor pressure attenuators in aerosol systems. Azeotropic mixtures, with their constant compositions and vapor pressures are useful as solvents and propellants in aerosols.
Azeotropic or azeotrope-like compositions are also useful as heat transfer media, gaseous dielectrics, fire extinguishing agents, power cycle working fluids such as for heat pumps, an inert medium for polymerization reactions, as a fluid for removing particulates from metal surfaces, and as a carrier fluid that may be used, for example, to place a fine film of lubricant on metal parts.
Azeotropic or azeotrope-like compositions are further useful as buffing abrasive detergents to remove buffing abrasive compounds from polished surfaces such as metal, as displacement drying agents for removing water such as from jewelry or metal parts, as resist-developers in conventional circuit manufacturing techniques employing chlorine-type developing agents, and as strippers for photoresists (for example, with the addition of a chlorohydrocarbon such as 1,1,1-trichloroethane or trichloroethylene).
Some of the fluorinated hydrocarbons that are currently used in these applications have been theoretically linked to depletion of the earth's ozone layer and to global warming. What is needed, therefore, are substitutes for fluorinated hydrocarbons that have low ozone depletion potentials and low global warming potentials.
SUMMARY OF THE INVENTION
The present invention relates to the discovery of azeotropic or azeotrope-like compositions comprising admixtures of effective amounts of 1,1,1,2,3,4,4,5,5,5-decafluoropentane (HFC-43-10mee, or CF 3 CHFCHFCF 2 CF 3 ) and trans-1,2-dichloroethylene, cis-1,2-dichloroethylene or 1,1-dichloroethane. One way to define the invention is in terms of weight percents of the components at atmospheric pressure. Azeotropic or azeotrope-like mixtures of HFC-43-10mee and trans-1,2-dichloroethylene include about 58-68 weight percent HFC-43-10mee and about 32-42 weight percent trans-1,2-dichloroethylene; azeotropic or azeotrope-like mixtures of HFC-43-10mee and cis-1,2-dichloroethylene include about 63-73 weight percent HFC-43-10mee and about 27-37 weight percent cis-1,2-dichloroethylene; and azeotropic or azeotrope-like mixtures of HFC-43-10mee and 1,1-dichloroethane include about 68-78 weight percent HFC-43-10mee and about 22-32 weight percent 1,1-dichloroethane, all at atmospheric pressure.
Compositions of the invention are useful as cleaning agents, expansion agents for polyolefins and polyurethanes, refrigerants, aerosol propellants, heat transfer media, gaseous dielectrics, fire extinguishing agents, power cycle working fluids, polymerization media, particulate removal fluids, carrier fluids, buffing abrasive agents, and displacement drying agents.
DETAILED DESCRIPTION OF THE INVENTION
The compositions of the instant invention are substantially constant boiling, azeotropic or azeotrope-like compositions, or mixtures, comprising admixtures of effective amounts of 1,1,1,2,3,4,4,5,5,5-decafluoropentane (HFC-43-10mee, or CF 3 CHFCHFCF 2 CF 3 , boiling point=53° C.) and trans-1,2-dichloroethylene (CHClCHCl, boiling point=48° C.), cis-1,2-dichloroethylene (CHClCHCl, boiling point=60° C.), or 1,1-dichloroethane (CHCl 2 CH 3 , boiling point=57° C.) to form an azeotropic or azeotrope-like composition.
Effective amounts of the 1,1,1,2,3,4,4,5,5,5-decafluoropentane and trans-1,2-dichloroethylene, cis-1,2-dichloroethylene or 1,1-dichloroethane to form an azeotropic or azeotrope-like composition, when defined in terms of weight percent of the components at atmospheric pressure, include the following.
Substantially constant-boiling, azeotropic or azeotrope-like compositions of HFC-43-10mee and trans-1,2-dichloroethylene comprise about 58-68 weight percent HFC-43-10mee and about 32-42 weight percent trans-1,2-dichloroethylene. These compositions boil at about 37.3°+/-1.6° C. at substantially atmospheric pressure. A preferred composition of the invention is the azeotrope, which comprises about 63.2 weight percent HFC-43-10mee and about 36.8 weight percent trans-1,2-dichloroethylene, and which boils at 37.3° C. at atmospheric pressure.
Substantially constant-boiling, azeotropic or azeotrope-like compositions of HFC-43-10mee and cis-1,2-dichloroethylene comprise about 63-73 weight percent HFC-43-10mee and about 27-37 weight percent cis-1,2-dichloroethylene. These compositions boil at about 42.3°+/-1.2° C. at substantially atmospheric pressure. A preferred composition of the invention is the azeotrope, which comprises about 67.9 weight percent HFC-43-10mee and about 32.1 weight percent cis-1,2-dichloroethylene, and which boils at 42.3° C. at atmospheric pressure.
Substantially constant-boiling, azeotropic or azeotrope-like compositions of HFC-43-10mee and 1,1-dichloroethane comprise about 68-78 weight percent HFC-43-10mee and about 22-32 weight percent 1,1-dichloroethane. These compositions boil at about 43.0°+/-2.8° C. at substantially atmospheric pressure. A preferred composition of the invention is the azeotrope, which comprises about 73.0 weight percent HFC-43-10mee and about 27.0 weight percent 1,1-dichloroethane, and which boils at about 43.0° C. at atmospheric pressure
By "azeotropic or azeotrope-like" composition is meant a constant boiling, or substantially constant boiling, liquid admixture of two or more substances that behaves as a single substance. One way to characterize an azeotropic or azeotrope-like composition is that the vapor produced by partial evaporation or distillation of the liquid has substantially the same composition as the liquid from which it was evaporated or distilled, that is, the admixture distills/refluxes without substantial composition change. Constant boiling or substantially constant boiling compositions, which are characterized as azeotropic or azeotrope-like, exhibit either a maximum or minimum boiling point, as compared with that of the nonazeotropic mixtures of the same components.
As used herein, the terms azeotropic and constant boiling are intended to mean also essentially azeotropic or essentially constant boiling. In other words, included within the meaning of these terms are not only the true azeotropes described above, but also other compositions containing the same components in different proportions, which are true azeotropes or are constant boiling at other temperatures and pressures, as well as those equivalent compositions which are part of the same azeotropic or constant boiling system and are azeotrope-like or substantially constant boiling in their properties. As is well recognized in this art, there is a range of compositions which contain the same components as the azeotrope, which not only will exhibit essentially equivalent properties for cleaning, refrigeration and other applications, but which will also exhibit essentially equivalent properties to the true azeotropic composition in terms of constant boiling characteristics or tendency not to segregate or fractionate on boiling.
For purposes of this invention, effective amount is defined as the amount of each component of the inventive compositions that, when combined, results in the formation of an azeotropic or azeotrope-like composition. This definition includes the amounts of each component, which amounts may vary depending upon the pressure applied to the composition, so long as the azeotropic or azeotrope-like, or constant boiling or substantially constant boiling compositions continue to exist at the different pressures, but with possible different boiling points. Therefore, effective amount includes the weight percentage of each component of the compositions of the instant invention, which form azeotropic or azeotrope-like, or constant boiling or substantially constant boiling, compositions at pressures other than atmospheric pressure.
It is possible to characterize, in effect, a constant boiling admixture, which may appear under many guises, depending upon the conditions chosen, by any of several criteria:
The composition can be defined as an azeotrope of A, B and C, since the very term "azeotrope" is at once both definitive and limitative, and requires that effective amounts A, B and C form this unique composition of matter, which is a constant boiling admixture.
It is well known by those skilled in the art that at different pressures, the composition of a given azeotrope will vary--at least to some degree--and changes in pressure will also change--at least to some degree--the boiling point temperature. Thus an azeotrope of A, B and C represents a unique type of relationship but with a variable composition which depends on temperature and/or pressure. Therefore compositional ranges, rather than fixed compositions, are often used to define azeotropes.
The composition can be defined as a particular weight percent relationship or mole percent relationship of A, B and C, while recognizing that such specific values point out only one particular such relationship and that in actuality, a series of such relationships, represented by A, B and C actually exist for a given azeotrope, varied by the influence of pressure.
Azeotrope A, B and C can be characterized by defining the composition as an azeotrope characterized by a boiling point at a given pressure, thus giving identifying characteristics without unduly limiting the scope of the invention by a specific numerical composition, which is limited by and is only as accurate as the analytical equipment available.
The following binary compositions are characterized as azeotropic or azeotrope-like in that compositions within these ranges exhibit a substantially constant boiling point at constant pressure. Being substantially constant boiling, the compositions do not tend to fractionate to any great extent upon evaporation. After evaporation, only a small difference exists between the composition of the vapor and the composition of the initial liquid phase. This difference is such that the compositions of the vapor and liquid phases are considered substantially the same and are azeotropic or azeotrope-like in their behavior.
1. 58-68 weight percent HFC-43-10mee and 32-42 weight percent trans-1,2-dichloroethylene;
2. 63-73 weight percent HFC-43-10mee and 27-37 weight percent cis1,2-dichloroethylene; and
3. 68-78 weight percent HFC-43-10mee and 22-32 weight percent 1,1-dichloroethane.
The following binary compositions of HFC-43-10mee and trans-1,2-dichloroethylene have been established, within the accuracy of the fractional distillation method, as a true binary azeotropes at substantially atmospheric pressure.
1. about 63.2 weight percent HFC-43-10mee and about 36.8 weight percent trans-1,2-dichloroethylene, boiling point of about 37.3° C.;
2. about 67.9 weight percent HFC-43-10mee and about 32.1 weight percent cis-1,2-dichloroethylene, boiling point of about 42.3° C.; and
3. about 73.0 weight percent HFC-43-10mee and about 21.0 weight percent 1,1-dichloroethane, boiling point of about 43.0° C.
The aforestated azeotropes have no ozone-depletion potentials, their Global Warming Potentials (GWP) are low and they have short atmospheric life spans, and are expected to decompose almost completely prior to reaching the stratosphere.
The azeotropes or azeotrope-like compositions of the instant invention permit easy recovery and reuse of the solvent from vapor defluxing and degreasing operations because of their azeotropic natures. As an example, the azeotropic mixtures of this invention can be used in cleaning processes such as described in U.S. Pat. No. 3,881,949, or as a buffing abrasive detergent.
Another aspect of the invention is a refrigeration method which comprises condensing a refrigerant composition of the invention and thereafter evaporating it in the vicinity of a body to be cooled. Similarly, still another aspect of the invention is a method for heating which comprises condensing the invention refrigerant in the vicinity of a body to be heated and thereafter evaporating the refrigerant.
A further aspect of the invention includes aerosol compositions comprising an active agent and a propellant, wherein the propellant is an azeotropic mixture of the invention; and the production of these compositions by combining said ingredients. The invention further comprises cleaning solvent compositions comprising the azeotropic mixtures of the invention.
The azeotropic or azeotrope-like compositions of the instant invention can be prepared by any convenient method including mixing or combining the desired component amounts. A preferred method is to weigh the desired component amounts and thereafter combine them in an appropriate container.
Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The following preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
The 1,1,1,2,3,4,5,5-decafluoropentane of this invention may be prepared in the manner disclosed in U.S. patent application Ser. No. 07/595,839 filed Oct. 11, 1990, now abandoned, the text of which is incorporated herein by reference, which discloses a process for manufacturing polyfluoroolefins having at least 5 carbon atoms by reacting together two polyfluoroolefins in the presence of a catalyst of the formula AlX 3 where X is one or more of F, Cl or Br, provided X is not entirely F. A five carbon perfluoroolefinic starting material may be prepared by the reaction of hexafluoropropene (HFP) with tetrafluoroethylene (TFE). A six carbon perfluoroolefinic starting material may be prepared by the reaction of 1,1,1,4,4,4-hexafluoro-2,3-dichloro-2-butene with TFE to yield an intermediate product comprising perfluoro-2,3-dichloro-2-hexene which may then be converted to perfluoro-2-hexene by reaction with potassium fluoride in refluxing N-methyl pyrolidone. A mixture of seven carbon perfluoroolefinic starting materials may be prepared by the reaction of hexafluoro-propene with 2 moles of TFE.
The CF 3 CHFCHFCF 2 CF 3 of this invention may be prepared by a process which comprises the step of reacting an olefinic starting material prepared as described above in the vapor phase with hydrogen over a metal catalyst from the palladium group. The olefinic starting material for this process has the same number of carbon atoms as the desired dihydropolyfluoroalkanes and may be CF 3 CF═CFCF 2 CF 3 , and has its olefinic bond between the carbon atoms which correspond to the carbons which bear the hydrogen in said dihydropolyfluoroalkane.
Unsupported metal catalysts and supported metal catalysts wherein the metal is palladium, rhodium or ruthenium are suitable for use in this process. Supports such as carbon or alumina may be employed. Palladium on alumina is the preferred catalyst.
The vapor phase reduction can be carried out at temperatures in the range of from about 50° C. to about 225° C.; the preferred temperature range is from about 100° C. to about 200° C. The pressure of the hydrogenation may vary widely from less than 1 atmosphere to 20 or more atmospheres. The molar ratio of hydrogen to olefinic starting material for this process is preferably between about 0.5:1 and 4:1, and is more preferably between about 0.5:1 and 1.5:1.
In the foregoing and in the following examples, unless otherwise indicated, all parts and percentages are by weight.
The entire disclosure of all applications, patents and publications, cited above and below, are hereby, incorporated by reference.
EXAMPLE 1
A solution which contained 65.35 weight percent HFC-43-10mee and 34.65 weight percent trans-1,2-dichloroethylene was prepared in a suitable container and mixed thoroughly.
The solution was distilled in a Perkin-Elmer Mode 251 Autoannular Spinning Band Still (200 plate fractionating capability), using a 50:1 reflux to take-off ratio. Head and pot temperatures were read directly to 0.1° C. The pressure was at about 765.5 mmHg. Distillate compositions were determined by gas chromatography. Results obtained are summarized in Table 1.
TABLE 1______________________________________DISTILLATION OF: (65.35 + 34.65)HFC-43-10meeAND TRANS-1,2-DICHLOROETHYLENE (TRANS) WT. % DISTILLEDTEMPER- OR WEIGHTATURE, °C. RE- PERCENTAGESCUTS POT HEAD COVERED HFC-43-10mee TRANS______________________________________PRE 38.3 36.6 9.5 64.2 35.91 38.3 36.9 20.5 64.8 35.22 38.4 37.0 32.1 63.7 36.33 38.5 37.3 44.1 63.3 36.74 38.8 37.6 53.7 62.7 37.75 39.2 37.9 62.8 61.6 38.46 39.5 38.1 73.1 61.0 39.07 42.0 38.5 81.9 59.9 40.3HEEL -- -- 90.1 97.4 2.6______________________________________
Analysis of the above data indicates very small differences between head temperatures and distillate compositions, as the distillation progressed. A statistical analysis of the data indicates that the true binary azeotrope of HFC-43-10mee and trans-1,2-dichloroethylene has the following characteristics at atmospheric pressure (99 percent confidence limits):
______________________________________HFC-43-10mee = 63.2 +/- 4.4 wt. %Trans = 36.8 +/- 4.4 wt. %Boiling point, °C. = 37.3 +/- 1.6° C.______________________________________
EXAMPLE 2
A solution which contained 75.36 weight percent HFC-43-10mee and 24.64 weight percent cis-1,2-dichloroethylene was prepared in a suitable container and mixed thoroughly.
The solution was distilled in a twenty-five plate Oldershaw distillation column, using a 15:1 reflux to take-off ratio. Head and pot temperatures were read directly to 0.1° C. The pressure was at about 766.7 mmHg. Distillate compositions were determined by gas chromatography. Results obtained are summarized in Table 2.
TABLE 2______________________________________DISTILLATION OF: (75.36 + 24.64)HFC-43-10mee (4310)AND CIS-1,2-DICHLOROETHYLENE (CIS) WT. % DISTILLEDTEMPER- OR WEIGHTATURE, °C. RE- PERCENTAGESCUTS POT HEAD COVERED HFC-4310 CIS______________________________________PRE 45.0 42.0 8.6 66.7 33.41 46.0 42.1 18.0 70.4 29.62 46.2 42.2 26.5 69.3 30.73 46.4 42.3 30.1 67.6 32.54 46.5 42.8 35.6 65.3 34.75 46.6 43.7 40.3 66.7 33.46 47.7 46.2 49.5 64.0 36.07 49.1 47.1 57.4 58.3 41.78 64.5 47.3 68.9 56.2 43.8HEEL -- -- 90.6 59.1 40.9______________________________________
Analysis of the above data indicates very small differences between head temperatures and distillate compositions, as the distillation progressed. A statistical analysis of the data indicates that the true binary azeotrope of HFC-43-10mee and cis-1,2-dichloroethylene has the following characteristics at atmospheric pressure (99 percent confidence limits):
______________________________________HFC-43-10mee = 67.85 +/- 7.63 wt. %CIS = 32.15 +/- 7.63 wt. %Boiling point, °C. = 42.3 +/- 1.2° C.______________________________________
EXAMPLE 3
A solution which contained 73.09 weight percent HFC-43-10mee and 26.91 weight percent 1,1-dichloroethane was prepared in a suitable container and mixed thoroughly.
The solution was distilled in a Perkin-Elmer Mode 251 Autoannular Spinning Band Still (200 plate fractionating capability), using a 50:1 reflux to take-off ratio. Head and temperatures were read directly to 0.1° C. The pressure was at about 766.4 mmHg. Distillate compositions were determined by gas chromatography. Results obtained are summarized in Table 3.
TABLE 3______________________________________DISTILLATION OF: (73.09 + 26.91)HFC-43-10mee AND 1,2-DICHLOROETHANE (DCE) WT. % DISTILLEDTEMPER- OR WEIGHTATURE, °C. RE- PERCENTAGESCUTS POT HEAD COVERED HFC-4310 DCE______________________________________PRE 45.8 42.2 8.0 73.2 26.81 46.4 42.8 20.6 73.1 26.92 47.0 43.3 31.7 73.2 26.83 47.8 43.6 45.6 72.4 27.74 49.0 45.2 57.5 70.6 29.45 49.2 45.8 70.7 69.4 30.66 53.0 46.1 80.0 66.7 33.3HEEL -- -- 97.2 75.7 24.3______________________________________
Analysis of the above data indicates very small differences between head temperatures and distillate compositions, as the distillation progressed. A statistical analysis of the data indicates that the true binary azeotrope of HFC-43-10mee and 1,1-dichloroethane has the following characteristics at atmospheric pressure (99 percent confidence limits):
______________________________________HFC-43-10mee = 73.0 +/- 1.9 wt. %1,1-dichloroethane = 27.0 +/- 1.9 wt. %Boiling point, °C. = 43.0 +/- 2.8° C.______________________________________
EXAMPLE 4
Several single sided circuit boards were coated with activated rosin flux and soldered by passing the boards over a preheater, to obtain top side board temperatures of approximately 200° F., and then through 500° F. molten solder. The soldered boards were defluxed separately, with the azeotropic mixtures cited in Examples 1,2 and 3 above, by suspending a circuit board, first, for three minutes in the boiling sump, which contained the azeotropic mixture, then, for one minute in the rinse sump, which contained the same azeotropic mixture, and finally, for one minute in the solvent vapor above the boiling sump. The boards cleaned in each azeotropic mixture had no visible residue remaining thereon.
Other components, such as aliphatic hydrocarbons having a boiling point of 35°-85° C., hydrofluorocarbonalkanes having a boiling point of 35°-85° C., hydrofluoropropanes having a boiling point of between 35°-85° C., hydrocarbon esters having a boiling point between 30°-80° C., hydrochlorofluorocarbons having a boiling point between 25°-85° C., hydrofluorocarbons having a boiling point of 25°-85° C., hydrochlorocarbons having a boiling point between 35°-85° C., chlorocarbons and perfluorinated compounds, can be added to the azeotropic or azeotrope-like compositions described above without substantially changing the properties thereof, including the constant boiling behavior, of the compositions. Examples of such components, which typically do not exceed about 10 weight percent of the total composition, include the following.
______________________________________COMPOUND FORMULA boiling point, °C.______________________________________HFCF-123 CHCl.sub.2 CF.sub.3 27HCFC-141b CFCl.sub.2 CH.sub.3 32HCFC-225aa CHF.sub.2 CCl.sub.2 CF.sub.3 53HCFC-225ca CHCl.sub.2 CF.sub.2 CF.sub.3 52HCFC-225cb CHClFCF.sub.2 CF.sub.2 Cl 56HCFC-225da CClF.sub.2 CHClCF.sub.3 50HFC-43-10 mf CF.sub.3 CH.sub.2 CF.sub.2 CF.sub.2 CF.sub.3 52HFC-43-10mcf CF.sub.3 CF.sub.2 CH.sub.2 CF.sub.2 CF.sub.3 52FC-C-51-12 cyclo-C.sub.4 F.sub.6 (CF.sub.3).sub.2 45 CH.sub.3 OCF.sub.2 CHFCF.sub.3 52HFC-C-456myc cyclo-CH.sub.2 CH.sub.2 CF.sub.2 CF(CF.sub.3)HFC-C-354 cyclo-CF.sub.2 CF.sub.2 CH.sub.2 CH.sub.2 50 C.sub.4 F.sub.9 CH═CH.sub.2 58MEK CH.sub.3 C(O)C.sub.2 H.sub.5 80THF cyclo-OC.sub.4 H.sub.8 66methyl formate HC(O)OCH.sub.3 32ethyl formate HC(O)OC.sub.2 H.sub.5 54methyl acetate CH.sub.3 C(O)OCH.sub.3 56ethyl acetate CH.sub.3 C(O)OC.sub.2 H.sub.5 77cyclohexane 81hexane 69cyclopentane 49acetone 561,2-dichloro- 84ethaneacetonitrile 82methylene 40chloride______________________________________
Additives such as lubricants, corrosion inhibitors, stabilizers, surfactants, dyes and other appropriate materials may be added to the novel compositions of the invention for a variety of purposes provided they do not have an adverse influence on the composition, for their intended applications. Examples of stabilizers include nitromethane and nitroethane.
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Azeotropic mixtures of 1,1,1,2,3,4,4,5,5,5-decafluoropentane (HFC-43-10mee) and trans-1,2-dichloroethylene, cis-1,2-dichloroethylene or 1,1-dichloroethane are useful as cleaning agents, expansion agents for polyolefins and polyurethanes, refrigerants, aerosol propellants, heat transfer media, gaseous dielectrics, fire extinguishing agents, power cycle working fluids, polymerization media, particulate removal fluids, carrier fluids, buffing abrasive agents, and displacement drying agents.
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This is a division of application Ser. No. 230,850, filed Aug. 10, 1988, now U.S. Pat. No. 4,953,261.
BACKGROUND OF THE INVENTION
The present invention relates to hinged enclosure panel assemblies, and more particularly to waterproof hinged door assemblies for shower stalls and bathtub alcoves.
Door assemblies that are commonly in use for shower stalls and bathtub enclosures generally require the use of door tracks above and below the doors which extend from one vertical wall support bracket along one wall of the stall or enclosure to the other wall support bracket along the opposite wall. The upper and lower door tracks are required to prevent the weight of the doors from pulling the vertical support brackets for the doors away from the wall, as well as to provide guide channels for the doors to keep them in alignment as they open. These door assemblies generally require such bracing and support because they include heavy tempered glass door panels, which also dictate heavy hinging and latching systems. Furthermore, the lower door track is usually necessary for sealing the bottom edge of the door assembly, since glass paneled doors cannot generally conform to the contour of stall or alcove installations.
However, assemblies with upper and lower door tracks require custom fitting of the door assembly to the shower stall or tub alcove. Furthermore, the doors or the vertical support brackets on the wall require custom sizing during fabrication or installation so that the assembly can be completely sealed when closed. Door assemblies with lower door tracks are also undesirable because they tend to collect dirt and pools of water. Also, with sliding doors, the entrance to the stall or alcove is restricted in size due to the amount of space required for the sliding panel or panels in their open position.
With the adoption of lightweight materials for such door assemblies, it has been possible to eliminate the upper and lower door tracks and rely upon the security of the vertical wall support brackets alone for support of the door assembly. Such door assemblies may rely upon ordinary drywall anchors for support. However, the door assemblies which are now in use which have dispensed with the door tracks rely upon close fitting or overlapping door panels for resistance to water seepage. Some such door assemblies also include lower door sections which bend inwardly to deflect the water spray which collects on them into the shower stall or bathtub.
All of the trackless door systems have poor water sealing performance, and their overlapping panel designs restrict their ability to remain closed. Yet, the overlapping panel design is necessary on such door assemblies, both to achieve a relatively water resistant partition and to allow such door assemblies to be designed for a wide range of shower stall and bathtub enclosure openings without custom fitting.
OBJECTS OF THE INVENTION
Accordingly, one object of the present invention is to secure a watertight trackless shower stall or bathtub alcove door assembly.
Another object of the present invention is to secure a universally adjustable shower stall or bathtub alcove door assembly.
Yet another object of the present invention is a shower stall or bathtub alcove door assembly which has a large entrance.
Still another object of the invention is to secure a lightweight shower stall or bathtub alcove door assembly which is supportable by ordinary drywall anchors.
A further object of the invention is to secure a shower stall or bathtub alcove door assembly which opens and closes securely.
SUMMARY OF THE INVENTION
The present invention achieves the above stated objects, as well as other advantages described herein, by means of a shower stall or bathtub alcove door assembly which uses a hinged multipanel door design, with special waterproof hinges and seams, adjustable wall panels retained by waterproof mounting sheaths, and door panel deflector sections with corresponding deflector shields to deflect water which collects on the inner surfaces of the door panels into the shower stall or bathtub enclosure without seepage, and a door closure system which firmly secures the doors when the door assembly is closed.
The waterproof hinges have special watertight edge surfaces which mate when the door assembly is closed. These watertight surfaces include magnetically attractive sealing strips which seal and secure the door assembly when it is closed. The door panel deflector sections are angled inwardly to deflect water, and the edges of the wall mounting panel deflector shields conform to the deflector sections when the door assembly is closed to prevent seepage.
Other advantages and features of the present invention are described in connection with the preferred embodiment described herein.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a preferred embodiment of a door assembly for a bathtub alcove according to the present invention shown in the closed position.
FIG. 2 is the embodiment of FIG. 1 shown in the open position.
FIG. 3 is a detailed view of the left side section of the embodiment of FIG. 1, shown in the closed position.
FIG. 4 is a detailed view of the right side section of the embodiment of FIG. 1, shown in the open position.
FIG. 5 is a cross sectional view of one of the door panel upper edge seals according to the cross section indicated in FIG. 1 along line 5--5.
FIG. 6 is a cross sectional view of the hinge assembly and door panel engagement assembly according to the cross section indicated in FIG. 1 along line 6--6.
FIG. 7 is a cross sectional view of the support panel attachment assembly according to the cross section indicated in FIG. 1 along line 7--7.
FIG. 8 is an alternative embodiment of a door assembly for a shower stall according to the present invention shown in the closed position.
FIG. 9 is a detailed view of the alternative embodiment of FIG. 8 shown in the open position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is adaptable as a watertight partition for both shower stalls and bathtub enclosures, and it is easily adjusted to fit a wide range of openings for either use.
Referring to the drawings, wherein reference characters designate like or corresponding parts throughout the views, FIG. 1 shows a preferred embodiment of the present invention adapted for a bathtub alcove, depicted in the closed position. A door assembly 2 includes a left support panel 4, a first left door panel 6 hinged to said left support panel 4 with a hinge 8, a second left door panel 10 hinged to the first left door panel 6 with a hinge 12, a right support panel 14 hinged to a first right door panel 16 with a hinge 18, and a second right door panel 20 hinged to the first right door panel 16 with a hinge 22. FIG. 2 shows the door assembly 2 in the open position.
FIG. 3 is a detailed view of the left side of the door assembly 2, including the left door support panel 4, the first left door panel 6 and the second left door panel 10, shown in the closed position The first left door panel 6 has a first left door deflector section 24 and the second left door panel 10 has a second left door deflector section 26. The first left door deflector section 24 and the second left door deflector section 26 are inwardly bent sections of the first left door panel 6 and second left door panel 10 respectively, having a sufficient inward deflection to have bottom edges of the left door deflector sections 24, 26 inside the tub when the door assembly 2 is closed. These left door deflector sections 24, 26 serve to direct water which sprays on the left door panels 6, 10 to flow into the tub. Of course, the left door deflector sections 24, 26 need not be linear sections as shown, and they can alternately have radii of curvature, or similar profile, so long as their bottom edges extend inwardly into the tub.
A left door support panel deflector shield 28 extends inwardly from the edge of the left door support panel 4 along its lower extremity to substantially fill the gap between the edge of the left door support panel 4 and the first left door deflector section 24. This shield 28 can be a molded section of the left support panel 4 extending inwardly or a separate piece attached to the left support panel 4. In any case, the inner edge of the left deflector shield 28 conforms to the profile of the first left door deflector section 24 when the door assembly 2 is closed. Consequently, the left deflector shield 28 prevents water from splashing out of the tub between the left door support panel 4 and the first left door deflector section 24.
FIG. 4 is a detailed view of the right side of the door assembly 2, including the right door support panel 14, the first right door panel 16 and the second right door panel 20, shown in the open position. The first right door panel 16 has a first right door deflector section 30 and the second right door panel 20 has second right door deflector section 32. The first right door deflector section 30 and the second right door deflector section 32 are inwardly bent sections of the first right door panel 16 and the second right door panel 20 respectively, having a sufficient inward deflection to have bottom edges of the right door deflector sections 30, 32 inside the tub when the door assembly 2 is closed, just as described above for the left door deflector sections 24, 26.
A right door support panel deflector shield 34 extends inwardly from the edge of the right door support panel 14 along its lower extremity to substantially fill the gap between the edge of the right door support panel 14 and the first right door deflector section 30 when the door assembly 2 is in the closed position, just as described above for the left door support panel deflector shield 28.
The right door support panel 14 is hinged to the first right door panel 16 with the hinge 18 to let the first right door panel 16 swing inwardly into the tub, so that in the open position it is proximate the right wall of the bathtub alcove, as shown in FIG. 3. The second right door panel 20 is hinged to the first right door panel 16 with the hinge 22 to let the second right door panel swing outwardly out of the tub relative to the first right door panel 16, so that in the open position the second right door panel 20 is proximate the first right door panel 16 along the right wall of the bathtub alcove, as shown in FIG. 3. With this hinging configuration, the right door panels 16, 20 swing aside to allow almost the entire right side of the bathtub alcove for entrance. This hinging configuration also orients the right door deflector sections 30, 32 to face in opposite directions when their respective right door panels 16, 20 are folded in the open position, so that they do not interfere with each other when the doors assembly 2 is opened, thereby allowing maximum clearance in the open position.
Likewise, the left door support panel 4 is hinged to the first left door panel 6 with the hinge 8 to let the first left door panel 6 swing into the tub, and the second left door panel 10 is hinged to the first left door panel 6 with the hinge 12 to let the second left door panel swing outwardly out of the tub relative to the first left door panel 6, just as described for the right door panels 16, 20 described above. Similarly, in the open position, the left door panels 6, 10 swing open to allow almost the entire left side of the bathtub alcove for entrance, as shown in FIG. 2.
Although the door support panels 4, 14 and the door panels 6, 10, 16, 20 may be fabricated of any convenient panel material, a panel material which is both light weight and rigid is most desirable, since a trackless configuration exerts its weight at the door support panels 4, 14 away from their respective bathtub alcove walls. An ideal material for his purpose is cellular plastic sheet stock, such as General Electric Lexan Thermoclear Sheet. The cellular structure of this plastic sheet stock is very rigid even though it is light weight. However, the use of such cellular sheet stock requires that the edges be properly sealed to prevent accumulation of moisture within the cellular structure.
FIG. 5 is a cross sectional view of the upper edge of the second left door panel 10 shown in FIG. 1, and is representative of the upper and lower edges for the door support panels 4, 14 and the door panels 6, 10, 16, 20. A linear edge channel 36 includes an edge section 38, which is substantially transverse to the surfaces of a second left door panel sheet 40, and two side sections 42, 44 which closely conform to the surfaces of the second left door panel 10. Thus, the end of the door panel 10 is completely sealed by the edge channel 36. Additionally, edge stops 46, 48 can be added to the side sections 42, 44 to provide any desired degree of protrusion of the edge section 38 away from the panel sheet 40. Although the edge channel 36 may be fabricated from component sections, it is most conveniently a single molded or extruded plastic piece
FIG. 6 is a cross sectional view of the side edge of the second left door panel 10, the hinge 12, and the proximate edges of the first left door panel 6 and the second right door panel 20, as indicated in FIG. 3. The view of the hinge 12 is also representative of the hinges 8, 18 and 22 in cross section. The hinge 12 includes a linear hinge channel 50 with linear rounded end protrusions 52, 54 along both sides of the interior of the hinge channel 50. A first hinge projection member 56 and a second hinge projection member 58 are coupled together and restricted in motion by the linear channel 50 because the projection members 56, 58 each have edges with linear sockets on one side which engage the rounded ends of the linear projections 52, 54, and bearing surfaces on the inner sides of the hinge projection members 56, 58 which engage each other and the inner perimeter of the hinge channel 50 to restrict the motion of each of the hinge projection members 56, 58 about their corresponding linear protrusions 52, 54. This rotational movement is depicted by the dotted outline of the hinge 12 in FIG. 6. The bearing surfaces on the hinge projection members 56, 58 may each include at least one longitudinal facet to provide a convenient stop position for the hinge assembly. The hinge projection members 54, 56 each are shown with two longitudinal facets in FIG. 6, one for a half open position and the other for a full open position. Alternately, more facets can be provided for intermediate stop positions. Likewise, the bearing surfaces can be completely smooth and curvilinear, or may include longitudinal meshing teeth. Door panel attachment channels 60, 62 extend at right angles to their corresponding hinge projection members 56, 58 to permit linear sealing strips 64, 66 to seal with each other when the hinge 12 is in the closed position, thus assuring a watertight fit. The attachment channels 60, 62 conform to their corresponding door panel sheets, the second door panel sheet 40 described above, and a first door panel sheet 68, as described above for the edge channel 36 in connection with FIG. 5. The sealing strips 64, 66 may be any convenient sealing material, but preferably a magnetically attractive material to hold them together when they butt together, such as magnetized rubber, and may be fastened in corresponding grooves in the attachment channels 60, 62 as shown in FIG. 6, or they may simply be applied on the butting surfaces of the attachment channels 60, 62. To prevent the axial movement of the hinge channel 50 along the hinge projections 56, 58, a hinge bearing plate 70 is laterally inserted into a conforming slot cut into and through the hinge channel 50 and the hinge projections 56, 58. The bearing plate 70 maintains alignment of the hinge channel 50 with the hinge protrusions 56, 58 without affecting the operation of the hinge 12.
Also shown in FIG. 6 are door closure channels 72, 74 which extend along the edges of the second left door panel 10 and the second right door panel 20 butted against each other when the door assembly 2 is closed. Closure strips 76, 78 extend along the butting sides of the closure channels 72, 74 and they may be of any convenient sealing material, but preferably a magnetically attractive material to hold them together when they butt together, such as magnetized rubber. The closure strips 76, 78 may be fastened in corresponding grooves in the closure channels 72, 74, or they may simply be applied to the butting surfaces of the closure channels 72, 74.
FIG. 7 is a cross sectional view of a portion of the left door support panel 4 shown in FIG. 1. A left wall sealing sheath 80 fits over the edge of the first left door panel sheet 68 described above in connection with FIG. 6. The left wall sealing sheath 80 is positioned to butt against the left wall of the bathtub alcove. The first left door panel sheet 68 is then slid within the left wall sealing sheath 80 to a desired position for best overall door panel alignment. The left wall sealing sheath 80 is fastened by at least one wall mounting bracket 82, which clamps the sheath 80 to the door panel sheet 68 with, for instance, a clamping screw 84, and serves as a mounting surface for bolting or otherwise fastening the door assembly 2 to the wall of the bathtub alcove. For convenience, each wall mounting bracket 82 may be first fastened to the alcove wall, and then the sheath 80 positioned to butt against each mounting bracket 82 and the alcove wall together. The sheath 80 may include notches along its wall butting edge for clearance around each wall mounting bracket 82. The left wall sealing sheath 80 permits the left door support panel 4 to have an adjustable width to permit the door assembly 2 to be mounted in a variety of bathtub alcove widths without modification. The right wall support panel 14 also has a sealing sheath fitting over a panel sheet, so both the door support panels 4, 14 may be adjusted in width to provide an even greater range of bathtub alcove widths.
FIG. 8 shows an alternate embodiment of the invention adapted for a shower stall in the closed position. Because a shower stall is relatively narrow, a single door is sufficient to enclose the stall. Therefore, only a single left or right side of the door assembly 2 as described above need be used. A shower stall door assembly 86 includes a shower door support panel 88, a first shower door panel 90 hinged to said shower door support panel 88 with a hinge 92, a second shower door panel 94 hinged to the first shower door panel 90 with a hinge 96, and a shower closure panel 98 which has an inner edge which engages the inner edge of the second shower door panel 94 when the shower door assembly 86 is in the closed position. The shower support panel 88, the shower door panels 90, 94 and the hinges 92, 96 are exactly as described above for the corresponding right door components of the door assembly in connection with FIG. 1. The shower closure door panel 98 is similar to the left door support panel 4 described above, except it has a closure channel (not shown) along its inner edge similar to the closure channels 72, 74 described above, instead of the hinge 8. FIG. 9 shows the shower stall door assembly 84 in the open position.
It will be understood that various changes in the details, materials and arrangement of parts and systems which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims.
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Shower stall and bathtub enclosure door assemblies which use a hinged multipanel door design, with special waterproof hinges and seams, adjustable wall panels retained by waterproof mounting sheaths, and door panel deflector sections with corresponding deflector shields to deflect water which collects on the inner surfaces of the door panels, and a door closure system which firmly secures the doors when the door assembly is closed.
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This application claims the benefit of provisional application No. 60/374,773 filed Apr. 24, 2002.
FIELD OF THE INVENTION
The instant invention relates to a device for attachment to the top rungs of a ladder to stabilize the ladder against a vertical surface and maintain tools and supplies within easy reach of the user.
BACKGROUND OF THE INVENTION
Ladders placed against a wall have always posed a stability problem. The problem is more serious when the ladder must be used on a corner or near a window where there is often insufficient surface on which to support the rails. A variety of devices have been developed that have attempted to solve this problem.
In U.S. Pat. No. 2,327,317 Randall teaches a hollow frame to be attached by means of brackets to the rails of a ladder. An independent arm extends outward from each side of the hollow frame as needed. Angled portions attached to the arms make contact with the wall. A second embodiment provides straight portions extending forward from the arms at right angles. Each of the straight portions can be extended as far as needed and independent of the other so that the ladder can be stabilized against an irregular wall. This same arrangement can be used at the bottom of the ladder to stabilize it on irregular ground. The ends of the contacting parts may be pointed or have rubber feet to prevent slippage. Similar devices are taught by Werner (U.S. Pat. No. 3,568,801), Wing (U.S. Pat. No. 4,502,566) and Southern (U.S. Pat. No. 5,113,973). None of these devices can be used at corners of intersecting walls.
In U.S. Pat. No. 6,152,262, Jung discloses stabilizing bars that are stored within one hollow rung of a ladder. The bars can extend from the ladder at an angle and are composed of telescoping segments that can be locked in place to extend as far as needed. Additional supporting members can also be stored within another rung of the ladder. This invention cannot be adapted to surfaces that are not flat.
Burk teaches a U-shaped brace that is attached at the top of a ladder. The arms of the U extend forward and make contact with the wall. Rubber grips at the ends of the arms prevent slipping. A cross bar adds strength and a chain extending from the cross bar to another rung provides additional support. Sockets mounted on the inside of each arm at a 45° angle can accept additional extension arms by threading into the sockets. These extensions enable the brace to stabilize the ladder on an outside corner by gripping the wall on each side of the outside corner. (U.S. Pat. No. 2,592,006) Another U-shaped brace for use on a ladder provides additions for insertion at the end of each forward extending arm. The additions have ends that are turned inward at a 45° angle and covered with rubber sleeves for the support of the ladder on an outside corner. (Peters, U.S. Pat. No. 3,072,218) Neither of these devices are horizontally adjustable and therefore are of limited use around windows or other structures within the wall.
Brewer et al. in U.S. Pat. No. 4,593,790, disclose a foldable device to be attached to a ladder for stability. The device can be folded into several orientations so the ladder can be stabilized at an outside corner, an inside corner, an overhang and can be set to span a window. Spring loaded hinges enable the various configurations. This device is quite complex and appears cumbersome and heavy.
In U.S. Pat. No. 3,693,756, Walker et al. teach a U-shaped brace that can be attached to the top of a ladder with arms extending forward for stability against a wall and to the bottom of a ladder with arms extending downward for stability on the ground. A compartment for holding supplies can be attached to the brace as can hooks for such things as paint cans. The brace is of fixed dimensions and so is of limited use. Terwilliger (U.S. Pat. No. 3,146,854) discloses a ladder positioning attachment that consists of an upper plate and a lower plate with a centralized separator in between. The plates extend forward of and beyond the sides of the ladder. The portion of the attachment that lies between the rails is bolted to a rung. On each side of the device a leg is pivotally attached between the plates. There are several holes through the upper plate and another hole in each leg. The legs can be moved into several positions and set in place by inserting a fastener through the selected hole in the plate and the hole in the leg. As the angle of the legs change, so does the distance of the upper part of the ladder from the wall. Tools or other objects can be set on the flat upper plate. This device is only usable against a flat wall.
None of the prior art devices provide stability for a ladder at all wall variations and also provide means to hold tools and supplies. None of the prior art provides a means to keep small objects such as nails and screws close at hand and easy to reach. And none of the prior art patents teach the technology that will enable a ladder to be stabilized against a column or tree. There is a need for a device that can be attached to the top of any ladder and accomplish all of these tasks.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a stabilizing means for attachment to a ladder to enable the ladder to be set securely against a variety of vertical surfaces and also provides means to hold numerous tools and supplies within easy reach.
It is an object of the present invention to provide a stabilizer that can be easily and securely attached to any straight ladder.
It is another object of the present invention to provide a stabilizer for ladders that prevents the ladder from slipping once set in place whether against a flat wall or corner.
A further object of the present invention is to provide a stabilizer for ladders that can be used against most vertical surfaces and can span various structural variations such as windows and corners.
A still further object of the present invention is to provide a stabilizer for ladders that can hold a ladder securely against a tree or column.
Another object of the present invention is to provide a stabilizer that can also hold tools and supplies, including small objects such as screws and nails, so they are within easy reach.
A further object of the present invention is to provide a stabilizer that can quickly and easily be adapted from one type of vertical surface to another.
A still further object of the present invention is to provide a stabilizer that is inexpensive to manufacture and can be manufactured using readily available materials.
Another object of the present invention is to provide a stabilizer that can be quickly fastened securely to the ladder and can easily be removed therefrom
A still further object of the present invention is to provide a stabilizer with parts that fit within the framework for compact storage and easy transport.
The instant invention is a stabilizer for supporting a ladder of a type having parallel side rails and a series of transverse rungs set at regular intervals therebetween against a substantially vertical surface. The stabilizer comprises a tubular frame comprising a first rearward frame member fixedly attached longitudinally to a second forward frame member, and two angled frame members affixed near the center of the forward frame member at opposing acute angles thereto and lying in the same plane with the first and second frame members. There are two sleeves pivotally attached to the underside of the frame with a tension spring connecting the two sleeves. Two support arms, a rearward support arm and a forward support arm, are dimensioned to fit slidably and reversibly within the first frame member, the second frame member, the angled frame members and the sleeves. Each support arm is bent to form a leg extending at a right angle therefrom. Attachment means are affixed to the tubular frame for reversibly attaching the stabilizer to the ladder.
Other features and advantages of the invention will be seen from the following description and drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a ladder with the stabilizer of the instant invention attached to the two top rungs;
FIG. 2 is bottom plan view of the stabilizer attached to a ladder and supported against a flat wall;
FIG. 3 is a side sectional view of the stabilizer through line 3 — 3 of FIG. 2;
FIG. 4 is a close up side plan view of the end of a support arm and the slip resistant contact foot;
FIG. 5 is a bottom plan view of the stabilizer with the support arms in opposing extensions to the view shown in FIG. 2;
FIG. 6 is a bottom plan view of the stabilizer with the arms in position for support against an outside corner;
FIG. 7 is bottom plan view of the stabilizer with the arms in position for support against a tree trunk;
FIG. 8 is bottom plan view of the stabilizer with the arms in position for support against an inside corner;
FIG. 9 is an exploded view of the stabilizer.
FIG. 10 is rear plan view of the first ladder fastener;
FIG. 11 is a side perspective view of the first ladder fastener;
FIG. 12 is a front perspective view of the first ladder fastener;
FIG. 13 is a rear plan view of the second form of the ladder fastener;
FIG. 14 is a sectional view through line 14 — 14 of the ladder fastener of FIG. 13;
FIG. 15 is a front perspective view of the ladder fastener of FIG. 13;
FIG. 16 is an exploded view of the connecting pin and opening in the plate; and
FIG. 17 is a side plan view of the connecting pin of FIG. 16 rotated 90°.
DETAILED DESCRIPTION OF THE INVENTION
The ladder stabilizer 20 of the instant invention may be seen in use in FIGS. 1 and 3. There may be a frame 25 composed of rigid tubular material that may be square or rectangular in cross section and may form the body and main support of the stabilizer 20 . The frame 25 may be composed of four lengths of the tubular material. There may be a rearward frame member 26 and forward frame member 27 , of equal length, which may be joined together longitudinally and extend a substantial distance beyond the rails 22 on each side of the ladder 21 . Two additional short frame members 29 may be affixed to the forward frame member 27 at 45° angles to form a broad V shape. The short frame members 29 may not be centered on the forward frame member 27 . All of the frame members may lie in the same plane. The rearward frame member 26 and the forward frame member 27 may have a series of communicating apertures 28 through their upper and lower surfaces. The apertures 28 may be disposed beginning at one end and continuing to a point beyond the center in the rearward frame member 26 and beginning at the opposing end and continuing to a point beyond the center in the forward frame member 27 .
There may be two support arms, a rearward support arm 30 and a forward support arm 31 which may be composed of rigid tubular material that is dimensioned to fit easily within the frame members. The rearward support arm 30 may be slidably and reversibly disposed within the rearward frame member 26 and the forward support arm 31 may be slidably and reversibly disposed within the forward frame member 27 . Each of the support arms may be bent at a right angle near one end to form a forward extending leg 32 . The length of the leg for each support member may be different to compensate for the different positions of the frame members 26 and 27 and so that the stabilizer is parallel to a wall when properly positioned. (FIGS. 2 and 5 ). Therefore, the leg of the rearward support arm 30 may be longer than the leg of the forward support arm 31 . The off center placement of the short frame members 29 may also accommodate the different lengths of the legs 32 .
There may be a spherical foot 33 at the end of each leg. Each foot 33 may be covered with a skid resistant material or may be composed of a skid resistant material to prevent slippage of the stabilizer 20 and in turn the ladder 21 once they are properly positioned. Each foot 33 may have a collar 35 with a protruding button. The foot 33 , collar 35 and button may be composed of the same material and may be of unified construction The material may also be non-marking. The collar 35 may be dimensioned to fit within the end 37 of the leg 32 which may also be curved to receive the spherical foot 33 . There may be an opening 36 near the end 37 of the leg to receive the button and retain the foot 33 securely in place. These structures may be seen in FIG. 4 . There may be an aperture 34 through the opposing end of each support arm 30 and 31 . The support arms 30 and 31 may be inserted into their respective frame members 26 and 27 as far as desired until the apertures 34 in the ends of the support arms 30 and 31 communicate with the apertures 28 in the frame members 26 and 27 . A connecting pin 38 may be inserted through the apertures 28 and 34 to hold each of the support arms 30 and 31 securely place. Adjustments in width of the support base may easily be made by removing a connecting pin 38 , sliding a support arm to a new position and reinserting the connecting pin 38 .
There may be two sleeves 39 each attached at one of its ends to the center of the underside of the rearward frame member 26 by pivot pins 41 . A tension spring 40 may connect the two sleeves 39 near the opposing ends. The sleeves 39 may be dimensioned to reversibly contain the support arms 30 and 31 . See FIG. 7 .
A substantially rectangular top plate 42 may be affixed to the upper surface of the frame 25 such that the rear edge of the plate 42 may be aligned with the rear edge of the rearward frame member 26 and the plate 42 may be longitudinally centered on the frame 25 . There may be a concavity 43 centered on the forward edge of the plate 42 . Two lines of openings 44 may be disposed along the rear of the plate 42 positioned to communicate with the apertures 28 in the frame members 26 and 27 and dimensioned to receive the connecting pins 38 used to secure the support arms 30 and 31 in place. There may be small cutouts 45 in the surface of the plate 42 where tools such as hammers and pliers may be placed for easy access. Larger cutouts 46 may be used to receive containers for small objects such as screws and nails. These may be seen in FIG. 9 . The cutouts 45 and 46 may be positioned such that they do not lie above any of the frame members.
A removable tray 47 may be placed on top of the plate 42 and maybe substantially the same shape as the plate 42 with the same concavity 43 in the front edge. There may be a raised edge 48 about the entire circumference of the tray 47 as well as a full apron 49 which conceals the frame when the stabilizer 20 is viewed from the top or side. There may be two rows of openings 50 along the rear edge of the tray 47 communicating with the openings 44 in the plate 42 and the apertures 28 in the frame 25 . Small cutouts 51 in the tray 47 may communicate with the small cutouts 45 in the plate 42 for placement of tools, and depressions 52 in the surface of the tray 47 may fit into the large cutouts 46 in the plate 42 and may serve as receptacles for small articles such as screws or nails. The raised edge 48 may prevent any objects placed on the tray from rolling off. The connecting pins 38 used to maintain the support arms 30 and 31 in place may be attached to the tray 47 by chains 53 or other type of flexible connectors that may be long enough so the connecting pins 38 may reach all of the openings 44 and may guarantee that the connecting pins 38 cannot be misplaced.
The connecting pins 38 may have rings 72 attached to their top ends to which the chains 53 or other such flexible connectors may be attached and there may also be threads 73 at their bottom ends. The tray 47 , plate 42 , rearward frame member 26 and forward frame member 27 may all have communicating openings to receive the connecting pins 38 , as noted above. However, there may be specially shaped openings 74 in the bottom walls 75 of the rearward frame member 26 and forward frame member 27 . These shaped openings 74 may be sized and dimensioned to receive the threaded ends 73 of the connecting pins 38 so that when a connecting pin 38 is given a turn, it may become locked in place. This may also insure that once a connecting pin 38 is placed into the openings through the tray 47 , the plate 42 and the rearward frame member 26 or the forward frame member 27 , and the support arms 30 and 31 and locked into the openings 74 in the bottom walls 75 of the frames, the support arms 30 and 31 cannot become dislodged. The ring 72 at the top of each connecting pin 38 may be used to attach the chains 53 to the connecting pins 38 and may also act as a handle to assist in locking the connecting pins 38 securely in the shaped openings 74 . These features may be seen in FIGS. 16 and 17.
The stabilizer 20 may be attached to the ladder 21 by a first ladder fastener 54 which may be composed of two inverted U-shaped clips, an upper clip 55 and a lower clip 56 , which are spaced apart to fit over any two consecutive rungs 23 of the ladder 21 . The upper clip 55 may be substantially the width of the rungs 23 while the lower clip 56 may be considerably narrower. The clips 55 and 56 may be connected to each other by two struts 57 which are angled to form a “V”. The fastener 54 may be attached to the stabilizer frame 25 by permanently affixing the forward surface of the upper clip 55 to the center of the rear face of the rearward frame member 26 . The clips 55 and 56 may each have one vertical side 58 , the front of the clip, and one stepped side 59 , the rear of the clip, and a flat top portion 60 . The stepped side 59 may protrude outward in graduated steps so that the first ladder fastener 54 may be securely seated over rungs of different shapes and diameters, thus permitting the stabilizer to be used with many different ladders.
A spring loaded catch 61 may be pivotally attached to the center near the bottom edge of the stepped side 59 of the upper fastening clip 55 . There may also be an opening 62 above the catch 61 to provide room for the catch 61 to pivot upward and make contact with the rung 23 of the ladder 21 . The first ladder fastener 54 may be attached to any two consecutive rungs of the ladder 21 . See FIGS. 10, 11 and 12 .
There may be a second ladder fastener 66 that may be used for all straight ladders regardless of the spacing between the rungs. The second ladder fastener 66 may be used with ladders built to metric standards as well as U.S. standards. There may be two U-shaped clips, an upper clip 67 and a lower clip 68 having the same configurations and relative sizes as in the first ladder fastener 54 described above and which may also be used with rungs of varying shapes and diameters. However, in the second ladder fastener 66 the upper clip 67 may be inverted and the lower clip 68 may not be inverted such that the openings 69 in the two clips are facing each other. The forward surface of the upper clip 67 may be permanently attached to the stabilizer frame 25 at the center of the rear face of the rearward frame member 26 in the same manner as the first ladder fastener 54 . The upper clip 67 and lower clip 68 may be connected to each other by two struts 70 that may be parallel to each other. Each strut 70 may be composed of two tubular sections that slidably fit one within the other. There may be a tension spring 71 within the two sections that may enable the second ladder fastener 66 to be tightly seated around any two consecutive rungs of the ladder. See FIGS. 13, 14 , and 15 . In use the two clips 67 and 68 may be manually pulled apart expanding the struts 70 so that the clips 67 and 68 may be seated about the two consecutive rungs. Thereafter, the tension on the clips 67 and 68 may be released so that the struts 70 contract and hold the rungs securely.
The stabilizer 20 of the instant invention may be easily adapted to stabilize a ladder against a variety of vertical surfaces. When used against a flat wall 24 the support arms 30 and 31 may be inserted into the rearward frame member 26 and forward frame member 27 respectively as far as necessary and retained in place using the connecting pins 38 . The stabilizer 20 may be adjusted for use near or around a window or other structure within a flat wall 24 by extending the support arms 30 and 31 outwardly or inserting the support arms 30 and 31 further into the frame members 26 and 27 . FIG. 2 may show the stabilizer 20 against a flat wall 24 with the forward support arm 31 in an extended orientation and the rearward support arm 30 in its fully inserted orientation while FIG. 5 may show the support arms 30 and 31 in the opposite orientations. Such selections may be determined by the surface on which the ladder 21 is placed or structures on or within the wall 24 .
When a ladder 21 must be supported against a corner the support arms 30 and 31 may be removed from the rearward frame member 26 and forward frame member 27 by removing the connecting pins 38 and sliding the support arms 30 and 31 outward. The support arms 30 and 31 may then be positioned within the short frame members 29 . When the ladder is to be set against an outside corner 63 the support arms 30 and 31 may be positioned within the short frame members 29 so that the legs 32 may be turned inward and the feet 33 rest against the walls as shown in FIG. 6 . When the ladder is to be set against an inside corner 64 the support arms 30 and 31 may be positioned within the short frame members 29 so the legs 32 may be turned inward and the sides of the legs 32 may rest against the walls as seen in FIG. 8 .
A unique feature of the stabilizer 20 enables a ladder 21 to be stabilized when it must be supported against a tree, structural column, or utility pole. For this use the support arms may be positioned within the two sleeves 39 with the legs 32 turned outward. The stabilizer 20 may rest directly against a tree 65 which may fit within the concavities 43 in the front edges of the plate 42 and in the tray 47 . The support arms 30 and 31 may grip the tree 65 because of the pivotability of the sleeves 39 and the tension exerted by the tension spring 40 connecting them. This may be seen in FIG. 7 .
The various parts of the instant invention may be made of aluminum which may provide strength while minimizing weight. Other strong rigid materials may also be used. Square tubing is preferable for the frame, sleeves and support arms, though tubing that is rectangular in cross section or otherwise shaped may be acceptable. The tray may be made of a moldable plastic or other polymeric material for ease of manufacture. The feet may be made of a form of rubber or other polymeric material that is non-marking.
The tray of the preferred embodiment may be 90 cm wide and 16 cm deep. The support arms may be 50 cm long and the leg of the rearward support arm may extend forward 30 cm and the leg of the forward support arm may extend forward 23 cm. Depending on the position of the support arms, the support base of the stabilizer may extend from 90 cm to 150 cm and so may be able to span obstacles of considerable width.
While one embodiment of the present invention has been illustrated and described in detail, it is to be understood that this invention is not limited thereto and may be otherwise practiced within the scope of the following claims.
HAIG PARTS LIST
20 LADDER STABILIZER
21 LADDER
22 SIDE RAIL OF LADDER
23 RUNG OF LADDER
24 WALL
25 FRAME
26 REARWARD FRAME MEMBER
27 FORWARD FRAME MEMBER
28 APERTURES IN FRAME
29 SHORT FRAME MEMBERS
30 REARWARD SUPPORT ARM
31 FORWARD SUPPORT ARM
32 LEG
33 FOOT
34 APERTURE IN SUPPORT ARM
35 COLLAR
36 CUTOUT
37 CURVED END OF FOOT
38 CONNECTING PIN
39 SLEEVE
40 TENSION SPRING
41 PIVOT PINS
42 PLATE
43 CONCAVITY IN PLATE EDGE
44 OPENINGS IN PLATE FOR PINS
45 SMALL CUT OUT FOR TOOL
46 LARGE CUT OUT FOR DISH
47 TRAY
48 RAISED EDGE ON TRAY
49 APRON ON TRAY
50 OPENINGS IN TRAY FOR DOWELS
51 CUTOUT
52 DEPRESSION
53 CHAINS TO HOLD DOWELS
54 LADDER FASTENER
55 FASTENING CLIP UPPER
56 FASTENING CLIP LOWER
57 STRUT
58 VERTICAL SIDE
59 STEPPED SIDE
60 FLAT TOP
61 SPRING LOADED CATCH
62 OPENING FOR CATCH
63 OUTSIDE CORNER
64 INSIDE CORNER
65 TREE
66 SECOND LADDER FASTENER
67 UPPER CLIP
68 LOWER CLIP
69 OPENING IN CLIP
70 STRUTS
71 SPRING
72 RING ON CONNECTING PIN
73 THREADED END OF PIN
74 SHAPED OPENING FOR PIN
75 BOTTOM WALL OF FRAME
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An attachment for a straight ladder that can stabilize the ladder when placed against vertical surfaces that include a flat wall, an inside corner and an outside corner. Adjustments permit use around a window or other such structure within the wall. A tubular framework accepts two support arms. The support arms may be arranged in several different orientations within the framework. Pivotable sleeves attached to the underside of the framework accept the support arms to stabilize the ladder when placed against a tree or column. A tension spring between the sleeves assist the support arms holding the ladder against the tree. A plate affixed to the top of the framework supports a tray with depressions and cutouts so that tools and supplies may be kept close at hand.
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BACKGROUND OF THE INVENTION
The present invention relates to a monitoring device for portable breathing apparatuses. Portable breathing apparatuses of this kind are used for example by divers, by fire fighters when fighting fires or generally whenever air is charged with noxious substances which make unaided breathing impossible. Portable breathing apparatuses usually consist of one or two metal bottles which are carried for example on the back of the user and in which a highly compressed oxygen gas mixture at a pressure of for example 350 bar is contained. This oxygen gas mixture is designated below, for the sake of simplification, as breathing air or simply as air. The breathing air is removed from the bottles via a shut-off valve and breathed in by the user by means of a so-called demand valve.
The problem in using breathing apparatuses of this kind is initially described by reference to the example of scuba diving:
In professional scuba diving today depths of over one hundred meters are reached and, even when diving as a hobby, experienced divers go down to considerable depths.
As the depth of water increases, the hydrostatic pressure acting on the diver becomes greater, which leads to the body tissues absorbing a relatively high amount of inert gases, that is to say in particular nitrogen. During resurfacing and the associated pressure reduction this process is reversed. If the pressure reduction occurs more quickly than the gas, which is being released, can be carried off and breathed out, decompression sickness occurs which in less severe cases leads to temporarily-health but in more severe cases can lead to permanent damage to health and even to death. In order to prevent a rapid release of the inert gases, when returning to the surface after a relatively long time spent at a relatively great depth divers must therefore remain at specific depths for relatively long resurfacing interludes which are referred to as so-called decompression stops. The duration of the necessary decompression stops is difficult to calculate since the human body has a multiplicity of different types of tissue which differ both with respect to the saturation and desaturation behavior as a function of the diving depth and duration of diving and also with respect to the medical hazard. Therefore, divers usually use diving tables in which the decompression times are given as a function of the diving depth reached and the duration of diving or they use diving computers in which the saturation and desaturation behavior of a selected number of types of tissue are mathematically simulated and the decompression times thus calculated are displayed to the driver via corresponding display devices.
A summary of the problems of decompression is given, for example, by the publication by A.A. Buhlmann: Decompression--Decompression Sickness, Berlin, Heidelberg, New York, Tokyo 1984, ISBN 3-540-13308-9, specifically in particular pages 1-62 for the medical aspect and pages 63-67 for the decompression calculation. Pages 68-82 contain decompression tables for divers.
Therefore, before the diver undertakes such a dive he must ensure that the air supply he carries is adequate for the planned bottom time and for the ascent time.
However, determining the required air supply is faced with considerable difficulties: the amount of air taken in by the diver per minute is not constant but changes, for example with the physical stress. In states of fear and panic, the air consumption can increase suddenly as a result of so-called hyperventilation. Furthermore, the amount of air removed is, of course, dependent on the respective ambient pressure and thus depends on how deep the diver is diving.
Therefore, the diver requires a monitoring device to be able to estimate the actual air consumption and the remaining possible bottom time under water.
Currently, in order to monitor the air supply divers use manometers which are connected to the breathing apparatus via a hose and indicate the current pressure of the air supply in the container. Since the pressure drops as air is continuously removed from the bottle, the appropriately experienced diver can estimate to a certain degree how much breathing time remains.
It has also already been proposed, see for example U.S. Pat. Nos. 4,794,803 or 4,586,136, to design a monitoring device which enables the remaining time available to the diver to be determined and indicated directly from the measured bottle pressure. However, these devices have the disadvantage that they are connected to the breathing apparatus via a hose and are thus cumbersome to operate and in addition can adversely affect the freedom of maneuver of the diver.
In order to overcome this problem, it has been proposed in the Australian Patent Document AU-B-78218/87 to provide, instead of the hose, an ultrasonic transmission between the pressure sensor on the bottle and a display device. In this case, the receiving and display device is arranged on the diver's mask.
The use of such monitoring devices, in particular when they operate with a wireless signal transmission, is however only acceptable if certain safety requirements are fulfilled.
Thus, it must be ensured that the signal transmission from the transmitter to the receiver takes place correctly under all circumstances, that is to say that movements of the diver and the water, that is to say external interference etc., do not have any influence on the transmission of the measurement signal.
At the same time, it is to be borne in mind that intellectual capacities are impaired from a depth of about 30 meters by the high N2 partial pressure which has a kind of narcotic effect (nitrogen narcosis). If the monitoring device, for example, falsely indicates an excessively low air supply, this can lead to an irrational panic-like reaction even among experienced divers. Therefore, it should be ensured as far as possible that the monitoring device does not display a false signal, even for only a brief period of time.
The problems described above relating to scuba diving also apply, in a correspondingly modified manner, to the use of breathing apparatuses for fire-fighting and rescue operations and for other applications. Here too, the user requires the remaining breathing time to be specified exactly in order, for example, to be able to begin his return to safety at the correct time. Furthermore, the user here is also usually in a particularly stressed state and it must therefore be ensured that incorrect measurements and incorrect information are avoided as far as possible.
SUMMARY OF THE INVENTION
The present invention is therefore based on the object of providing a monitoring device for portable breathing apparatuses by means of which the user is informed at least about his air supply and which operates reliably and in particular free of external interferences and whose display is easy to read.
This object is achieved according to the invention by means of the subject-matter of claim 1.
Preferable further developments of the device are the subject-matter of subclaims.
The monitoring device according to the invention consists of a transmitter and of a receiver separate therefrom. This design has the advantage that the receiver, which is usually combined directly with the display device, can be arranged in the field of vision of the user without his freedom of maneuver being unnecessarily restricted, for example by means of a hose device, and without a special manipulation being required to read the display device.
The receiver can thus be carried by the user in any desired manner. It is preferable for the receiver to be arranged directly on the user's wrist. This has the advantage over an arrangement on a mask that the user does not have any focussing difficulties when reading the display. Furthermore, he does not have the display instruments constantly in his field of vision, which could confuse or distract him. The arrangement on the wrist permits the user to read the appropriate, displayed data easily when, for example, he is carrying out any tasks with his hands.
However, on the other hand, wireless signal transmission entails considerable risks for the reliability of the signal transmission. With this design, the receiver could interpret interference signals, such as are caused, for example, by movements of the diver or also by external sources, as a pressure signal and thus display false or frequently changing values to the user. The user would then no longer be able to read the data reliably.
A risk which is associated with wireless transmission and is not to be underestimated is also due to the fact that the operations or dives in question are not normally undertaken alone but rather that several persons carry out the operation or dive together. Since identical apparatuses are frequently used within a rescue organization or a diving club for all the members of such a group, there is a very high risk that a receiver will pick up the signals of a neighbour's transmitter and thus display false values to the user.
It is possible to solve the problem of the use of several monitoring devices within a group by assigning to each device an individual transmission frequency which can only be received by a correspondingly tuned receiver. However, this design has several disadvantages. If a relatively large number of such monitoring devices with differing frequencies were to be made available, the frequency band still available for the individual device would have to be tightly dimensioned. However, this requires a relatively high degree of technical complexity with regard to the receiver in order reliably to filter out from a plurality of received frequencies that frequency which is intended for each respective receiver. As a result, the receiver becomes complex and the probability of potential errors increases.
Also the fact that the intensity of the received signals decreases with distance is not sufficient to ensure in this case a clear allocation of the devices.
Firstly, it would only be possible to achieve an intensity of reception which was constant to some extent if the transmitter and receiver were arranged at a relatively short distance from one another and always had the same spatial arrangement with respect to one another. However, this is not even the case if the transmitter is installed on the pressure container and the receiver is installed in the region of the head or, for example, of a mask of the user. In this case, even turning the head is sufficient to change the spatial arrangement and thus the intensity of reception. If the transmitter is installed on the pressure container and the receiver on the wrist of the user, severe fluctuations in the intensity of reception are to be expected as a function of the movement of the user. Moreover, further interference, for example air bubbles when diving, can additionally affect the intensity of reception.
Moreover, the distance between different users, for example when they are recovering objects or rescuing people, may be very small so that the distance-related difference in intensity is no longer significant. This applies for example if a diver tries to help a colleague in difficulty.
The monitoring device according to the invention solves these problems reliably. By the use of an identification signal it is ensured that each receiving device only receives and further processes the signals which are emitted by the associated transmitting device. In this way, it is not only the case that signals from other devices are prevented from being received; it is also the case, by virtue of the strictly predetermined identification pattern, that the signals which originate from external interference, for example from any other transmitters, are prevented from being further processed. In this way, it is ensured that only that signal is further processed which corresponds exactly to the respective identification pattern. It is very improbable that interference signals from any other transmitters contain corresponding identification patterns.
According to a preferred embodiment, the transmission of the data and of the identification signal takes place in digital form. As a result, a relatively high degree of data transmission reliability is achieved and it is also possible to select a high number of identification patterns by virtue of the fact that this signal is composed of a correspondingly high number of individual bits.
It is possible for a specific receiving component to be assigned to each transmission element and vice versa, as early as during production. However, this has the disadvantage that, for example in the event of a failure of the receiving element, the associated transmitting element also becomes unusable and vice versa. According to a preferred further development of the invention, it is therefore proposed to make the assignment between the transmitting element and receiving element variable.
In this case, provision is preferably made for the transmitting element and the respective receiving element to be used with it to be capable of being placed in an identification signal change mode which permits the receiving element to receive and store the identification signal of the transmitting element assigned to it. According to a preferred further development, this assignment or pairing mode has several safety steps so that unintentional and incorrect assignment of a transmitting element and receiving element is avoided.
According to a preferable further development, the transmitting and receiving elements are designed in such a way that the identification signal change mode is always triggered by one device, and preferably by the transmitting element, this device then preferably also having a fixed, invariable identification signal.
The possibility of the free assignment of transmitting element and receiving element has considerable advantages in practical use. Organizations such as, for example, a diving club, a fire-fighting unit and the like usually have a number of portable breathing apparatuses which, when using a monitoring device according to the invention, are each provided with a transmitting element and a receiving element. If, in such a group, for example one transmitting element and one receiving element of a non-assigned pair fail, a total of two monitoring devices would become unusable in the case of an invariable assignment. When using a variable assignment, the remaining devices could continue to be used.
It is also ultimately not necessary to store the transmitting element and receiving element in each case in such a way that it is impossible to mix up the devices. If it is found that the devices do not match, a new assignment can be performed at any time.
Furthermore, in particular if the monitoring device is to be used for diving, the battery which is necessary both for the transmitting element and receiving element must be arranged in a pressure tight manner in the respective housing and can thus not be changed by the user himself. Since it is to be expected that the batteries of the transmitting element and receiving element are used up at differing rates as a function of the respective use profile, both devices of such a combination would be out of operation for the time of the battery change of a device which can usually only be performed by the manufacturer. This disadvantage is also avoided by the variable assignment.
The variable assignment also has the advantage that two receiving device can also be assigned to a transmitting device. It is then possible for example for a diving instructor to use two receiving devices with which he can observe his air supply and the air supply of a trainee diving with him. If the devices are to be additionally provided with an air consumption measuring device, the diving instructor can also evaluate the state of stress of his trainee from this display.
Finally, it is also conceivable that, in particular for the receiver which can be combined with other functions, differing device models will be offered which the user will be able to use without having to obtain a new transmitting element in each case. In addition, the manufacture of the monitoring device is substantially simplified by the variable assignment.
The identification signal change mode is preferably triggered by the transmitter being made, manually, to emit a fixed signal (the identification control signal) which indicates to the receiving device that an assignment process is to take place. In order to prevent the assignment of a plurality of receiving devices to one transmitting device, appropriate safety measures can be provided with regard to the receiver.
The actual assignment takes the form of the identification signal of the transmitting element also being emitted with the identification control signal. The receiving device which has been placed in the identification signal change mode receives this identification signal and stores it in a corresponding memory until it receives a different identification signal within the scope of a new assignment.
It is improbable that any third transmitter emits a pattern which corresponds to the identification signal. The small remaining uncertainty factor can be greatly reduced by means of a further safety measure which also serves to eliminate the effect of signal interference such as is caused, for example, by movements of the diver.
One of the preferred aims of the monitoring device is to calculate the breathing time still available to the user of the breathing apparatus. This breathing time is preferably calculated by means of a computing device which is installed either in the transmitting device or in the receiving device. As a result, it can be indicated to the user of the breathing apparatus how long the breathing air will last under the current conditions.
In accordance with a preferable further development of the invention, this computing device is installed in the receiving element and continues the air consumption calculation in the manner of a prognosis if no signal is received from the transmitting element. As a result, a signal which is received after an interruption can be tested for its plausibility.
If, therefore, as a result of a fault, the receiver does not receive a signal, it extrapolates the air consumption on the basis of the preceding measurements until the next signal is reliably received. Then a check is carried out as to whether this received signal lies in a specific tolerance range of the extrapolated air consumption. If this is the case, the signal is displayed as a new value. If this is not the case, no display is given. Also, for as long as the reception situation is unclear, it is also preferable for no display value to be given.
This design has the advantage that the receiver can be reliably prevented from displaying a false value, due to an incorrectly received signal, which could confuse the user.
The transmission of the signals from the transmitting element to the receiving element can take place with all the methods suitable for signal transmission. If the monitoring device is used under water, the data transmission can take place with ultrasonic sound. However, when using the device under water the use of radio signals, and here in particular the use of signals in the long wave range is preferred, that is to say the use of radio signals of a frequency of 5 hertz to 100 kilohertz.
Investigations carried out by the inventor have shown that for electromagnetic transmission of the signal in water a frequency range between 5 hertz and 50 kilohertz is particularly suitable for transmitting the desired signals.
Both the transmitting element and receiving element can be provided with further functions.
If the monitoring device is used when diving, according to a preferable further development of the invention it can be combined with a decompression computer. This computer is preferably accommodated in the receiving element and is connected to a pressure sensor which measures the hydrostatic pressure of the water and thus the diving depth. In addition, a further timer is provided by means of which the diving time can be measured. By means of a computer circuit the saturation or desaturation behavior are determined for an infinite number of tissue types from the measured values of diving depth and diving time, as is illustrated for example in the quoted work by Buhlmann. It can be determined from these values and displayed to the diver how long the ascent to the surface of the water will last overall and at which depths, and for how long, decompression stops are to be included during this process. By combining the calculation of the decompression times with the air consumption calculation, it can then be calculated and displayed to the diver how long he can stay at the appropriate diving depth level before he must begin his ascent again in order to have a sufficient air supply available for an ascent free from medical risks.
From medical research into diving it is known that the saturation and the desaturation of the tissues does not depend only on diving depth and diving time but is also dependent on whether the diver has had to exert himself physically or not. If the diver carries out work during the dive, the required decompression times may rise by up to 50%. A corresponding increase in the decompression times can also result if the diver, for example when diving as a hobby, does not perform any actual task but must, for example, maintain his position against a relatively strong current so that a relatively high level of physical exertion is also required.
According to a preferred further development of the present invention, the physical exertion is included in the decompression calculation with the aid of the monitoring device according to the invention. The air consumption measurement is used as a measure of the exertion. At the same time, the air consumption measurement can take place both relatively and absolutely.
In an absolute air consumption measurement, it is calculated from the pressure reduction with a known bottle volume what quantity of air the diver is taking in per unit of time. From this value conclusions are made with respect to an average or an increased level of physical exertion which can then be taken into account during the decompression calculation.
In the relative air consumption measurement, it is simply determined how high the average air consumption of the diver is, which is averaged over a specific period of time. If the air consumption increases in comparison with this value, an increased level of physical exertion is assumed.
Both absolute and relative air consumption measurements can be continued during the dive in order to influence the decompression calculation further. As a result, it is possible to detect physical exertion during the decompression phase which usually shortens the decompression time. In addition to air consumption measurement, the pulse frequency of the diver can also be detected by means of a corresponding sensor and transmitted to the decompression meter. The pulse frequency also supplies a measure of physical exertion. If the pulse frequency is picked up for example via electrodes which are arranged in the chest area of the diver, the values can be passed on, for example by means of a cable connection, to the transmitting device on the air bottle and transferred in a wireless fashion from there with the monitoring device to the receiving device worn on the wrist.
When using a monitoring device in fire-fighting and rescue operations, a plurality of additional functions can also be integrated in the receiving element. Thus, in addition to the display of current pressure in the pressure container of the breathing apparatus, the remaining breathing time and/or the breathing frequency can be calculated and displayed. In addition, it is possible to provide measuring sensors in the receiving device which give information to the user relating to the state of the air surrounding him. Thus, for example when fire-fighting, the carbon monoxide portion of the air is measured and displayed so that the user of the breathing apparatus is informed for example as to the risk facing those people to be saved. Of course, in addition to gas detectors, sensors for all other types of measurable harmful influences can however also be used (for example Geiger counters and the like).
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the present invention is now described with reference to the figures, in which:
FIG. 1 shows a diagrammatic functional view of a portable breathing apparatus with an exemplary embodiment of the monitoring device according to the invention;
FIG. 2 shows a diagrammatic view of the transmitting element of the exemplary embodiment according to FIG. 1;
FIG. 3 shows a diagrammatic view of the functional modes of the transmitting element of the exemplary embodiment according to FIG. 1;
FIG. 4 shows a diagrammatic view of the encoding of the transmission signal of the exemplary embodiment according to FIG. 1;
FIG. 5 shows a diagrammatic view of the structure of the transmission signal during normal operation of the exemplary embodiment according to FIG. 1;
FIG. 6 shows a diagrammatic view of the structure of the transmission signal in the identification change mode of the exemplary embodiment according to FIG. 1;
FIG. 7 shows a diagrammatic view of the receiving element of the exemplary embodiment according to FIG. 1;
FIG. 8 shows a diagrammatic view of a further exemplary embodiment of the invention in which the receiver is combined with a decompression computer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The first exemplary embodiment of the invention presented in FIGS. 1 to 7 is provided for use with the breathing apparatus for a diver. However, if appropriate it can also be used with corresponding modifications for breathing apparatuses such as are also used for example for fire-fighting and rescue operations.
FIG. 1 shows a highly diagrammatic view of the monitoring device which is designated as a whole by 1 and which has a transmitting element 2, which contains the transmitter, and a receiving element 3, which contains the receiver.
In the present example (not shown in the figures) the transmitting element 2 is permanently attached to an air bottle 5. The air bottle is a conventional steel bottle with a volume of, for example, 7 to 18 liters and a maximum storage pressure of, for example, 350 bar which can be closed off with a manually actuated shut-off valve 6. During use, the shut-off valve 6 is open and the pressure of the air fed to the user is controlled via a diagrammatically indicated pressure control valve 9. This valve 9 which is usually referred to as a demand valve can have one of the different designs which are known in the prior art. The user then takes the air from the breathing apparatus via a hose connection (not shown) by means of a mouthpiece.
A pressure sensor 7 which detects the pressure prevailing in the bottle is arranged between the shut-off valve and the demand valve. The arrangement of the pressure sensor downstream of the shut-off valve 6 has the advantage that the pressure sensor is not subjected to the apparatus pressure during storage of the bottle; furthermore, as is explained below, this has advantages for the safety design of the monitoring device.
When in use, the receiving element 3 is used at a spacial distance from the transmitting element 2 and is coupled to a display device 4 which is usually integrated directly in the housing of the receiving element.
The transmitting element 2 illustrated diagrammatically in FIG. 2 has a housing 10 consisting of nonmagnetic material, preferably plastic, in which the electrical and electronic constructional elements of the transmitting element are held. The interior of the housing 10 of the transmitting element 2 is completely filled with electrically non-conductive oil, silicone or the like. The area of the housing 10a, in which the pressure sensor 7 is arranged, is designed in such a way that during use it is subjected to the pressure in the bottle 5. This is diagrammatically illustrated by the connecting pieces 11, 12. The other part 10b of the housing is also sealed in order to avoid the ingress of water.
In addition, a battery 13 which supplies the transmitting element with electrical power and which is thus also subjected to the pressure in the housing is accommodated in the housing 10.
The configuration of the electrical components of the transmitting element is now described with reference to FIG. 2.
The pressure sensor 7 is connected to a signal preprocessing circuit 20 with electrical lines which are only illustrated diagrammatically here and below. All commercially available types of sensor can be used as the pressure sensor provided that they can be operated with a battery voltage of less than 5 V and use as little power as possible. Therefore, pressure sensors which operate according to the piezoelectric principle are particularly preferred.
The analog signal of the pressure sensor is converted in the signal preprocessing circuit 20 into a digital signal by means of an analog-to-digital convertor. The signal preprocessing circuit 20 is also connected to a quartz-controlled timer 21 whose function is explained below. The digitally preprocessed signal is fed to a commercially available microprocessor computing unit 22. The microprocessor computing unit 22 is connected to a memory 23 and also receives the signals from the timer 21. The memory 23 (and the corresponding memory in the receiving element) can be made up completely from RAM elements. However, it is also possible to use a mixed memory consisting of ROM (read-only memories) and RAM elements. Since the battery voltage is permanently available, the memory contents can be ensured over a long period of time even when using volatile memory elements.
The pressure signal and the other signals to be transmitted are converted by the microprocessor 22 into a transmission signal in accordance with a program stored in the memory 23 and fed to a transmission output step 25. From the transmission output step 25 the signal is transmitted to the aerial 26.
The aerial 26 consists of a ferrite core wrapped with copper wire. An inductivity of the transmission coil in the range between 10 and 50 mhenry has proven particularly favorable.
Different operating modes of the transmitter are now described with reference to FIG. 3 in which the various functional modes of the transmitting element are plotted against the time axis 40.
In the time period 41 in the left-hand part of the figure, the transmitter is in the standby mode. In this mode, the signal preprocessing circuit is made to carry out a pressure measurement at specific time intervals, which is characterized by columns 42. A time period of approx. 5 sec. has proven a preferable time interval here. Between two measurements the microprocessor 22 is always switched into a standby mode in which it only uses a very small degree of power. As a result, it is possible to operate the transmitting element with a typical use profile for approximately five years with one lithium battery.
The starting signal for the pressure measurement originates from the timer 21 of the transmitter. The microprocessor 22 is subsequently activated and the pressure measured by means of the pressure sensor 7.
As soon as a specific switch-on criterion is fulfilled, the transmitter is switched over from the standby mode into the transmission mode. Various criteria can be used as the switch-on criterion. It has proven particularly advantageous to compare the results of two successive pressure measurements and to switch over into the transmission mode in the case of a pressure rise. Preferably, the switch-on criterion is dimensioned in such a way that the transmission mode is switched on if a rise of pressure from below 5 bar to, for example, 30 bar or higher is detected within five seconds. This rise is achieved in any case when the user of the breathing apparatus opens the shut-off valve 6 of the bottle 5 and thus subjects the pressure sensor 7 to the bottle pressure. Random pressure fluctuations, such as arise for example due to temperature changes, changes in altitude etc., are not sufficient to fulfill this switch-on criterion.
After switching on, a so-called identification change mode or pairing mode, which is explained later, takes place initially in the time period 43.
The identification change mode is followed by the actual normal mode in time section 45 which constitutes the actual use phase of the apparatus. As is diagrammatically illustrated in FIG. 3, in this mode a measuring interval 46 alternates with a transmission interval 47. It has proven favorable also to operate with a time interval for the pressure measurements of five seconds during the normal mode. After each measured value is recorded, the transmission signal is then generated by the microprocessor and fed to the aerial 26 via the transmission output step 25.
The time interval between the pressure measurement and the transmission of the signal is not constant but rather is varied by the microprocessor within a predetermined time range in accordance with a random process. However, the transmission of the signal always takes place before the next measured value is recorded. This time variation gives the advantage that, with two monitoring devices which are operated simultaneously at a short distance and which monitor different breathing apparatuses, a collision of transmitted signal values can only occur by accident. If the time interval between measuring interval and transmission interval are always the same, the unfavorable situation could arise in which the values emitted by two transmitting elements collide with one another over a relatively long period of time.
As soon as a predetermined switch-off criterion is fulfilled, the transmitter is switched back into the standby mode, which is shown in time period 49. The switch-off criterion is present if no further pressure reduction is determined for a predetermined number of measuring intervals.
The signal transmission from the transmitter 2 to the receiver 3 takes place by means of an electromagnetic radio wave of constant frequency. The quartz-controlled timer 21 serves to control the transmission frequency. Since the frequency of the oscillator quartz is 32,768 Hz, the structure of the transmitting element is made simpler if a frequency is used which is derived from this frequency with the divisor 2 n . The frequencies 32,768 (n=0), 16,384 (n=1), 8,192 (n=2) and 4,096 (n=3) are particularly preferred. Tests have shown that a particularly good data transmission is achieved under water by using a carrier frequency of 8,192 hertz.
In the interests of fault-free data transmission, the data signals to be transmitted are digitally encoded in the transmitting element 2. In the prior art there are various processes for transmitting the digital values, with which processes the frequency, the amplitude or the phase position of the carrier signal are changed.
A known method, which could also be used for the monitoring device of the type shown, is to change the frequency of the transmission signal with the so-called frequency shift keying. In this method, different frequencies are assigned to the bit information contents 0 and 1. However, this requires two frequencies to be transmitted which increases the complexity with regard to the transmitter and receiver.
The best possible type of transmission has proven to be influencing the phase position with the so-called phase shift keying (PSK), in which case in the present exemplary embodiment a further particular variant of the PSK method is used, namely the differential phase shift keying (DPSK).
In this method, the transmission signal experiences a phase jump if a 1 is transmitted; if a 0 is transmitted, the transmission signal remains unchanged. Since, in this method, the first bit of the transmitted bit pattern contains an uncertainty, it must not be used as information carrier.
An example of this digital encoding is illustrated in FIG. 4. Here, a bit pattern consisting of the bits 0110100011 . . . is illustrated in the diagram 60 against a time axis 61 and a number axis 62.
In the diagram 64, a voltage signal 67 is plotted against the identically scaled time axis 65 and the voltage axis 66 and has a constant frequency, but on which the bit pattern is impressed by the prescribed DPSK modulation as a phase change.
Within each transmission interval, a signal sequence is transmitted which, as is shown by FIG. 5, is built up of a preamble, the identification signal, a data block and a postamble. The preamble serves to permit the receiver to synchronize to the transmitted signal. The identification code contains the transmitter-specific identification. The actual data block to be transmitted adjoins the identification code. In every case, the data block contains the measured pressure value but, in a preferred embodiment, it can also contain a temperature value which is detected via a corresponding temperature sensor. Furthermore, it is possible to transmit in this data block the breathing frequency derived for example from the measurement of the pressure signal. Of course, other data can also be transmitted if this is of interest for a specific application. This is adjoined by the postamble which serves inter alia for error correction.
In the illustrated exemplary embodiment, the synchronization interval comprises 16 bits, the identification code 24 bits, the data block 32 bits and the postamble 4 bits. Each signal is therefore 76 bits long.
Tests have shown that it is favorable for the DPSK used to emit a total of 8 periods of the carrier frequency at 8196 hertz per bit. As a result, period of emission of a total of 0.976 msec/bit or a total signal duration of approx. 74 msec. is obtained.
The structure of the receiving element is now described with reference to FIG. 7.
The receiving element 3 is accommodated separately from the transmitting element in a plastic housing 70 and does not have any connection, of mechanical type or by means of electrical lines, to the transmitting element 2. The plastic housing 70 is filled with electrically non-conductive oil, silicone or the like and has a battery 71 in order to supply the electrical and electronic components with electrical power. In addition, there is a flexible strap (not illustrated) arranged on the housing 70, which strap permits the user to secure the receiving element on his wrist like a wrist watch.
The housing is designed in such a way that it withstands the water pressure even at the greatest depths which may be reached by divers and has no movable electrical switching devices on its exterior in contact with the water. In order to be able to activate the device and to confirm assignment in pairing mode, however, a plurality of electrically conductive metal pins 73 are let into the housing, which pins can be spanned by the diver, for example with his fingers, which is interpreted by the receiving element under specific circumstances as a switching event.
The receiving element has one or two ferrite aerials 80 as illustrated diagrammatically in the figure. The received signal is initially fed to a signal processing and amplification step 81 which is adjoined by a digitization step 82. Both constructional elements correspond to usual designs.
The digital signal is fed to a comparator 83. This comparator determines whether the received and preprocessed signal contains the identification signal or the identification control signal. If this is the case, the signal is fed to a microprocessor 85 which, controlled via a program stored in a memory 86, assumes the further processing.
The use of the upstream comparator step has the advantage that the microprocessor 85 is only fed with the signal when it is clear that the individual receiver has been addressed.
The time control of the receiving element takes place via a timer 84.
The data derived from the received signal and, if appropriate, further data are displayed to the user in the display 87. The display 87 is arranged for this purpose behind a transparent area in the wall of the housing 70 of the receiving element 3. The pressure prevailing in the bottle 5 and preferably also the remaining breathing time are displayed on the display. For this, a further pressure sensor 89 is required which measures the respective ambient pressure. The remaining breathing time is determined in that the current air consumption is determined by the microprocessor from the pressure reduction measured per unit of time taking into account the ambient pressure. The air consumption can be averaged here for a period of time which has just elapsed or over a relatively long period of time in order to obtain realistic values. From this, the expected time for the air supply to run out completely is extrapolated.
The respective data are displayed in the display until new data are determined after a renewed measurement and the transmission of values.
The receiver also has a switching device 88 (illustrated only diagrammatically) with the metal pins 73 already mentioned. The metal pins 73 can also be arranged at a relatively large distance from one another or at different sides of the housing in order to prevent accidental bridging of the contacts.
Below, it is described how the assignment or the pairing of transmitting element and receiving element is carried out within the identification change mode.
As already explained, during manufacture an identification signal, which is only ever allocated once, is permanently assigned to each transmitting element. In the present exemplary embodiment, a 24-bit signal is used for this, from which a total of 16.7 million different identification possibilities are obtained. By virtue of this high number it is ensured that no two transmitting elements have the same signal.
The identification signal of the transmitting component is stored in a ROM area of the memory 23 of the transmitting element 2. It is also possible to store the identification signal in a RAM area; in this case, the signal must however be fixed elsewhere in the device for example by means of the simultaneous use as a manufacturer's number so that the signal can be correctly read in again in the event of a battery change.
The identification change mode is started whenever the transmitting element is activated. This occurs, as explained above, preferably by means of a fixed switched-on criterion, for example the opening of the apparatus valve 6 of the bottle 5. The transmitting element then goes into the identification change mode and transmits, as illustrated in FIG. 6, a signal which consists of a preamble, an identification control signal, the actual identification signal and a postamble. In the exemplary embodiment, the preamble is 16 bits long, the postamble 4 bits long and the identification control signal and the identification signal 24 bits long each.
The identification control signal is understood by all receiving elements of the corresponding types. As soon as a receiving element receives this signal it is switched over via the microprocessor into the identification change mode. The processor then inquires via the display whether the identification signal of the transmitting element is to be taken over. If this is confirmed by the user via the switching device 88 by means of the metal pins 73, the identification signal of the transmitting element is taken over and stored in the memory 86 as an identification comparison signal.
The control program of the receiving element stored in the memory 86 can be designed in such a way that as soon as it receives the identification control signal of the transmitting element in the identification change mode the receiving element tests whether its stored identification comparison signal matches the identification signal of the transmitting element. If this is the case, the receiving element can then indicate that it is set to this transmitting element so that the user knows that the two devices are assigned to one another.
In order to avoid an accidental assignment of devices, the identification control mode in the exemplary embodiment has a plurality of safety steps.
The first step is the coupling of the start of the identification change mode to the switch-on criterion of the transmitting element. The identification change is always performed only directly after the occurrence of the switch-on criterion. In this way, an identification change is reliably prevented from being started during the normal use of the devices.
As a second safety step, a power measurement of the signal received in the identification change mode is carried out by the receiving element with a corresponding device. The program of the receiving element is therefore designed in such a way that a power measurement of the entire signal is carried out whenever the identification control signal is received. Only if the transmission power exceeds a specific threshold value is an assignment possible.
The transmission of the power from the transmitting element to the receiving element depends, as known, on the distance and, to a considerable degree, also on the respective alignment of the two aerials in relation to one another. Only if the devices are arranged in a specific way with respect to one another in terms of angle and space is the power absorbed by the receiving element at a maximum. The threshold value for the power measurement is therefore selected in such a way that an assignment can only take place if the transmitting and receiving elements are arranged at a small distance in relation to one another and, in addition, have a predetermined angular alignment in relation to one another. In order to simplify the angular assignment, the aerials of the transmitting element and receiving element are preferably arranged in the respective housing in such a way that the maximum power is obtained with a parallel or T-shaped arrangement of the devices in relation to one another. In order to exclude random occurrences here also, the transmission of the identification control signal is repeated several times and an adequate signal power is then only assumed if the measured value lies above the threshold value over a specific percentage of the transmissions.
Finally, the user must also actuate the switching device 88, and this constitutes the next safety step, in order to confirm the identification change. For this, for example the three metal pins must be used in such a way that only two can be spanned in the case of an identification change mode. In this way, an identification assignment under water (in this case all three metal pins would be electrically connected) is prevented from taking place. It is also possible to use three metal pins in such a way that initially a first pair and then a second pair have to be spanned.
An assignment therefore only takes place if
1. the transmitting and receiving elements are arranged virtually directly next to one another in a defined angular position;
2. in this state, the shut-off valve of the air bottle is opened;
3. and the identification is manually confirmed by the user.
It is described below how the illustrated receiver tests the plausibility of the received data.
As stated at the beginning, the monitoring device should, as far as possible, not display false values, even for only a short period of time. Due to the wireless transmission, it may however occur that the reception of the entire signal transmitted during a transmission interval, or parts of the signal, is adversely affected, for example by vigorous movements of the user or the like.
If two transmitting elements operate in close proximity to one another, it could also occur that the two transmitting elements transmit essentially at the same time so that the signals are superimposed upon one another and thus can no longer be clearly identified.
Furthermore, it could be the case, even though this is improbable, that due to the superimposition of different signals for a short period of time a pattern is produced which happens to correspond to the identification signal.
This problem can be counteracted by suppressing the appropriate display whenever the signal has not been received absolutely correctly.
In the exemplary embodiment shown, a plausibility check is provided as an additional safety measure in order to exclude any risk of an incorrect display. The plausibility check takes place by the calculation of the pressure drop to be expected in the bottle of the breathing apparatus by the microprocessor of the receiving element.
When in use, breathing air is removed from the breathing apparatus essentially continuously and the pressure in the bottle 5 drops continuously in a corresponding fashion, from which the current air consumption is determined. By reference to the air consumption, the microprocessor calculates how the pressure drop in the bottle would have to drop further with a continuous removal of air. At each pressure measurement, it can then be determined whether the newly measured pressure is plausible with respect to the previously measured pressure values. If this is the case, the new pressure value is displayed in the display. If the pressure value is not plausible or if no signal or no complete signal is received in the predetermined time interval, either no pressure value is displayed or the last pressure value measured is displayed but it is indicated by means of an additional symbol or for example by flashing of the display but this is the result of a previous pressure measurement.
If no pressure signal is received over a plurality of measuring intervals or if the signal is not clearly identifiable as a result of faults, this display is retained until a time frame fixed in the control program of the microprocessor 86 is exceeded. From this time point onwards, it is assumed that reliable pressure values are no longer available and the calculation of the air consumption is terminated. This is indicated accordingly in display 87.
If pressure signals are received again which originate from the transmitting element assigned to the receiving element, these are displayed but with an additional symbol, for example with a flashing display or the like, by means of which the user is informed that a plausibility check of these values is no longer possible.
In a further exemplary embodiment of the monitoring device according to the invention which is illustrated diagrammatically in FIG. 8, the monitoring device is combined with a decompression computer. The decompression computer could be arranged both in the transmitting device and in the receiving device. However, as in the exemplary embodiment shown, the receiving element of the monitoring device and the decompression computer are preferably combined with one another in a housing since the decompression computer then remains functional even in the event of a failure of the transmitter.
Decompression computers of the type in question here are known in the prior art. The applicant has already marketed devices of this kind for example in relatively large numbers in 1989 in Europe, USA, Japan, Australia and many other countries, for example under the name "Aladin pro". In decompression computers of this type, the current ambient pressure, which is a measure for the diving depth, and the entire diving time are detected via a corresponding manometer and a time measuring device. With these input values the saturation and desaturation behavior of a specific number, for example 6 or 16, of different tissues is simulated by means of a microprocessor with a program stored in a memory. By comparing the stressing of the individual tissues the computing unit calculates which tissue, the so-called control tissue, is indicative of the decompression and accordingly determines the number, the depth and the respective duration of the necessary decompression steps. At the same time, the entire diving time, the current diving depth, the respective next decompression stop and the entire time which is necessary to reach the water surface at a specific predetermined ascent speed and with the prescribed decompression steps are displayed to the diver on a display. Furthermore, the decompression computer is provided with memory devices, a so-called log book in which the diving profile of previous dives is stored so that the diver can make a note of his respective diving times etc. after leaving the water. Moreover, such a decompression computer is provided with a device for measuring the air pressure before diving so that the device can be used even in lakes which lie at a higher altitude than sea level and fluctuations in air pressure can be prevented from influencing the measurement results.
It is possible to combine the receiving element of the monitoring device according to the invention and the computing unit for the decompression calculation in such a way that both are controlled by a common microprocessor.
However, the programing and the design are simplified if a solution with two microprocessors is used instead.
The exemplary embodiment of the monitoring device according to the invention shown in FIG. 8 operates with a transmitting element such as explained with reference to FIG. 2 and therefore no longer illustrated in FIG. 8. The receiving element has a pressure-tight, non-magnetic housing 100 in which, as is indicated by the area shown by dot-dash lines, the receiver 103 and the decompression computer 104 are arranged together. The housing is filled with oil and has an internal pressure which is equal to the pressure of the water surrounding the housing. The dimensions of a pattern of this housing which is designed to be carried on the wrist are approximately 75 mm (length transversely to the direction of the arm) and approximately 75 mm in width, measured along the arm. The housing has a thickness of approximately 20 mm.
The receiving element 103 is constructed as described above and has an aerial 110 and a first microprocessor 112 with a memory 113. The components serving essentially for signal processing are combined diagrammatically in the constructional unit 111.
The decompression computer has a microprocessor 120 with a memory 121 for program and data. The pressure of the surrounding water is detected via a pressure sensor 125. The other electrical components, such as timer etc., are combined diagrammatically in the constructional unit 127.
At least the battery 130 serving to supply power, a display 132 let into the housing wall and a switching device 134 with four metal pins 136 are provided as common constructional elements.
A common display-monitoring device and a common timer and the like can be used as further common constructional elements.
The microprocessors are each controlled via a separate program but exchange data via a diagrammatically indicated data line 138. From this, the following data are determined and presented on the display 132 with numbers and/or symbols:
the pressure in the breathing air bottle in bar or psi;
the time remaining for the stay at the respective diving depth, taking into account the time required for the ascent (remaining air time) in minutes or with a symbol, for example an emptying hourglass;
the entire diving time from entry into the water;
the current diving depth;
the next decompression stop and the first decompression time to be spent there;
the entire diving time;
the maximum diving depth;
the current ascent speed.
In addition, the following functions or incorrect functions can be displayed or indicated by the flashing of the corresponding values or by additional visual and/or acoustic warnings:
a signal, for example a flashing of the pressure display, which indicates that the current displayed bottle pressure is not being monitored by the air consumption prognosis since the connection between the transmitting component and the receiving component has been disconnected for a relatively long time;
a display for a brief interruption of the connection between the transmitting component and receiving component;
a signal when the maximum ascent speed exceeds the permitted value (this value can be determined with the pressure sensor 125 by pressure measurements occurring at brief time intervals).
Furthermore, in accordance with this exemplary embodiment the monitoring device can also be coupled to displays which only become visible after leaving the water, for example a warning display in the form of an aircraft which indicates to the diver that the use of an aircraft is not yet possible again, a log book display, etc.
The decompression data are determined, as described above, by the microprocessor 120 via the simulation of the behavior of a specific number of types of tissue. The admissible time spent at a specific depth is obtained by means of a, for example, iteratively occurring approximation in which the previously computed time for which the air supply is still adequate is divided up into the remaining time spent at a particular depth and into the overall ascent time which is necessary to rise to the surface from this depth after the bottom time has expired.
In addition to the input variables of pressure and time, the calculated air consumption can also be taken into account in the decompression calculation. Since the air consumption is a measure of the physical exertion of the diver the influence of physical exertion on the decompression times can thus be taken into account in accordance with the results of medical research into diving.
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A monitoring device for portable breathing apparatuses having a manometer by means of which the pressure in the pressure container of the breathing apparatus is detected, and having a transmitter by means of which a signal corresponding to the pressure is transmitted at regular intervals. The transmitter also has a signal generating device which generates an identification signal which is characteristic of the transmitter. The pressure signal and identification signal are received and tested by a receiver. If the identification signal matches an identification comparison signal stored in the receiving device, the measured pressure value is displayed on a display device.
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FIELD OF THE INVENTION
[0001] This invention relates to solid cleaning compositions and the method for using the solid compositions to clean appliances and other soiled surfaces. The solid cleaning composition is generally comprised of a majority by weight of a cleaning active system; ingredients for forming the cleaning active system into a solid form; and optionally, a fragrance. The cleaning active system is generally comprised of a solid oxidizing agent and one or more compounds selected from the group consisting of a metal chelating agent and a carbonate-based compound. The solid oxidizing agent may be selected from percarbonate-based compounds. The ingredients for forming the cleaning active system into a solid form are selected from the group consisting of an acid component, a polyalkylene glycol compound, and mixtures thereof. The solid cleaning composition is ideally suited for reducing and/or eliminating microbial growth, including biofilm growth, contained within and/or on appliances, particularly those appliances that have water contact surfaces such as washing machines and dishwashers. The solid cleaning composition further provides reduction and/or elimination of undesirable odor and staining typically associated with such microbial growth.
BACKGROUND OF THE INVENTION
[0002] Many different types of cleaning compositions have been developed for use in preventing and controlling the growth of microbes. These include, for example, bleach compositions and detergent formulations that include bleach compositions. However, with the continual introduction of new consumer products, there exists a constant demand in the marketplace for protection against bacterial and fungal growth presented by some of these new products. Of particular concern, the present invention is directed toward reducing and/or eliminating the growth of microbes and biofilm in home appliances and/or equipment that have water contact surfaces. Examples of home appliances having water contact surfaces include washing machines, dishwashing machines, and the like. Other equipment having water contact surfaces include whirlpool-type bathtubs, in-home humidifiers and de-humidifiers, air conditioning units, dishwashers, and the like.
[0003] Using the example of washing machines, the growth and proliferation of microbes in a washing machine generally occurs from prolonged exposure to warm, moist environments which may contain soap residue and clothing residue, such as body oils, fiber particles, and dirt and bacteria from the clothing. This environment leads to the development of undesirable odors and biofilm. Biofilm is the growth of microbes, such as bacteria and fungi, on a surface. Biofilms are commonly surrounded by an exopolymeric matrix. Both the abundant microbial growth and matrix production result in visible microbial communities, thus damaging the aesthetic appeal of the surface. Additionally, secondary metabolites produced as a result of microbial growth include volatile organic compounds (VOCs) that can be detected by the consumer as foul odors.
[0004] Front loading laundry machines, in particular, provide an ideal environment for microbial growth in any of the water-contact locations in the machine. The four major components of the machine are generally the polypropylene wash tub, stainless steel wash cylinder, aluminum support bracket and the circular door sealing gasket (also known as a “bellow”) which provides a seal between the wash compartment and the door of the washing machine. Biofilms may form on the washing machine bellow, on the piping and tubing which connects the parts and carries the water to and from the machine, on the inner surface of the outer wash tub and on the outer surface of the inner wash tub. As the microbes in the biofilm grow, they tend to penetrate the supporting surface resulting in staining of the surface to which the microbes attach. Microbial growth further leads to degradation of the machine parts which potentially results in reduced life cycle of the parts or the entire laundry machine. Additionally, in the process of biofilm growth and maturation, portions of the biofilm may detach and come into contact with clothing, towels, sheets, etc. that are laundered in the washing machine. This biofilm-to-clothing contact may undesirably and irreversibly stain and leave a residual odor on the clothing that comes into contact with the detached biofilm during the laundering process.
[0005] Both top loading and front loading washing machines experience foul odors (both in the machine and transferred to the clothes) as well as mold and staining issues. These problems are thought to originate from biofilm formation on components comprising the washers. The staining on the rubber door bellow is often visible to the consumer after several months. Foul odors caused by the biofilm in other areas of the machine are often noticeable within three months of field use. In worst case scenarios, the odor from the machine is transferred to the clothing.
[0006] This problem of microbial growth and proliferation in appliances and equipment having water contact surfaces, particularly in washing machines, has been manifested, in part, by the desire to manufacture more energy efficient and environmentally friendly consumer products. For instance, the laundry care industry is producing high efficiency washing machines designed to clean clothing at lower wash water temperatures. Regulations restricting water volumes in such appliances and the use of excessive liquid laundry detergents have been mandated in some countries. Thus, increased production of front loading washing machines and machines designed to clean clothing at lower temperatures and lower water volumes has created a need for cleaning compositions capable of reducing and/or eliminating microbial growth on water contact surfaces contained within these machines.
[0007] One remedy to this problem that is provided by washing machine manufacturers is to include a cleaning cycle as part of the standard offering on the machine cycle dial. Thus, the user care guide and machine cycle dial recommends to machine owners that they should run a periodic cleaning cycle on the machine using a large amount of bleach. In some washing machine models, such as the high efficiency front loading machine, an indicator maintenance light is built into the machine. The light is designed to turn on at regular time intervals (e.g. every 30 days, every six months, etc.) as a reminder to the consumer that it is time to run a cleaning cycle in the machine.
[0008] For instance, US Patent Publication Nos. 2005/0262883 to Yang et al., 2005/0265890 to Yang et al., and 2005/0262645 to Yang et al. disclose a washing machine having a deodorizing unit contained therein for removing odors from objects placed in the wash tub. An electronic nose sensor generates a response based on the type and kind of odor particles or gas present in the tub. Odors are removed by spraying water onto the objects in the tub and blowing hot air, thereby moving the offensive odor particles to an air outlet present on one side of the tub. This deodorizing cycle is operated separately from the wash cycle. In addition to the deodorizing unit, the washing machine may also possess an ozone-generating unit and/or an ultraviolet lamp for deodorizing objects.
[0009] Additionally, U.S. Pat. No. 6,463,766 to Kubota et al. discloses a washing machine with means for preventing propagation of microorganisms. The washing machine is manufactured with a deposition section in the water supply hose from the water source to the wash tub (i.e., a split water line) which also includes a solid antimicrobial agent disposed therein. The solid antimicrobial agent is contained in a cassette case. Upon contact with water, the solid antimicrobial agent, e.g. an organic compound having nitrogen and halogen atoms, releases the antimicrobial agent, e.g. hypohalogenous acid, into the water of the washing machine. The antimicrobial mode is provided as a cycle on the washing machine which the consumer can choose to activate. This product requires a filter for catching any pieces of the antimicrobial agent that breaks off from the solid shape and may enter the washing machine. If the pieces were to enter the washing machine, the antimicrobial agent may discolor the laundry items contained in the wash tub. The cycle time for running the antimicrobial agent into the machine is also longer than the normal wash cycle.
[0010] Other attempts to control this problem are addressed by US Patent Publication No. 2003/0008085 to Davenet et al. which discloses a laundry bag for holding soiled laundry in a washing machine. The laundry bag may include a dispensing unit which allows for the delayed release of a bleaching agent into the washing machine.
[0011] Thus, since washing machines are currently being designed to have a cleaning cycle built in for use by the consumer in preventing/removing microbial growth, the need exists for chemical compositions which may be added to the machine for use during this cleaning cycle. Attempts by others to create cleaning compositions for use in appliances and equipment as described herein have included bleach or bleach-containing compositions and other peroxide-based compositions which, as will be shown by example herein, fail to adequately clean and remove microbes, biofilm and any other buildup from the interior of machines having water contact surfaces. Furthermore, the use of bleach or bleach-containing products (e.g. chlorine bleach products) often leads to corrosion problems on various parts within the machine.
[0012] U.S. Pat. No. 5,620,527 to Kramer et al. discloses a cleansing and disinfecting composition using an alkaline per-salt and a positively charge phase transfer agent. The composition also contains a surfactant. U.S. Pat. No. 5,320,805 to Kramer et al. discloses a composition including from about 10% to about 90% weight of an alkaline water-soluble salt having hydrogen peroxide of crystallization and from about a fraction of a percent to about 30% by weight of a positively charged phase-transfer agent. These compositions are useful as disinfectants in the health care industry by application directly to the skin or by incorporation into wipes, sponges, and brushes.
[0013] U.S. Pat. No. 7,018,642 to Degenhardt et al. teaches compounds, compositions and methods for controlling biofilms in high humidity home appliances. The composition is comprised nitrogen heterocyclic compounds chemistries to control biofilms.
[0014] U.S. Pat. No. 7,041,633 to Tcheou discloses a process for preparing a detergent tablet, comprising the step of contacting a liquid binder to a base powder. The liquid binder includes a nonionic surfactant and a dissolution aid. The tablet is coated with a combination of dicarboxylic acid and an anion exchange resin or a clay. The liquid binder may include twenty percent or less of polyethylene glycol; however, it is most preferred that the liquid binder if free of polyethylene glycol. The dissolution aid preferably comprises an organic sulfonated compound such as salts of aryl sulfonic acids. The base powder is typically a pre-formed detergent granule.
[0015] U.S. Pat. No. 6,254,892 to Duccini et al. discloses chemical compositions in the form of pellets which disintegrate quickly and efficiently in aqueous media and a method of producing the pellets. The pellets are comprised of three parts: a chemical active portion (such as laundry detergent), a disintegration component (such as cross-linked polyacrylate water absorbent polymers), and a water transport agent (such as amorphous cellulose or synthetic hollow fibers).
[0016] U.S. Pat. No. 6,670,320 to Cao et al. teaches a unit dose wash cycle fabric softening composition for softening and conditioning fabrics in the wash cycle of an automatic washing machine. The fabric softener is in an amount sufficient to form a unit dose capable of providing effective fabric softening. The fabric softener is comprised of montmorillonite-containing clay compound and a disintegration agent, such as swelling polymers, cellulose and electrolytes.
[0017] U.S. Pat. No. 7,041,632 to Holderbaum et al. discloses a process for the production of single-phase or multi-phase detergent shaped bodies containing surfactants, builder, perfume and other typical ingredients of detergent shaped bodies. The detergent shaped bodies are formed by subjecting a perfume-free detergent shaped body to a perfume such that the resulting product exhibits improved odor impression. The detergent shaped bodies are of the type used in laundry or dishwashing detergents.
[0018] U.S. Pat. Nos. 6,518,313; 6,028,113; and 5,977,183 to Scepanski disclose solid sanitizers and cleaner disinfectants and solid antimicrobial compositions. The compositions are comprised of solidified, non-flowable quaternary ammonium salts, alcohol alkoxylates, urea, and optionally fragrance and dyes. The compositions are initially prepared as a liquid melt which can be poured into a container where, upon cooling, the compositions solidify. The container is inverted and connected to a water supply, which dissolves the composition, and the dissolved composition may then be sprayed through a dispensing hose for use in sanitizing tables and fixtures in a food processing plant.
[0019] The present disclosure addresses and overcomes the problems described above. As one potentially preferred embodiment of the present invention, the solid cleaning composition is generally comprised of (a) a majority by weight of a cleaning active system which includes a solid oxidizing agent and one or more compounds selected from the group consisting of a metal chelating agent and a carbonate-based compound, (b) an acid component and (c) a polyalkylene glycol component. The solid cleaning composition may optionally include a fragrance. The composition is ideally suited for reducing and/or eliminating microbial growth, including biofilm growth and scum build up contained within and/or on appliances, particularly those appliances that have water contact surfaces such as washing machines and dishwashers. Unlike many of the solutions previously described, the composition of the present invention does not have a negative effect on the machine parts, clothes, tableware, septic/sewer system, etc. Additionally, the composition has been designed to work with the machine cycle conditions (time, temperature, water volume, etc.) and to reduce or eliminate both the biological and the abiotic build up. For these reasons and others that will be described herein, the present solid cleaning composition represents a useful advance over the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a bar graph illustrating the biofilm removal efficacy of cleaning tablets of the present invention on various substrates both with and without scale build-up.
DETAILED DESCRIPTION OF THE INVENTION
[0021] All U.S. and foreign patents and U.S. patent applications disclosed in this specification are hereby incorporated by reference in their entirety.
Solid Cleaning Composition
[0022] The solid cleaning composition is generally comprised of a majority by weight of a cleaning active system; ingredients for forming the cleaning active system into a solid form; and optionally, a fragrance.
“Cleaning Active System”
[0023] The cleaning active system is generally comprised of a solid oxidizing agent and one or more compounds selected from the group consisting of a metal chelating agent and a carbonate-based compound.
[0024] The solid oxidizing agent may be selected from percarbonate-based compounds. Percarbonate-based compounds include, for example, sodium percarbonate compounds. Sodium percarbonate is also known by other names such as sodium carbonate peroxyhydrate and sodium carbonate peroxide.
[0025] One commercially available percarbonate-based product suitable for the solid cleaning composition of the present invention is FB® 400 sodium percarbonate available from Solvay Chemicals. This product is a free flowing white granular powder and has an average particle size of 400-550 microns. This product also contains an active available oxygen content equivalent to 27.5% hydrogen peroxide.
[0026] The solid oxidizing agent may be present in an amount between 1% and 95% by weight of the total composition, preferably between 10% and 95% by weight, and more preferably between 30% and 95% by weight. It may be most preferable that the solid oxidizing agent is present in an amount between 50% and 95% by weight of the total composition. Thus, the cleaning composition may be comprised of a majority by weight of a solid oxidizing agent.
[0027] The metal chelating agent may be selected from the group consisting of ethylene diamine tetracetic acid (“EDTA”), tetraacetylethylenediamine (“TAED”) and combinations thereof. The metal chelating agent may aid in the removal of deposits from the machine and/or to remove calcium from the biofilm to weaken its structure and allow for easier removal of the biofilm. The metal chelating agent may be present in an amount between 0.001% and 30% by weight of the total composition, preferably between 0.01% and 20% by weight, and more preferably between 0.1% and 10% by weight of the total composition. It may be most preferable that the metal chelating agent is present in an amount between 1% and 5% by weight of the total composition.
[0028] The carbonate-based compound may include, for example, sodium carbonate, sodium bicarbonate and mixtures thereof. It may be preferable that the carbonate-based compound has a particle size that is smaller than the percarbonate-based compound. Accordingly, the carbonate-based compound may complement the percarbonate-based compound, by occupying the small spaces between the percarbonate-based compounds. Also, the carbonate-based compound may serve as a carrier for other compounds present in the solid cleaning composition. For example, the carbonate-based compound may serve as a carrier for liquid ingredients that are added to the composition. In this capacity, the carbonate-based compound may assist in providing a solid cleaning composition in which all of the ingredients are uniformly dispersed within the composition.
[0029] The carbonate-based compound may be present in an amount between 0.001% and 90% by weight of the total composition, preferably between 1% and 60% by weight, and more preferably between 5% and 30% by weight. It may be most preferable that the carbonate-based compound is present in an amount between 10% and 25% by weight of the total composition.
[0030] In one embodiment, it may be desirable that the cleaning active system consists of a solid oxidizing agent and a metal chelating agent. More specifically, it may be desirable that the cleaning active system consists of sodium percarbonate and ethylene diamine tetracetic acid. Even more specifically, it may be desirable that the cleaning active system consists of sodium percarbonate in an amount between 50% and 95% by weight of the total weight of the solid cleaning composition and ethylene diamine tetracetic acid in an amount between 0.1% and 10% by weight of the total weight of the solid cleaning composition. Thus, the solid cleaning composition is comprised of a majority by weight of the cleaning active system.
[0031] In another embodiment, it may be desirable that the cleaning active system consists of a solid oxidizing agent, a metal chelating agent and a carbonate-based compound. More specifically, it may be desirable that the cleaning active system consists of sodium percarbonate, ethylene diamine tetracetic acid and sodium carbonate. Even more specifically, it may be desirable that the cleaning active system consists of sodium percarbonate in an amount between 50% and 70% by weight of the total weight of the solid cleaning composition, ethylene diamine tetracetic acid in an amount between 1% and 5% by weight of the total weight of the solid cleaning composition, and sodium carbonate in an amount between 10% and 25% by weight of the total weight of the solid cleaning composition. Thus, the solid cleaning composition is comprised of a majority by weight of the cleaning active system.
[0000] “Ingredients for Forming the Cleaning Active System into a Solid Form”
[0032] The ingredients for forming the cleaning active system into a solid form generally include one or more compounds selected from the group consisting of an acid component and a polyalkylene glycol component.
[0033] The acid component may be selected based on its functionality and compatibility with the other ingredients of the solid cleaning composition. Functionality may include features such as effervescence, dissolution rate, tablet hardness, mold release, and the like. It may be also be preferable to choose acid components that are readily available in powder form, since the cleaning composition is intended for use as a solid. Examples of suitable acid components include carboxylic acids such as citric acid, succinic acid, fumaric acid, stearic acid, and the like, and mixtures thereof. These carboxylic acids tend to provide an effervescent feature to the solid cleaning composition. Other acid components, such as boric acid, may aid in providing release of the solid cleaning composition from a forming mold, such as a mold used to form tablets. Additional non-limiting examples of acid components include lactic acid. Mixtures of any of the foregoing acid components may be utilized.
[0034] The acid component may be present in an amount between 0.001% and 60% by weight of the total composition, preferably between 1% and 50% by weight, and more preferably between 5% and 40% by weight of the total composition. It may be even more preferable that the acid component is between 10% and 40% by weight of the total composition, and most preferable that the acid component is present in an amount between 20% and 40% by weight of the total composition.
[0035] The polyalkylene glycol component may be selected from the group consisting of polypropylene glycol, polyethylene glycol, polybutylene glycol and combinations thereof. The polyalkylene glycol component may serve to aid in binding the components of the cleaning composition together. Without being bound by theory, the polyalkylene glycol component may also aid releasing the solid cleaning composition from a mold, such as a mold used to form tablets. It may be preferable that the polyalkylene glycol component has a molecular weight of less than or equal to 10,000. It may be more preferably that the polyalkylene glycol component has a molecular weight of less than or equal to 8000. It may be even more preferably that the polyalkylene glycol component has a molecular weight of less than or equal to 1000. It may be most preferable that the polyalkylene glycol component has a molecular weight of less than or equal to 500.
[0036] The solid cleaning composition may contain the polyalkylene glycol component within the composition, or the solid cleaning composition may be coated with the polyalkylene glycol component. Alternatively, the solid cleaning composition may contain the polyalkylene glycol component within the composition, and it may be coated with the polyalkylene glycol component. The polyalkylene glycol component may be present in an amount between 0.001% and 30% by weight of the total composition, preferably between 0.01% and 20% by weight, and more preferably between 0.1% and 10% by weight of the total composition. It may be most preferable that the polyalkylene glycol component is present between 0.5% and 5% by weight of the total composition.
“Optional Ingredients”
[0037] One or more optional ingredients may be added to the solid cleaning composition. For example, a compound which provides a desirable odor to the solid cleaning composition, such as a fragrance or perfume, may be included in the solid cleaning composition. A fragrance, or perfume, may be any compound known to impart a desirable odor to a composition. A fragrance may be included in the composition to leave the machine with a fresh, clean scent after removal of the odor-causing microbes and biofilm. The fragrance may be comprised of naturally occurring compounds, or it may be comprised of synthetically made compounds. Fragrances may include, merely as an example, oils, such as citric oils. The fragrance may be present in an amount between 0.001% and 20% by weight of the total composition, preferably between 0.01% and 10% by weight, and more preferably between 0.1% and 5% by weight of the total composition. It may be most preferable that the acid component is between 0.1% and 3% by weight of the total composition.
[0038] Other ingredients may be added to the solid cleaning composition, depending on the specific end-use of the composition. These additives may include, for example, defoamers or antifoaming agents, surfactants, pesticides, coloring agents, antifungal agents, antimicrobial agents, effervescents, slow release agents, coating agents, soil release agents, fillers (e.g. sorbitol), and the like, and mixtures thereof. These other additives may be present in an amount between 0.001% and 25% by weight of the cleaning composition, preferably between 0.01% and 15% by weight, and more preferably between 0.1% and 5% by weight of the cleaning composition.
[0039] A defoamer or antifoaming agent may be desired to aid in the prevention or reduction of foaming during the cleaning cycle. Non-limiting examples of defoamers include silicone-containing compounds, mineral oils, fatty acids, and the like, and combinations thereof.
[0040] Surfactants may be added to help reduce the surface tension of the water in the washing machine and/or to loosen the deposits for removal. The surfactant may be selected from the group consisting of anionic surfactants, cationic surfactants, nonionic surfactants, inorganic surfactants, and combinations thereof. Nonionic surfactants, inorganic surfactants and combinations thereof may be preferred surfactants. Specific examples of these preferred surfactants include quaternary ammonium compounds, amines (such as coco alkyl dimethyl amine), alcohol ethoxylates (such as lauryl alcohol ethoxylate) and combinations thereof.
[0041] It is further contemplated that one or more additional ingredients may be added to the solid cleaning composition as a coating or film. For instance, a coating or film may be added to the solid cleaning composition including, for example, PEG coatings or films, water soluble films, water soluble coatings and the like.
Method of Forming a Solid Cleaning Composition
[0042] The ingredients of the solid cleaning composition may be combined together into any solid form that is desired for its intended end use application. For example, the solid cleaning composition may be formed into granulated particles of generally uniform size, or it may be formed into a solid tablet. If it is desirable that the solid cleaning composition be provided in the form of granulated particles, it may be desirable that the particle shape be greater than one-quarter of an inch in size so that the granulated particles will not fall through the holes in the bottom of the wash tub. Alternatively, if the cleaning composition is formed into a solid tablet, it may be desirable that the size of the tablet is modified to fit into any dispensers or areas of the machine in which it will be placed by the consumer for use. The tablet may have a weight in the range from about 5 grams to about 200 grams, more preferably from about 20 grams to about 150 grams, and most preferably from about 40 grams to about 100 grams.
[0043] Formation of the cleaning composition into solid form may be achieved by generally standard processes known in the art for creating granulated particles or solid tablets. If the ingredients of the composition are provided in liquid form, then they should be dehydrated by any means known to those skilled in the art for removing liquid from a composition. For instance, dehydration may be accomplished by heating the composition, such as in a hot air oven, by evaporation, by exposure to an infrared source, and the like, and combinations thereof.
[0044] After dehydration of the cleaning composition, the dry residue that remains may be combined with other ingredients, such as those described previously, and formed into the desired shape for the solid cleaning composition. Such shape manipulation may be performed by any means known for forming particles and other solid shapes. For instance, the dry ingredients may be combined together in a hydraulic press to form a solid tablet. After formation of the granulated particles or solid tablet, other additives may be added to the outside of the solid cleaning composition if desired.
[0045] One potentially preferred embodiment includes the formation of a solid cleaning tablet for use in a washing machine. In front loading washing machines, it is desirable that the solid cleaning tablet have a size and shape that allows the tablet to remain in the back of the wash tub so that the tablet does not contact the baffles that protrude inward from the wash tub. Such contact with the baffles would lead to early breaking and dissolution of the tablet and thus, less than optimal cleaning of the machine. The tablet should also be large enough and have a slow enough dissolution rate that it does not dissolve significantly during the first rinse cycle of the cleaning cycle and leave the wash tub through the drain holes in the wash tub. Finally, the tablet should be of a small enough size and weight that it does not set off the weight sensors that are built into the cleaning cycle of the washing machine. The cleaning cycle is designed to sense whether there are clothes in the machine at the beginning of the cycle. If there is a tablet in the wash tub that is too large, the weight sensors will detect it and send a signal to the machine that a normal wash cycle should occur rather than the cleaning cycle. Such a situation would result in wasted cleaning products, water, and energy.
[0046] After the first rinse cycle, the second rinse cycle will begin and the tablet should be designed to dissolve completely during this second rinse cycle for optimum cleaning of the washing machine. Ideally, the solid cleaning composition should dissolve completely in either hot water or cold water and should contain ingredients which are not detrimental to the machine or the clothing that will be put into the machine after a cleaning cycle has been performed.
[0047] Thus, the solid cleaning tablet exhibits a rate of dissolution in the wash tub of a washing machine during a cleaning cycle characterized in that: (a) the tablet does not substantially dissolve during an initial rinse phase of the cleaning cycle and (b) the tablet dissolves during a subsequent phase of the cleaning cycle such that a substantial amount of the tablet does not remain in the wash tub at the end of the cleaning cycle.
[0048] While it is may be desirable that the cleaning composition of the present invention is formed into a solid tablet for ease of use, it is also contemplated to be within the scope of this invention that the cleaning composition is provided in any form that is capable of delivering the composition to the device which is to be cleaned. For instance, the solid cleaning composition may be in the form of a powder that is placed within a sachet or pouch. The solid cleaning composition may be present as a textile sheet coated with the composition. The solid cleaning composition may be present as a powder that is encapsulated within a water soluble film.
EXAMPLES
[0049] The invention may be further understood by reference to the following examples which are not to be construed as limiting the scope of the present invention.
A. Solid Cleaning Compositions
[0050] The following solid cleaning compositions were prepared. Many of the compositions were tested for various performance parameters such as biofilm removal and odor reduction. The values shown below for the formulations are provided as percent by weight based on the total weight of the solid cleaning composition.
[0051] The powder formulations below were made by dry blending the various ingredients in a tumble blender or by using a kitchen aid style mixer at ambient temperature. When preparing formulations containing effervescence ingredients (e.g. citric acid), the relative humidity of the mixing environment was controlled to as low a level as practically possible.
[0052] The solid tablet formulations were initially prepared in the same manner as the powder formulations. The resultant mixed powder was then placed into a machined stainless mold (i.e. a mold used to form tablets) available from Carver, Inc. of Wabash, Ind. The tablets were formed at compression pressures ranging from 500 psig to 2000 psig.
[0000]
“Formula 1”
(Granular Powder)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
83.25
EDTA
15
Syn Fac DG
1.05
(lauryl alcohol ethoxylate
surfactant)
Fragrance
0.7
[0000]
“Formula 2”
(Granular Powder)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
98.25
Syn Fac DG
1.05
Fragrance
0.7
[0000]
“Formula 3”
(Granular Powder)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
92
EDTA
7.3
Fragrance
0.7
[0000]
“Formula 4”
(Granular Powder)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
89
EDTA
7.3
Syn Fac DG
1
Antifoam Y 30 (silicon-
2
based defoamer)
Fragrance
0.7
[0000]
“Formula 5”
(Solid Tablet)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
71.2
EDTA
5.8
Citric Acid
20.0
Antifoam Y 30
1.6
Syn Fac DG
0.8
Fragrance
0.6
[0000]
“Formula 6”
(Solid Tablet)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
72
EDTA
5
Granulated PEG 8000
20.0
(polyethylene glycol having
molecular weight of 8000)
Antifoam Y 30
1.5
Syn Fac DG
0.9
Fragrance
0.6
[0000]
“Formula 7”
(Solid Tablet)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
74.4
EDTA
5
Granulated PEG 8000
20
Fragrance
0.6
[0000]
Ingredients
Amount (Percent by Weight)
“Formula 8”
(Solid Tablet)
Sodium percarbonate
72
EDTA
5
Flaked PEG 3350
20
(polyethylene glycol having
molecular weight of 3350)
Formula A
3
“Formula A”
Antifoam Y 30
50
Syn Fac DG
30
Fragrance
20
[0000]
“Formula 9”
(Solid Tablet)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
72
EDTA
5
Granulated PEG 8000
20
Formula A
3
[0000]
“Formula 10”
(Solid Tablet)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
74.4
EDTA
5
Citric acid
20
Fragrance
0.6
[0000]
“Formula 11”
(Solid Tablet)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
70
Boric acid
30
[0000]
“Formula 12”
(Solid Tablet)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
52
EDTA
4
Granulated PEG 8000
4
Citric acid
10
Boric acid
29.5
Polypropylene glycol 425
0.5
(molecular weight = 425)
[0000]
“Formula 13”
(Solid Tablet)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
52
EDTA
4
Citric acid
10
Boric acid
31.9
Polypropylene glycol 425
1.5
Fragrance
0.6
[0000]
“Formula 14”
(Solid Tablet)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
60
EDTA
3.83
Sodium carbonate
11.37
Boric acid
23.25
Polypropylene glycol 425
1.03
Fragrance
0.52
[0000]
“Formula 15”
(Solid Tablet)
Ingredients
Amount (Percent by Weight)
Sodium percarbonate
69.0
EDTA
4.4
Sodium bicarbonate
6.0
Granulated PEG 8000
5.0
Sorbitol
15.0
Fragrance
0.6
B. Comparative Example Description
[0053] Several commercially available cleaning compositions were also purchased for evaluation. These compositions are described as Comparative Examples 1-5 below.
Comparataive Example 1
[0054] “Shout Oxy Power,” a powder cleaning product available from S.C. Johnson & Son, Inc.
Comparative Example 2
[0055] “Clorox Regular Bleach,” a liquid cleaning product (containing 6% sodium hypochlorite) available from The Clorox Company.
Comparative Example 3
[0056] “Ultra-Kleen™ CW502 Powder,” a powder cleaning product available from Sterilex Corporation.
Comparative Example 4
[0057] “Washer Magic,” a liquid cleaning product available from Summit Brands.
Comparative Example 5
[0058] “Purewasher,” a powder cleaning product available from “smellywasher.com” website.
C. Test Methods and Evaluation
[0059] Test 1: Viability Validation of P. aeruginosa
[0060] Test 2: Biofilm/Microbial Growth Removal Test: Polypropylene Plaques
[0061] Test 3: Biofilm/Microbial Growth Removal Test: Inventive Granular Compositions vs. Comparative Cleaning Compositions
[0062] Test 4: Biofilm/Microbial Growth Removal Test: Inventive Granular Compositions vs. Comparative Cleaning Compositions—Effect of Temperature
[0063] Test 5: Biofilm/Microbial Growth Removal Test: Inventive Granular Cleaning Compositions—Effect of Antifoaming Agent
[0064] Test 6: Biofilm/Microbial Growth Removal Test: Inventive Granular Formulation vs. Inventive Solid Tablet—Effect of Citric Acid
[0065] Test 7: Biofilm/Microbial Growth Removal Test: Inventive Granular Formulation vs. Inventive Solid Tablet—Effect of Polyalkylene Glycol
[0066] Test 8: Biofilm/Microbial Growth Removal Test: Inventive Solid Tablet—Effect of Ethoxylated Alcohol
[0067] Test 9: Biofilm/Microbial Growth Removal Over Scale Test: Solid Inventive Tablet and Various Disk Substrates and Solid Cleaning Tablets
[0000] Test 1: Viability Validation of P. aeruqinosa
[0068] In order to develop a laboratory test that would simulate the wash and spin cycle of a standard washing machine, the following experiment was performed. Pseudomonas aeruginosa was selected due to its prevalence in water environments and its high predisposition for biofilm formation. Two samples of 10 6 CFU/ml of P. aeruginosa were placed in sterile tap water in 30 mL plastic vials. The plastic vials were subjected to 3 cycles of 30 second sonication followed by 30 seconds vortexing. The number of viable cells in each vial was compared before (“Initial viability”) and after the sonication and vortexing cycles. The results are shown in Table 1 below.
[0000]
TABLE 1
Viability of P. aeruginosa
Viability after 3 cycles of
30″ sonication +
Samples
Initial viability
30″ vortexing
1
4.28 × 10 4 CFU/ml
2.12 × 10 4 CFU/ml
2
4.28 × 10 4 CFU/ml
4.28 × 10 4 CFU/ml
[0069] Test results show that 3 cycles of sonication and vortexing do not affect the viability of P. aeruginosa in tap water.
Test 2: Biofilm/Microbial Growth Removal Test:
Polypropylene Plaques
[0070] In order to determine the biofilm/microbial growth removal efficiency of the chemical compositions of the present invention, polypropylene disks (1.5 cm in diameter; also referred to herein as “plaques”) were used to simulate polypropylene wash tubs. The plaques were inoculated with 10 8 cells/ml of P. aeruginosa and allowed to grow a biofilm by incubating for eight weeks at ambient temperature and 180 rpm. After eight weeks, loosely adhered cells were removed from the plaques by lightly dipping the plaques in sterile water. The plaques were then placed in glass vials with 100 mM sodium/potassium phosphate buffer. The vials were then subjected to the following removal protocols:
[0071] A. Control (No Vortexing or Sonication, Just Rinse)
[0072] B. 3 cycles of 30 sec sonication followed by 30 sec vortexing.
[0073] The plaques were removed from the glass vials, and the number of cells recovered in the solution (i.e. removed from the plaques) was determined. The plaques were also stained with crystal violet to aid in determining removal efficacy. Staining of the plaque (i.e. positive result) indicates that the biofilm is still present on the plaque. No staining of the plaque (i.e. a negative result) indicates that the biofilm has been removed from the plaque. Test results are provided in Table 2 below.
[0000]
TABLE 2
Biofilm Removal Efficacy of P. aeruginosa
From Polypropylene Plaques
Removal Protocol
Crystal Violet Stain
A
Positive
B
Negative
[0074] The results indicate that 3 cycles of sonication and vortexing appear to be sufficient to remove the eight week biofilm present on the polypropylene plaques.
Test 3: Biofilm/Microbial Growth Removal Test:
[0075] Inventive Granular Compositions vs. Comparative Cleaning Compositions
[0076] Eight week old biofilms were grown on polypropylene disks (1.5 cm diameter) inoculated with a biofilm mixture recovered from a washing machine. The disks were treated with several inventive and comparative cleaning compositions to determine their ability to remove biofilm from the plaques and reduce odor. For sample preparation, 0.1 grams of each of Formulas 1 and 2 and Shout Oxy Power (“Comparative Example 1”) were independently added to 15 milliliters of water. Also, 0.53 ml of bleach was added to 15 ml liters of water (“Comparative Example 2”). The biofilms were treated with the cleaning composition for 15 minutes at 56° C. and 180 rpm. Crystal violet staining was used to determine whether the biofilm was removed from each plaque. Odor reduction was also evaluated. The results are provided in Table 3 below.
[0000]
TABLE 3
Biofilm Removal Efficacy of
Inventive Granular Compositions versus
Comparative Cleaning Compositions
Sample
Crystal Violet Stain
Odor Reduction
Tap Water
Positive
No odor reduction
Formula 1
Negative
Good odor reduction
Formula 2
Negative
Slight odor reduction
Comparative
Negative
Good odor reduction
Example 1
Comparative
Positive
Strong chlorine odor
Example 2
Test 4: Biofilm/Microbial Growth Removal Test:
[0077] Granular Inventive Compositions vs. Comparative Compositons—Effect of Temperature
[0078] Nine week old biofilms were grown on polypropylene disks (1.5 cm diameter) inoculated with a biofilm mixture recovered from a washing machine as described previously. The disks were treated with several inventive and comparative cleaning compositions to determine their ability to remove biofilm from the plaques and reduce odor. For sample preparation, 0.1 grams of each of Formulas 1 and 2 and Shout Oxy Clean (“Comparative Example 1”) and “Ultra-Kleen™ CW502” (“Comparative Example 3”) were independently added to 15 milliliters of water. Comparative Example 2 was prepared by adding 0.53 grams of bleach to 15 milliliters of water. A liquid cleaning composition, Washer Magic (“Comparative Example 4”), was also tested with 0.709 mL of the composition added to 15 milliliters of water.
[0079] The biofilms were treated with the cleaning composition for 15 minutes and 180 rpm at both 22° C. (i.e. room temperature) and at 56° C. Crystal violet staining was used to determine whether the biofilm was removed from each disk. Odor reduction was also evaluated.
[0080] After the treatment at 22° C., the odor reduction appeared to be good and fairly uniform among the samples. After the treatment at 56° C., the odor reduction was best for Comparative Example 1, followed by Comparative Example 3 and then Formula 1 and Formula 2. Again, Comparative Example 2 replaced the foul odor with a strong chlorine odor. Comparative Example 4 provided only a slight odor reduction.
[0081] With regard to biofilm removal, the samples were rated from best removal to least removal as follows:
[0082] Comparative Example 1 (56° C.)>Comparative Example 1 (22° C.)=Comparative Example 2 (56° C. and 22° C.)=Formula 1 (22° C. and 56° C.)>Formula 2 (22° C. and 56° C.)=Comparative Example 4 (56° C.)=Comparative Example 3 (56° C.)>Comparative Example 4 (22° C.)=Comparative Example 3 (22° C.).
Test 5: Biofilm/Microbial Growth Removal Test:
Inventive Granular Cleaning Compositions—Effect of Antifoaming Agent
[0083] Two week old biofilms were grown on polypropylene disks (1.5 cm in diameter) inoculated with biofilm mixture recovered from a washing machine as described previously. The disks were then treated with several inventive granular cleaning compositions to determine the effect of an antifoaming agent on their ability to remove biofilm from the plaques. For sample preparation, 0.1 grams of each of Formula 3 (no antifoaming agent) and Formula 4 (with antifoaming agent) were independently added to 15 milliliters of water.
[0084] The biofilms were treated with the cleaning composition for 15 minutes at 22° C. (i.e. room temperature) and 180 rpm. Crystal violet staining was used to determine whether the biofilm was removed from each plaque.
[0085] Both Formula 3 and Formula 4 removed biofilm from the plaques; however, Formula 4 performed better at removing the biofilm than Formula 3. Thus, the addition of an antifoaming agent to the formulations did not appear to have a detrimental effect on the biofilm removal capabilities of the formulations.
Test 6: Biofilm/Microbial Growth Removal Test:
[0086] Inventive Granular Formulation vs. Inventive Solid Tablet—Effect of Citric Acid
[0087] Three week old biofilms were grown on polypropylene disks (1.5 cm in diameter) inoculated with biofilm mixture recovered from a washing machine as described previously. The disks were then treated with several inventive powder formulations and solid tablet formulations to determine their ability to remove biofilm from the plaques. For sample preparation, 0.1 gram of Formula 1 (granular) and Formula 5 (tablet form containing citric acid) were independently added to 15 milliliters of water.
[0088] The biofilms were treated with the cleaning composition for 15 minutes at 22° C. (i.e. room temperature) and 180 rpm. Crystal violet staining was used to determine whether the biofilm was removed from each plaque.
[0089] After the treatment at 22° C., both Formula 1 and Formula 5 effectively removed the biofilm. The addition of citric acid to the formulation did not appear to have a detrimental effect on the ability of the formulation to remove biofilm.
Test 7: Biofilm/Microbial Growth Removal Test:
[0090] Inventive Granular Formulation vs. Inventive Solid Tablet—Effect of Polyalkylene Glycol
[0091] Two week old biofilms were grown on polypropylene disks (1.5 cm in diameter) inoculated with biofilm mixture recovered from a washing machine as described previously. The disks were then treated with several inventive and comparative cleaning compositions to determine their ability to remove biofilm from the plaques. Table 4 describes the samples that were prepared and tested.
[0000]
TABLE 4
Granular and Solid Inventive Formulations
versus Comparative Cleaning Compositions
Sample Description
Concentration in Water
Formula 4
0.4%
(granular form)
Formula 5
0.4%
(solid tablet)
Formula 6
0.4%
(solid tablet)
Comparative Example 1
0.4%
(Shout Oxy Power)
Comparative Example 5
0.4%
(Purewasher)
Comparative Example 5
0.8%
(Purewasher)
Tap water
control
[0092] For test preparation, samples were added to a sufficient amount of water to create a solution containing either 0.4% or 0.8% of each cleaning composition.
[0093] The biofilms were treated with the cleaning composition for 15 minutes at 25° C. and 180 rpm. Crystal violet staining was used to determine whether the biofilm was removed from each plaque.
[0094] After the treatment at 22° C., all of the solid samples were able to remove the two week old biofilm, except for Comparative Example 5. This was achieved even for those samples which were present at 0.4% concentration. The performance at removing biofilm is ranked as follows from best removal to least removal: Formula 5>Formula 4=Formula 6>Comparative Example 1>tap water control>Comparative Example 5 (0.8%)>Comparative Example 5 (0.4%).
[0095] The incorporation of citric acid or polyethylene glycol did not appear to affect the biofilm removal efficacy of the solid cleaning compositions. The replacement of citric acid with polyethylene glycol did not appear to have a substantial effect on the performance of the solid cleaning tablet.
Test 8: Biofilm/Microbial Growth Removal Test:
Inventive Solid Tablet—Effect of Ethoxylated Alcohol
[0096] Two week old biofilms were grown on polypropylene disks (1.5 cm in diameter) inoculated with biofilm mixture recovered from a washing machine as described previously. The disks were then treated with several inventive solid tablet cleaning compositions to determine their ability to remove biofilm from the plaques. For sample preparation, Formula 6 and Formula 7 (0.4%; no antifoaming agent “Y-30” or ethoxylated alcohol “DG”) were independently added to 15 milliliters of water to obtain a final concentration of 0.4%.
[0097] The biofilms were treated with the cleaning composition for 15 minutes at 25° C. and 180 rpm. Crystal violet staining was used to determine whether the biofilm was removed from each plaque.
[0098] After the treatment at 25° C., both formulations effectively removed the biofilm from the plaques. The presence of the antifoaming agent or ethoxylated alcohol did not appear to have a detrimental effect on the efficacy of these formulations.
Test 9: Biofilm/Microbial Growth Removal Over Scale Test:
Solid Inventive Tablet and Various Disk Substrates
[0099] Scale formation was added to various disk substrates via incubation in the presence of sodium carbonate, calcium hydroxide, stearic acid, sodium hydroxide and calcium chloride.
[0100] Two week old biofilms were then grown on these disks (1.5 cm in diameter) inoculated with biofilm mixture recovered from a washing machine as described previously. The disk substrates include polypropylene, polystyrene, aluminum and stainless steel. The biofilms were then treated with Formula 5 solid tablet cleaning composition or with tap water (“Control”) to determine the ability of the cleaning composition to remove biofilm from the disks, as compared to that of tap water. For sample preparation, Formula 5 was added to a sufficient amount of water to yield a final concentration of Formula 5 in water of 0.2%.
[0101] The biofilms were treated with the cleaning composition of Formula 5 for 15 minutes at 25° C. and 180 rpm. Loose cells were removed by rinsing the biofilm plaques in three cycles of 30 second sonication and 30 seconds of vortexing. Microbial counts were measured and compared with the control disks (disks treated only with tap water). Cells were dislodged in 10 mL of solution; thus, cells/disk is calculated by multiplying cells/mL by 10. Test results are graphically illustrated in FIG. 1 .
[0102] FIG. 1 demonstrates that, unlike the Control samples, the Formula 5 solid cleaning tablet is effective at removing the biofilm from the disks (1-3 log reduction) on various disk substrates both with and without scale. However, the biofilm removal of polypropylene and aluminum appeared to be slightly better in the absence of scale. There was no difference between the Control sample and Formula 5 with scale for the aluminum substrate.
[0103] Thus, the above description and examples show that the inventive solid cleaning composition is efficacious at removing both scale and biofilm from various surfaces under worse case field scenarios with respect to the extent of biofilm buildup and the usage of low water temperature, and thus it is an effective product for both the prevention of biofilm formation and the renewal of appliances currently in use. As has been described herein, the solid cleaning composition possesses a significant advantage over current products, in that it does not have a deleterious effect on the appliance components, the clothing articles and tableware that may be washed therein, or the septic/sewer systems accepting waste from the cleaning process. Additionally, the composition has been designed to work with the machine cycle conditions (time, temperature, water volume, etc.) and to reduce or eliminate both the biological and the abiotic buildup.
[0104] These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the scope of the invention described in the appended claims.
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This invention relates to solid cleaning compositions and the method for using the solid compositions to clean appliances and other soiled surfaces. The solid cleaning composition is generally comprised of a majority by weight of a cleaning active system; ingredients for forming the cleaning active system into a solid form; and optionally, a fragrance. The solid cleaning composition is ideally suited for reducing and/or eliminating microbial growth, including biofilm growth, contained within and/or on appliances, particularly those appliances that have water contact surfaces such as washing machines and dishwashers. The solid cleaning composition further provides reduction and/or elimination of undesirable odor and staining typically associated with such microbial growth.
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RELATED APPLICATIONS AND INCORPORATION BY REFERENCE
[0001] This application claims priority to U.S. provisional patent application Ser. No. 61/475,933 filed Apr. 15, 2011. Reference is made to international patent application Serial No. PCT/US2009/046783 filed 9 Jun. 2009, which published as PCT Publication No. WO 2009/152176 on 17 Dec. 2009, Serial No. PCT/US2010/044964 filed 10 Aug. 2010, which published as PCT Publication No. WO 2011/019686 on 17 Feb. 2011, Serial No. PCT/US2010/044964 filed 10 Aug. 2010 and Serial No. PCT/US12/31104 filed 29 Mar. 2012.
[0002] The foregoing applications, and all documents cited therein or during their prosecution (“application cited documents”) and all documents cited or referenced in the application cited documents, and all documents cited or referenced herein (“herein cited documents”), and all documents cited or referenced in herein cited documents, together with any manufacturer's instructions, descriptions, product specifications, and product sheets for any products mentioned herein or in any document incorporated by reference herein, are hereby incorporated herein by reference, and may be employed in the practice of the invention. More specifically, all referenced documents are incorporated by reference to the same extent as if each individual document was specifically and individually indicated to be incorporated by reference.
FIELD OF THE INVENTION
[0003] The invention relates to a recovery and/or purification process of hydrophobins involving organic solvents and does not require separation techniques.
BACKGROUND OF THE INVENTION
[0004] Hydrophobins are small proteins of about 100 to 150 amino acids which occur in filamentous fungi, for example Schizophyllum commune . They usually have 8 cysteine units. Hydrophobins can be isolated from natural sources, but can also be obtained by means of genetic engineering methods (see, e.g., WO 2006/082251 and WO 2006/131564).
[0005] Hydrophobins are spread in a water-insoluble form on the surface of various fungal structures, such as e.g. aerial hyphae, spores, fruiting bodies. The genes for hydrophobins could be isolated from ascomycetes, deuteromycetes and basidiomycetes. Some fungi have more than one hydrophobin gene, e.g. Schizophyllum commune, Coprinus cinereus, Aspergillus nidulans . Different hydrophobins are evidently involved in different stages of fungal development. The hydrophobins here are presumably responsible for different functions (van Wetter et al., 2000, Mol. Microbiol., 36, 201-210; Kershaw et al. 1998, Fungal Genet. Biol, 1998, 23, 18-33).
[0006] Hydrophobins identified to date are generally classed as either class I or class II. Both types have been identified in fungi as secreted proteins that self-assemble at interfaces into amphipathic films. Assemblages of class I hydrophobins are generally relatively insoluble whereas those of class II hydrophobins readily dissolve in a variety of solvents.
[0007] As biological function for hydrophobins, besides the reduction in the surface tension of water for the generation of aerial hyphae, the hydrophobicization of spores is also described (Wosten et al. 1999, Curr. Biol., 19, 1985-88; Bell et al. 1992, Genes Dev., 6, 2382-2394). Furthermore, hydrophobins serve to line gas channels in fruiting bodies of lichen and as components in the recognition system of plant surfaces by fungal pathogens (Lugones et al. 1999, Mycol. Res., 103, 635-640; Hamer & Talbot 1998, Curr. Opinion Microbiol., volume 1, 693-697).
[0008] Previously, hydrophobins were prepared only with moderate yield and purity using customary time-consuming protein-chemical purification (such as column purification and HPLC) and isolation methods (such as crystallization). Attempts of providing larger amounts of hydrophobins with the aid of genetic methods have also not been successful.
[0009] There is a need in the art for more effective method for faster and more economical methods for purifying large quantities of hydrophobin.
[0010] Citation or identification of any document in this application is not an admission that such document is available as prior art to the present invention.
SUMMARY OF THE INVENTION
[0011] The present invention relates to a use or a method for purifying a biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, which may comprise adding a precipitation agent, preferably an organic modifier, more preferably an alcohol, most preferably a C1-C3 alcohol, to a biosurfactant solution to generate a first precipitate, decanting a supernatant from the precipitation agent/biosurfactant solution and adding a same or different precipitation agent to the supernatant, to generate a second precipitate, wherein the second precipitate may be a purified biosurfactant, advantageously a purified hydrophobin, more advantageously purified hydrophobin II. The precipitation agent to generate the first precipitate may be the same or different precipitation agent to generate a second precipitate.
[0012] Preferably, the present invention relates to a use or a method for purifying hydrophobin II which may comprise adding a C1-C3 alcohol to a hydrophobin solution to generate a first precipitate, decanting a supernatant from the C1-C3 alcohol/hydrophobin solution and adding a C1-C3 alcohol to the supernatant, to generate a second precipitate, wherein the second precipitate may be purified hydrophobin II. The alcohol to generate the first precipitate may be the same or different alcohol to generate a second precipitate.
[0013] The invention, is based in part, on Applicant's surprising finding that pure class II hydrophobin can be purified by isopropanol precipitation from a crude concentrate.
[0014] In a first embodiment, the alcohol may be isopropanol. In an advantageous embodiment, about two to three volumes, preferably two to three volumes, more preferably two and a half volumes, of isopropanol may be added to generate the first precipitate. In another advantageous embodiment, about one volume, preferably one volume, of isopropanol may be added to the supernatant to generate the second precipitate.
[0015] In a second embodiment, the alcohol may be methanol. In an advantageous embodiment, about one to two volumes, preferably one to two volumes, more preferably one and a half volumes, of methanol may be added to generate the first precipitate. In another advantageous embodiment, about one volume, preferably one volume, of methanol may be added to the supernatant to generate the second precipitate.
[0016] In a third embodiment, the alcohol may be ethanol. In an advantageous embodiment, about one to two volumes, preferably one to two volumes, more preferably one and a half volumes, of ethanol may be added to generate the first precipitate. In another advantageous embodiment, about one volume, preferably one volume, of ethanol may be added to the supernatant to generate the second precipitate.
[0017] In the above embodiments, the first precipitate may be a brown precipitate and/or the second precipitate may be a white precipitate.
[0018] In a particularly advantageous embodiment, the use or method may be carried out at room temperature. Furthermore, the precipitation agent, preferably an organic modifier, more preferably an alcohol, most preferably a C1-C3 alcohol, may be recycled or reused for purifying a biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II.
[0019] The biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, purified by the above use or method may be lyophilized. In particular, the purity of the purified biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, may be assayed by SDS-PAGE, HPLC, mass spectrometry or amino acid analysis.
[0020] Accordingly, it is an object of the invention to not encompass within the invention any previously known product, process of making the product, or method of using the product such that Applicants reserve the right and hereby disclose a disclaimer of any previously known product, process, or method. It is further noted that the invention does not intend to encompass within the scope of the invention any product, process, or making of the product or method of using the product, which does not meet the written description and enablement requirements of the USPTO (35 U.S.C. §112, first paragraph) or the EPO (Article 83 of the EPC), such that Applicants reserve the right and hereby disclose a disclaimer of any previously described product, process of making the product, or method of using the product.
[0021] It is noted that in this disclosure and particularly in the claims and/or paragraphs, terms such as “comprises”, “comprised”, “comprising” and the like can have the meaning attributed to it in U.S. patent law; e.g., they can mean “includes”, “included”, “including”, and the like; and that terms such as “consisting essentially of” and “consists essentially of” have the meaning ascribed to them in U.S. patent law, e.g., they allow for elements not explicitly recited, but exclude elements that are found in the prior art or that affect a basic or novel characteristic of the invention.
[0022] These and other embodiments are disclosed or are obvious from and encompassed by, the following Detailed Description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The following detailed description, given by way of example, but not intended to limit the invention solely to the specific embodiments described, may best be understood in conjunction with the accompanying drawings.
[0024] FIG. 1 depicts purified HFBII analyzed by SDS-PAGE by diluting the samples in buffer as indicated (10 mM Tris-HCl, pH 8.0, 0.01% Tween-80) and mixing 2:1 with LDS Sample buffer containing 1× Reducing agent (Invitrogen). The samples were incubated at 90° C. for 5 min and 15 μL were loaded into each well of an SDS-PAGE gel (12%, 1 mM Bis-Tris, 10 lane, Invitrogen). The gel was run at 200 V for 35 min in 1×MES buffer (Invitrogen), stained using Coomassie Brilliant Blue, and destained (10% ethanol, 10% acetic acid). The resulting gel image shows a clear band for HFBII in the purified HFBII and no trace of the non-hydrophobin bands visible in the unpurified concentrate (1/100).
[0025] FIG. 2 depicts a RP-HPLC of a 1 mg/g solution of HFBII was prepared by diluting the sample in 10% acetonitrile. HFBII was separated by a reverse-phase HPLC system (Agilent) on a C5 column (Supelco Discovery C5, 300 Å, 5 μm, 2.1×100 mm) using a gradient of sodium phosphate buffer (“A”, 25 mM, pH 2.5) and acetonitrile (“B”, 0.05% TFA). The HFBII solution was injected (20 μL) onto the column (60° C.) and eluted by ramping from 10% solvent B to 70% B over 6 min at 0.8 mL/min. The system was returned to 10% B and equilibrated for 2 min before the next injection. HFBII was monitored by absorbance at 222 nm. HFBII elutes from the column at 4.38 min as one large peak and a small shoulder corresponding to the N-terminal phenylalanine truncation. No other peaks are observed in the chromatogram.
[0026] FIG. 3 depicts a mass spectrometry of purified HFBII (0.5 μL) that was spotted onto a stainless steel MALDI plate (Applied Biosystems), mixed with 0.5 μL of a saturated sinapinic acid solution (50% acetonitrile) and dried. The sample was analyzed by MALDI-TOF MS (Voyager, Applied Biosystems), acquiring in the positive mode between 4,000 and 20,000 m/z. The resulting spectrum shows a dominant peak at 7189.8 m/z, which corresponds to the mass of HFBII (calculated m+1=7189.4 m/z). The other peaks can be attributed to a known N-terminal phenylalanine truncation (m+1=7040.49 m/z) and the gas-phase HFBII dimer (14380 m/z).
DETAILED DESCRIPTION OF THE INVENTION
[0027] As used herein, a “biosurfactant” or a “biologically produced surfactant” may be a protein, a glycolipid, a lipopeptide, a lipoprotein, a phospholipid, a neutral lipid or a fatty acid, and may decrease surface tension, such as the interfacial tension between water and a hydrophobic liquid, or between water and air, and that may be produced or obtained from a biological system. Biosurfactants include hydrophobins. Biosurfactants include lipopeptides and lipoproteins such as surfactin, peptide-lipid, serrawettin, viscosin, subtilisin, gramicidins, polymyxins. Biosurfactants include glycolipids such as rhamnolipids, sophorolipids, trehalolipids and cellobiolipids. Biosurfactants include polymers such as emulsan, biodispersan, mannan-lipid-protein, liposan, carbohydrate-protein-lipid, protein PA. Biosurfactants include particulates such as vesicles, fimbriae, and whole cells. Biosurfactants include glycosides such as saponins. Biosurfactants include fibrous proteins such as fibroin. The biosurfactant may occur naturally or it may be a mutagenized or genetically engineered variant not found in nature. This includes biosurfactant variants that have been engineered for lower solubility to help control foaming by lowering the biosurfactant solubility according to this invention. Biosurfactants include, but are not limited to, related biosurfactants, derivative biosurfactants, variant biosurfactants and homologous biosurfactants as described herein.
[0028] As used herein, a “biological system” comprises or is derived from a living organism such as a microbe, a plant, a fungus, an insect, a vertebrate or a life form created by synthetic biology. The living organism can be a variant not found in nature that is obtained by classical breeding, clone selection, mutagenesis and similar methods to create genetic diversity, or it can be a genetically engineered organism obtained by recombinant DNA technology. The living organism can be used in its entirety or it can be the source of components such as organ culture, plant cultivars, suspension cell cultures, adhering cell cultures or cell free preparations.
[0029] The biological system may or may not contain living cells when it sequesters the biosurfactant. The biological system may be found and collected from natural sources, it may be farmed, cultivated or it may be grown under industrial conditions. The biological system may synthesize the biosurfactant from precursors or nutrients supplied or it may enrich the biosurfactant from its environment.
[0030] As used herein, “production” relates to manufacturing methods for the production of chemicals and biological products, which includes, but is not limited to, harvest, collection, compaction, exsanguination, maceration, homogenization, mashing, brewing, fermentation, recovery, solid liquid separation, cell separation, centrifugation, filtration (such as vacuum filtration), formulation, storage or transportation.
[0031] As used herein, a “fermentation broth composition” refers to cell growth medium that contains a protein of interest, such as hydrophobin. The cell growth medium may include cells and/or cell debris, and may be concentrated. An exemplary fermentation broth composition is hydrophobin-containing, ultrafiltration-concentrated fermentation broth. Microfiltration is conventionally used to retain cell debris and pass proteins, e.g., for cell separation, while ultrafiltration is conventionally used to retain proteins and pass solutes, e.g., for concentration.
[0032] As used herein, the terms “polypeptide” and “protein” are used interchangeably to refer to polymers of any length comprising amino acid residues linked by peptide bonds. The conventional one-letter or three-letter code for amino acid residues is used herein. The polymer may be linear or branched, it may comprise modified amino acids, and it may be interrupted by non-amino acids. The terms also encompass an amino acid polymer that has been modified naturally or by intervention; for example, disulfide bond formation, glycosylation, lipidation, acetylation, phosphorylation, or any other manipulation or modification, such as conjugation with a labeling component. Also included within the definition are, for example, polypeptides containing one or more analogs of an amino acid (including, for example, unnatural amino acids, etc.), as well as other modifications known in the art.
[0033] As used herein, a “culture solution” is a liquid comprising a biosurfactant and other soluble or insoluble components from which the biosurfactant of interest is intended to be recovered. Such components include other proteins, non-proteinaceous impurities such as cells or cell debris, nucleic acids, polysaccharides, lipids, chemicals such as antifoam, flocculants, salts, sugars, vitamins, growth factors, precipitants, and the like. A “culture solution” may also be referred to as “protein solution,” “liquid media,” “diafiltered broth,” “clarified broth,” “concentrate,” “conditioned medium,” “fermentation broth,” “lysed broth,” “lysate,” “cell broth,” or simply “broth.” The cells, if present, may be bacterial, fungal, plant, animal, human, insect, synthetic, etc.
[0034] As used herein, the term “recovery” refers to a process in which a liquid culture comprising a biosurfactant and one or more undesirable components is subjected to processes to separate the biosurfactant from at least some of the undesirable components, such as cells and cell debris, other proteins, amino acids, polysaccharides, sugars, polyols, inorganic or organic salts, acids and bases, and particulate materials.
[0035] As used herein, a “biosurfactant product” refers to a biosurfactant preparation suitable for providing to an end user, such as a customer. Biosurfactant products may include cells, cell debris, medium components, formulation excipients such as buffers, salts, preservative, reducing agents, sugars, polyols, surfactants, and the like, that are added or retained in order to prolong the functional shelf-life or facilitate the end use application of the biosurfactant. A biosurfactant product may also be purified.
[0036] As used herein, functionally and/or structurally similar biosurfactants are considered to be “related biosurfactants.” Such biosurfactants may be derived from organisms of different genera and/or species, or even different classes of organisms (e.g., bacteria and fungus). Related biosurfactants also encompass homologs determined by primary sequence analysis, determined by tertiary structure analysis, or determined by immunological cross-reactivity.
[0037] As used herein, the term “derivative biosurfactant” refers to a protein-based biosurfactant which is derived from a biosurfactant by addition of one or more amino acids to either or both the N- and C-terminal end(s), substitution of one or more amino acids at one or a number of different sites in the amino acid sequence, and/or deletion of one or more amino acids at either or both ends of the protein or at one or more sites in the amino acid sequence, and/or insertion of one or more amino acids at one or more sites in the amino acid sequence. The preparation of a biosurfactant derivative may be achieved by modifying a DNA sequence which encodes for the native protein, transformation of that DNA sequence into a suitable host, and expression of the modified DNA sequence to form the derivative protein. A “derivative biosurfactant” may also encompass biosurfactant derivatives where either lipid or carbohydrate moieties have been attached to protein backbone either during or after synthesis.
[0038] Related (and derivative) biosurfactants include “variant biosurfactant.” Variant protein-based biosurfactants differ from a reference/parent biosurfactant, e.g., a wild-type biosurfactant, by substitutions, deletions, and/or insertions at one or more amino acid residues. The number of differing amino acid residues may be one or more, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 30, 40, 50, or more amino acid residues. Variant biosurfactants share at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 91%, at least about 92%, at least about 93%, at least about 94%, at least about 95%, at least about 96%, at least about 97%, at least about 98%, or even at least about 99%, or more, amino acid sequence identity with a wildtype biosurfactant. A variant biosurfactant may also differ from a reference biosurfactant in selected motifs, domains, epitopes, conserved regions, and the like.
[0039] As used herein, “chimera” or “chimeric” refers to a single composition, advantageously a polypeptide, possessing multiple components, which may be from different organisms. As used herein, “chimeric” is used to refer to tandemly arranged moieties, including a biosurfactant or a variant biosurfactant thereof, that is engineered to result in a fusion protein possessing regions corresponding to the functions or activities of the individual protein moieties.
One Embodiment
[0040] As used herein, the term “analogous sequence” refers to a sequence within a protein-based biosurfactant that provides similar function, tertiary structure, and/or conserved residues as the biosurfactant. For example, in epitope regions that contain an alpha-helix or a beta-sheet structure, the replacement amino acids in the analogous sequence preferably maintain the same specific structure. The term also refers to nucleotide sequences, as well as amino acid sequences. In some embodiments, analogous sequences are developed such that the replacement amino acids result in a variant enzyme showing a similar or improved function. In some embodiments, the tertiary structure and/or conserved residues of the amino acids in the biosurfactant are located at or near the segment or fragment of interest. Thus, where the segment or fragment of interest contains, for example, an alpha-helix or a beta-sheet structure, the replacement amino acids preferably maintain that specific structure.
[0041] As used herein, the term “homologous biosurfactant” refers to a biosurfactant that has similar activity and/or structure to a reference biosurfactant. It is not intended that homologs necessarily be evolutionarily related. Thus, it is intended that the term encompass the same, similar, or corresponding biosurfactant(s) (i.e., in terms of structure and function) obtained from different organisms. In some embodiments, it is desirable to identify a homolog that has a quaternary, tertiary and/or primary structure similar to the reference biosurfactant.
[0042] The degree of homology between sequences may be determined using any suitable method known in the art (see, e.g., Smith and Waterman (1981) Adv. Appl. Math. 2:482; Needleman and Wunsch (1970) J. Mol. Biol., 48:443; Pearson and Lipman (1988) Proc. Natl. Acad. Sci. USA 85:2444; programs such as GAP, BESTFIT, FASTA, and TFASTA in the Wisconsin Genetics Software Package (Genetics Computer Group, Madison, Wis.); and Devereux et al. (1984) Nucleic Acids Res. 12:387-395).
[0043] For example, PILEUP is a useful program to determine sequence homology levels. PILEUP creates a multiple sequence alignment from a group of related sequences using progressive, pair-wise alignments. It can also plot a tree showing the clustering relationships used to create the alignment. PILEUP uses a simplification of the progressive alignment method of Feng and Doolittle, (Feng and Doolittle (1987) J. Mol. Evol. 35:351-360). The method is similar to that described by Higgins and Sharp (Higgins and Sharp (1989) CABIOS 5:151-153). Useful PILEUP parameters including a default gap weight of 3.00, a default gap length weight of 0.10, and weighted end gaps. Another example of a useful algorithm is the BLAST algorithm, described by Altschul et al. (Altschul et al. (1990) J. Mol. Biol. 215:403-410; and Karlin et al. (1993) Proc. Natl. Acad. Sci. USA 90:5873-5787). One particularly useful BLAST program is the WU-BLAST-2 program (See, Altschul et al. (1996) Meth. Enzymol. 266:460-480). Parameters “W,” “T,” and “X” determine the sensitivity and speed of the alignment. The BLAST program uses as defaults a word-length (W) of 11, the BLOSUM62 scoring matrix (See, Henikoff and Henikoff (1989) Proc. Natl. Acad. Sci. USA 89:10915) alignments (B) of 50, expectation (E) of 10, M′5, N′-4, and a comparison of both strands. Advantageously, a BLAST program or a program running the BLAST algorithm is utilized to determine sequence homology or identity levels.
[0044] As used herein, the phrases “substantially similar” and “substantially identical,” in the context of at least two nucleic acids or polypeptides, typically means that a polynucleotide or polypeptide comprises a sequence that has at least about 70% identity, at least about 75% identity, at least about 80% identity, at least about 85% identity, at least about 90% identity, at least about 91% identity, at least about 92% identity, at least about 93% identity, at least about 94% identity, at least about 95% identity, at least about 96% identity, at least about 97% identity, at least about 98% identity, or even at least about 99% identity, or more, compared to the reference (i.e., wild-type) sequence. Sequence identity may be determined using known programs such as BLAST, ALIGN, and CLUSTAL using standard parameters. (See e.g., Altschul, et al. (1990) J. Mol. Biol. 215:403-410; Henikoff et al. (1989) Proc. Natl. Acad. Sci. USA 89:10915; Karin et al. (1993) Proc. Natl. Acad. Sci USA 90:5873; and Higgins et al. (1988) Gene 73:237-244). Software for performing BLAST analyses is publicly available through the National Center for Biotechnology Information. Also, databases may be searched using FASTA (Pearson et al. (1988) Proc. Natl. Acad. Sci. USA 85:2444-2448). Advantageously, a BLAST program or a program running the BLAST algorithm is utilized to determine sequence homology or identity levels. One indication that two polypeptides are substantially identical is that the first polypeptide is immunologically cross-reactive with the second polypeptide. Typically, polypeptides that differ by conservative amino acid substitutions are immunologically cross-reactive. Thus, a polypeptide is substantially identical to a second polypeptide, for example, where the two peptides differ only by a conservative substitution. Another indication that two nucleic acid sequences are substantially identical is that the two molecules hybridize to each other under stringent conditions (e.g., within a range of medium to high stringency).
[0045] As used herein, “wild-type” and “native” biosurfactants are those found in nature. The terms “wild-type sequence,” and “wild-type gene” are used interchangeably herein, to refer to a sequence that is native or naturally occurring in a host cell. In some embodiments, the wild-type sequence refers to a sequence of interest that is the starting point of a protein engineering project. The genes encoding the naturally-occurring protein may be obtained in accord with the general methods known to those skilled in the art. The methods generally comprise synthesizing labeled probes having putative sequences encoding regions of the biosurfactant, preparing genomic libraries from organisms expressing the protein, and screening the libraries for the gene of interest by hybridization to the probes. Positively hybridizing clones are then mapped and sequenced.
[0046] The methods of the present invention can be applied to the isolation of a biosurfactant from a culture solution. Advantageously, the biosurfactant is a soluble extracellular biosurfactant that is secreted by microorganisms.
[0047] A group of exemplary biosurfactants are the hydrophobins, a class of cysteine-rich polypeptides expressed by filamentous fungi. Hydrophobins are small (˜100 amino acids) polypeptides known for their ability to form a hydrophobic coating on the surface of objects, including cells and man-made materials. First discovered in Schizophyllum commune in 1991, hydrophobins have now been recognized in a number of filamentous fungi. Based on differences in hydropathy and other biophysical properties, hydrophobins are categorized as being class I or class II.
[0048] The expression of hydrophobin conventionally requires the addition of a large amount of one or more antifoaming agents (i.e., antifoam) during fermentation. Otherwise, the foam produced by hydrophobin polypeptides saturates breather filters, contaminates vents, causes pressure build-up, and reduces protein yield. As a result, crude concentrates of hydrophobin conventionally contain residual amounts of antifoam, as well as host cell contaminants, which are undesirable in a hydrophobin preparation, particularly when the hydrophobin is intended as a food additive.
[0049] Hydrophobin can reversibly exist in forms having an apparent molecular weight that is greater than its actual molecular weight, which make hydrophobin well suited for recovery using the present methods. Liquid or foam containing hydrophobin can be continuously or periodically harvested from a fermentor for protein recovery as described, or harvested in batch at the end of a fermentation operation.
[0050] As used herein, the term “hydrophobin” may refer to a polypeptide capable of self-assembly at a hydrophilic/hydrophobic interface, and having the general formula (I):
[0000] ( Y 1 ) n - B 1 -( X 1 ) a - B 2 -( X 2 ) b - B 3 -( X 3 ) c - B 4 -( X 4 ) d - B 5 -( X 5 ) e - B 6 -( X 6 ) f - B 7 -( X 7 ) g - B 8 -( Y 2 ) m (I)
[0000] wherein: m and n are independently 0 to 2000; B 1 , B 2 , B 3 , B 4 , B 5 , B 6 , B 7 and B 8 are each independently amino acids selected from Cys, Leu, Ala, Pro, Ser, Thr, Met or Gly, at least 6 of the residues B 1 through B 8 being Cys; X 1 , X 2 , X 3 , X 4 , X 5 , X 6 , X 7 , Y 1 and Y 2 independently represent any amino acid; a is 1 to 50; b is 0 to 5; c is 1 to 100; d is 1 to 100; e is 1 to 50; f is 0 to 5; and g is 1 to 100.
[0051] In some embodiments, the hydrophobin has a sequence of between 40 and 120 amino acids in the hydrophobin core. In some embodiments, the hydrophobin has a sequence of between 45 and 100 amino acids in the hydrophobin core. In some embodiments, the hydrophobin has a sequence of between 50 and 90, preferably 50 to 75, or 55 to 65 amino acids in the hydrophobin core. The term “the hydrophobin core” means the sequence beginning with the residue B 1 and terminating with the residue B 8 .
[0052] In the formula (I), at least 6, or at least 7, or all 8 of the residues B 1 through B 8 are Cys.
[0053] In the formula (I), in some embodiments m is suitably 0 to 500, or 0 to 200, or 0 to 100, or 0 to 20, or 0 to 10, or 0 to 5, or 0.
[0054] In the formula (I), in some embodiments n is suitably 0 to 500, or 0 to 200, or 0 to 100, or 0 to 20, or 0 to 10, or 0 to 3.
[0055] In the formula (I), in some embodiments, a is 3 to 25, or 5 to 15. In one embodiment, a is 5 to 9.
[0056] In the formula (I), in some embodiments, b is 0 to 2, or preferably 0.
[0057] In the formula (I), in some embodiments, c is 5 to 50, or 5 to 40. In some embodiments, c is 11 to 39.
[0058] In the formula (I), in some embodiments, d is 2 to 35, or 4 to 23. In some embodiments, d is 8 to 23.
[0059] In the formula (I), in some embodiments, e is 2 to 15, or 5 to 12. In some embodiments, e is 5 to 9.
[0060] In the formula (I), in some embodiments, f is 0 to 2, or 0.
[0061] In the formula (I), in some embodiments, g is 3 to 35, or 6 to 21. In one embodiment, g is 6 to 18.
[0062] In some embodiments, the hydrophobins used in the present invention may have the general formula (II):
[0000] ( Y 1 ) n - B 1 -( X 1 ) a - B 2 -( X 2 ) b - B 3 -( X 3 ) c - B 4 -( X 4 ) d - B 5 -( X 5 ) e - B 6 -( X 6 ) f - B 7 -( X 7 ) g - B 8 -( Y 2 ) m (II)
[0000] wherein: m and n are independently 0 to 20; B 1 , B 2 , B 3 , B 4 , B 5 , B 6 , B 7 and B 8 are each independently amino acids selected from Cys, Leu, Ala, Pro, Ser, Thr, Met or Gly, at least 7 of the residues B 1 through B 8 being Cys; a is 3 to 25; b is 0 to 2; c is 5 to 50; d is 2 to 35; e is 2 to 15; f is 0 to 2; and g is 3 to 35.
[0063] In the formula (II), at least 7, or all 8 of the residues B 1 through B 8 are Cys.
[0064] In some embodiments, the hydrophobins used in the present invention may have the general formula (III):
[0000] ( Y 1 ) n B 1 -( X 1 ) a - B 2 - B 3 -( X 3 ) c - B 4 -( X 4 ) d - B 5 -( X 5 ) e - B 6 - B 7 -( X 7 ) g - B 8 -( Y 2 ) m (III)
[0000] wherein: m and n are independently 0 to 20; B 1 , B 2 , B 3 , B 4 , B 5 , B 6 , B 7 and B 8 are each independently amino acids selected from Cys, Leu, Ala, Pro, Ser, Thr, Met or Gly, at least 7 of the residues B 1 through B 8 being Cys; a is 5 to 15; c is 5 to 40; d is 4 to 23; e is 5 to 12; and g is 6 to 21.
[0065] In the formula (III), at least 7, or 8 of the residues B 1 through B 8 are Cys.
[0066] In the formulae (I), (II) and (III), when 6 or 7 of the residues B 1 through B 8 are Cys, it is preferred that the residues B 3 through B 7 are Cys.
[0067] In the formulae (I), (II) and (III), when 7 of the residues B 1 through B 8 are Cys, in some embodiments: (a) B 1 and B 3 through B 8 are Cys and B 2 is other than Cys; (b) B 1 through B 7 are Cys and B 8 is other than Cys, (c) B 1 is other than Cys and B 2 through B 8 are Cys. When 7 of the residues B 1 through B 8 are Cys, it is preferred that the other residue is Ser, Pro or Leu. In some embodiments, B 1 and B 3 through B 8 are Cys and B 2 is Ser. In some embodiments, B 1 through B 7 are Cys and B 8 is Leu. In further embodiments, B 1 is Pro and B 2 through B 8 are Cys.
[0068] The cysteine residues of the hydrophobins used in the present invention may be present in reduced form or form disulfide (—S—S—) bridges with one another in any possible combination. In some embodiments, when all 8 of the residues B 1 through B 8 are Cys, disulfide bridges may be formed between one or more (preferably at least 2, more preferably at least 3, most preferably all 4) of the following pairs of cysteine residues: B 1 and B 6 ; B 2 and B 5 ; B 3 and B 4 ; B 7 and B 8 . In some embodiments, when all 8 of the residues B 1 through B 8 are Cys, disulfide bridges may be formed between one or more (at least 2, or at least 3, or all 4) of the following pairs of cysteine residues: B 1 and B 2 ; B 3 and B 4 ; B 5 and B 6 ; B 7 and B 8 .
[0069] Examples of specific hydrophobins useful in the present invention include those described and exemplified in the following publications: Linder et al., FEMS Microbiology Rev. 2005, 29, 877-896; Kubicek et al., BMC Evolutionary Biology, 2008, 8, 4; Sunde et al., Micron, 2008, 39, 773-784; Wessels, Adv. Micr. Physiol. 1997, 38, 1-45; Wösten, Annu. Rev. Microbiol. 2001, 55, 625-646; Hektor and Scholtmeijer, Curr. Opin. Biotech. 2005, 16, 434-439; Szilvay et al., Biochemistry, 2007, 46, 2345-2354; Kisko et al. Langmuir, 2009, 25, 1612-1619; Blijdenstein, Soft Matter, 2010, 6, 1799-1808; Wösten et al., EMBO J. 1994, 13, 5848-5854; Hakanpää et al., J. Biol. Chem., 2004, 279, 534-539; Wang et al.; Protein Sci., 2004, 13, 810-821; De Vocht et al., Biophys. J. 1998, 74, 2059-2068; Askolin et al., Biomacromolecules 2006, 7, 1295-1301; Cox et al.; Langmuir, 2007, 23, 7995-8002; Linder et al., Biomacromolecules 2001, 2, 511-517; Kallio et al. J. Biol. Chem., 2007, 282, 28733-28739; Scholtmeijer et al., Appl. Microbiol. Biotechnol., 2001, 56, 1-8; Lumsdon et al., Colloids & Surfaces B: Biointerfaces, 2005, 44, 172-178; Palomo et al., Biomacromolecules 2003, 4, 204-210; Kirkland and Keyhani, J. Ind. Microbiol. Biotechnol ., Jul. 17 2010 (e-publication); Stübner et al., Int. J. Food Microbiol., 30 Jun. 2010 (e-publication); Laaksonen et al. Langmuir, 2009, 25, 5185-5192; Kwan et al. J. Mol. Biol. 2008, 382, 708-720; Yu et al. Microbiology, 2008, 154, 1677-1685; Lahtinen et al. Protein Expr. Purif., 2008, 59, 18-24; Szilvay et al., FEBS Lett., 2007, 5811, 2721-2726; Hakanpää et al., Acta Crystallogr. D. Biol. Crystallogr. 2006, 62, 356-367; Scholtmeijer et al., Appl. Environ. Microbiol., 2002, 68, 1367-1373; Yang et al, BMC Bioinformatics, 2006, 7 Supp. 4, S16; WO 01/57066; WO 01/57528; WO 2006/082253; WO 2006/103225; WO 2006/103230; WO 2007/014897; WO 2007/087967; WO 2007/087968; WO 2007/030966; WO 2008/019965; WO 2008/107439; WO 2008/110456; WO 2008/116715; WO 2008/120310; WO 2009/050000; US 2006/0228484; and EP 2042156A; the contents of which are incorporated herein by reference.
[0070] The hydrophobin can be any class I or class II hydrophobin known in the art, for example, hydrophobin from an Agaricus spp. (e.g., Agaricus bisporus ), an Agrocybe spp. (e.g., Agrocybe aegerita ), an Ajellomyces spp., (e.g., Ajellomyces capsulatus, Ajellomyces dermatitidis ), an Aspergillus spp. (e.g., Aspergillus arvii, Aspergillus brevipes, Aspergillus clavatus, Aspergillus duricaulis, Aspergillus ellipticus, Aspergillus flavus, Aspergillus fumigatus, Aspergillus fumisynnematus, Aspergillus lentulus, Aspergillus niger, Aspergillus unilateralis, Aspergillus viridinutans ), a Beauveria spp. (e.g., Beauveria bassiana ), a Claviceps spp. (e.g., Claviceps fusiformis ), a Coccidioides spp., (e.g., Coccidioides posadasii ), a Cochliobolus spp. (e.g., Cochliobolus heterostrophus ), a Crinipellis spp. (e.g., Crinipellis perniciosa ), a Cryphonectria spp. (e.g., Cryphonectria parasitica ), a Davidiella spp. (e.g., Davidiella tassiana ), a Dictyonema spp. (e.g., Dictyonema glabratum ), an Emericella spp. (e.g., Emericella nidulans ), a Flammulina spp. (e.g., Flammulina velutipes ), a Fusarium spp. (e.g., Fusarium culmorum ), a Gibberella spp. (e.g., Gibberella moniliformis ), a Glomerella spp. (e.g., Glomerella graminicola ), a Grifola spp. (e.g., Grifola frondosa ), a Heterobasidion spp. (e.g., Heterobasidion annosum ), a Hypocrea spp. (e.g., Hypocrea jecorina, Hypocrea lixii, Hypocrea virens ), a Laccaria spp. (e.g., Laccaria bicolor ), a Lentinula spp. (e.g., Lentinula edodes ), a Magnaporthe spp. (e.g., Magnaporthe oryzae ), a Marasmius spp. (e.g., Marasmius cladophyllus ), a Moniliophthora spp. (e.g., Moniliophthora perniciosa ), a Neosartorya spp. (e.g., Neosartorya aureola, Neosartorya fennelliae, Neosartorya fischeri, Neosartorya glabra, Neosartorya hiratsukae, Neosartorya nishimurae, Neosartorya otanii, Neosartorya pseudofischeri, Neosartorya quadricincta, Neosartorya spathulata, Neosartorya spinosa, Neosartorya stramenia, Neosartorya udagawae ), a Neurospora spp. (e.g., Neurospora crassa, Neurospora discreta, Neurospora intermedia, Neurospora sitophila, Neurospora tetrasperma ), a Ophiostoma spp. (e.g., Ophiostoma novo - ulmi, Ophiostoma quercus ), a Paracoccidioides spp. (e.g., Paracoccidioides brasiliensis ), a Passalora spp. (e.g., Passalora fulva ), Paxillus filamentosus Paxillus involutus ), a Penicillium spp. (e.g., Penicillium camemberti, Penicillium chrysogenum, Penicillium marneffei ), a Phlebiopsis spp. (e.g., Phlebiopsis gigantea ), a Pisolithus (e.g., Pisolithus tinctorius ), a Pleurotus spp., (e.g., Pleurotus ostreatus ), a Podospora spp. (e.g., Podospora anserina ), a Postia spp. (e.g., Postia placenta ), a Pyrenophora spp. (e.g., Pyrenophora tritici - repentis ), a Schizophyllum spp. (e.g., Schizophyllum commune ), a Talaromyces spp. (e.g., Talaromyces stipitatus ), a Trichoderma spp. (e.g., Trichoderma asperellum, Trichoderma atroviride, Trichoderma viride, Trichoderma reesii [formerly Hypocrea jecorina ]), a Tricholoma spp. (e.g., Tricholoma terreum ), a Uncinocarpus spp. (e.g., Uncinocarpus reesii ), a Verticillium spp. (e.g., Verticillium dahliae ), a Xanthodactylon spp. (e.g., Xanthodactylon flammeum ), a Xanthoria spp. (e.g., Xanthoria calcicola, Xanthoria capensis, Xanthoria ectaneoides, Xanthoria flammea, Xanthoria karrooensis, Xanthoria ligulata, Xanthoria parietina, Xanthoria turbinata ), and the like. Hydrophobins are reviewed in, e.g., Sunde, M et al. (2008) Micron 39:773-84; Linder, M. et al. (2005) FEMS Microbiol Rev. 29:877-96; and Wösten, H. et al. (2001) Ann. Rev. Microbiol. 55:625-46.
[0071] In a particularly advantageous embodiment, the hydrophobin is from a Trichoderma spp. (e.g., Trichoderma asperellum, Trichoderma atroviride, Trichoderma viride, Trichoderma reesii [formerly Hypocrea jecorina ]), advantageously Trichoderma reseei.
[0072] In the art, as described herein, hydrophobins are divided into Classes I and II. It is known in the art that hydrophobins of Classes I and II can be distinguished on a number of grounds, including solubility. As described herein, hydrophobins self-assemble at an interface (e.g., a water/air interface) into amphipathic interfacial films. The assembled amphipathic films of Class I hydrophobins are generally re-solubilized only in strong acids (typically those having a pK a of lower than 4, such as formic acid or trifluoroacetic acid), whereas those of Class II are soluble in a wider range of solvents.
[0073] In some embodiments, the hydrophobin is a Class II hydrophobin. In some embodiments, the hydrophobin is a Class I hydrophobin.
[0074] In some embodiments, the term “Class II hydrophobin” includes a hydrophobin having the above-described self-assembly property at a water/air interface, the assembled amphipathic films being capable of redissolving to a concentration of at least 0.1% (w/w) in an aqueous ethanol solution (60% v/v) at room temperature. In some embodiments, the term “Class I hydrophobin” includes a hydrophobin having the above-described self-assembly property but which does not have this specified redissolution property.
[0075] In some embodiments, the term “Class II hydrophobin” includes a hydrophobin having the above-described self-assembly property at a water/air interface and the assembled amphipathic films being capable of redissolving to a concentration of at least 0.1% (w/w) in an aqueous sodium dodecyl sulfate solution (2% w/w) at room temperature. In some embodiments, the term “Class I hydrophobin” includes a hydrophobin having the above-described self-assembly property but which does not have this specified redissolution property.
[0076] Hydrophobins of Classes I and II may also be distinguished by the hydrophobicity/hydrophilicity of a number of regions of the hydrophobin protein.
[0077] In some embodiments, the term “Class II hydrophobin” includes a hydrophobin having the above-described self-assembly property and in which the region between the residues B 3 and B 4 , i.e. the moiety (X 3 ) c , is predominantly hydrophobic. In some embodiments, the term “Class I hydrophobin” includes a hydrophobin having the above-described self-assembly property but in which the region between the residues B 3 and B 4 , i.e. the group (X 3 ) c , is predominantly hydrophilic.
[0078] In some embodiments, the term “Class II hydrophobin” includes a hydrophobin having the above-described self-assembly property and in which the region between the residues B 7 and B 8 , i.e. the moiety (X 7 ) g , is predominantly hydrophobic. In some embodiments, the term “Class I hydrophobin” includes a hydrophobin having the above-described self-assembly property but in which the region between the residues B 7 and B 8 , i.e. the moiety (X 7 ) g , is predominantly hydrophilic.
[0079] In some embodiments, the term “Class II hydrophobin” includes a hydrophobin having the above-described self-assembly property and in which the region between the residues B 3 and B 4 , i.e. the moiety (X 3 ) c , is predominantly hydrophobic. In some embodiments, the term “Class I hydrophobin” includes a hydrophobin having the above-described self-assembly property but in which the region between the residues B 3 and B 4 , i.e. the group (X 3 ) c , is predominantly hydrophilic.
[0080] In some embodiments, the term “Class II hydrophobin” includes a hydrophobin having the above-described self-assembly property and in which the region between the residues B 7 and B 8 , i.e. the moiety (X 7 ) g , is predominantly hydrophobic. In some embodiments, the term “Class I hydrophobin” includes a hydrophobin having the above-described self-assembly property but in which the region between the residues B 7 and B 8 , i.e. the moiety (X 7 ) g , is predominantly hydrophilic.
[0081] The relative hydrophobicity/hydrophilicity of the various regions of the hydrophobin protein can be established by comparing the hydropathy pattern of the hydrophobin using the method set out in Kyte and Doolittle, J. Mol. Biol., 1982, 157, 105-132. A computer program can be used to progressively evaluate the hydrophilicity and hydrophobicity of a protein along its amino acid sequence. For this purpose, the method uses a hydropathy scale (based on a number of experimental observations derived from the literature) comparing the hydrophilic and hydrophobic properties of each of the 20 amino acid side-chains. The program uses a moving-segment approach that continuously determines the average hydropathy within a segment of predetermined length as it advances through the sequence. The consecutive scores are plotted from the amino to the carboxy terminus. At the same time, a midpoint line is printed that corresponds to the grand average of the hydropathy of the amino acid compositions found in most of the sequenced proteins. The method is further described for hydrophobins in Wessels, Adv. Microbial Physiol. 1997, 38, 1-45.
[0082] Class II hydrophobins may also be characterized by their conserved sequences.
[0083] In one embodiment, the Class II hydrophobins used in the present invention may have the general formula (IV):
[0000] ( Y 1 ) n - B 1 -( X 1 ) a - B 2 - B 3 -( X 3 ) c - B 4 -( X 4 ) d - B 5 -( X 5 ) e - B 6 - B 7 -( X 7 ) g - B 8 -( Y 2 ) m (IV)
[0000] wherein: m and n are independently 0 to 200; B 1 , B 2 , B 3 , B 4 , B 5 , B 6 , B 7 and B 8 are each independently amino acids selected from Cys, Leu, Ala, Ser, Thr, Met or Gly, at least 6 of the residues B 1 through B 8 being Cys; a is 6 to 12; c is 8 to 16; d is 2 to 20; e is 4 to 12; and g is 5 to 15.
[0084] In the formula (IV), in some embodiments, a is 7 to 11.
[0085] In the formula (IV), in some embodiments, c is 10 to 12. In some embodiments, c is 11.
[0086] In the formula (IV), in some embodiments, d is 4 to 18. In some embodiments, d is 4 to 16.
[0087] In the formula (IV), in some embodiments, e is 6 to 10. In some embodiments, e is 9 or 10.
[0088] In the formula (IV), in some embodiments, g is 6 to 12. In some embodiments, g is 7 to 10.
[0089] In some embodiments, the Class II hydrophobins used in the present invention may have the general formula (V):
[0000] ( Y 1 ) n - B 1 -( X 1 ) a - B 2 - B 3 -( X 3 ) c - B 4 -( X 4 ) d - B 5 -( X 5 ) e - B 6 - B 7 -( X 7 ) g - B 8 -( Y 2 ) m (V)
[0000] wherein: m and n are independently 0 to 10; B 1 , B 2 , B 3 , B 4 , B 5 , B 6 , B 7 and B 8 are each independently amino acids selected from Cys, Leu or Ser, at least 7 of the residues B 1 through B 8 being Cys; a is 7 to 11; c is 11; d is 4 to 18; e is 6 to 10; and g is 7 to 10.
[0090] In the formulae (IV) and (V), in some embodiments, at least 7 of the residues B 1 through B 8 are Cys, or all 8 of the residues B 1 through B 8 are Cys.
[0091] In the formulae (IV) and (V), in some embodiments, when 7 of the residues B 1 through B 8 are Cys, it is preferred that the residues B 3 through B 7 are Cys.
[0092] In the formulae (IV) and (V), in some embodiments, when 7 of the residues B 1 through B 8 are Cys, it is preferred that: (a) B 1 and B 3 through B 8 are Cys and B 2 is other than Cys; (b) B 1 through B 7 are Cys and B 8 is other than Cys, or (c) B 1 is other than Cys and B 2 through B 8 are Cys. In some embodiments, when 7 of the residues B 1 through B 8 are Cys, it is preferred that the other residue is Ser, Pro or Leu. In some embodiments, B 1 and B 3 through B 8 are Cys and B 2 is Ser. In some embodiments, B 1 through B 7 are Cys and B 8 is Leu. In some embodiments, B 1 is Pro and B 2 through B 8 are Cys.
[0093] In the formulae (IV) and (V), in some embodiments, the group (X 3 ) c comprises the sequence motif ZZXZ, wherein Z is an aliphatic amino acid; and X is any amino acid. The term “aliphatic amino acid” means an amino acid selected from the group consisting of glycine (G), alanine (A), leucine (L), isoleucine (I), valine (V) and proline (P).
[0094] In some embodiments, the group (X 3 ) c comprises the sequence motif selected from the group consisting of LLXV, ILXV, ILXL, VLXL and VLXV. In some embodiments, the group (X 3 ) c comprises the sequence motif VLXV.
[0095] In the formulae (IV) and (V), in some embodiments, the group (X 3 ) c comprises the sequence motif ZZXZZXZ, wherein Z is an aliphatic amino acid; and X is any amino acid. In some embodiments, the group (X 3 ) c comprises the sequence motif VLZVZXL, wherein Z is an aliphatic amino acid; and X is any amino acid.
[0096] Applicants have observed that hydrophobin II produced by other methods can result in one or more amino acids clipped at the C terminus. The methods of the present invention will precipitate both full length hydrophobin II and hydrophobin II clipped at the C terminus.
[0097] Hydrophobin-like proteins (e.g.“chaplins”) have also been identified in filamentous bacteria, such as Actinomycete and Streptomyces sp. (WO01/74864; Talbot, 2003, Curr. Biol, 13: R696-R698). These bacterial proteins by contrast to fungal hydrophobins, may form only up to one disulfide bridge since they may have only two cysteine residues. Such proteins are an example of functional equivalents to hydrophobins, and another type of molecule within the ambit of biosurfactants of methods herein.
[0098] Fermentation to produce the biosurfactant is carried out by culturing the host cell or microorganism in a liquid fermentation medium within a bioreactor or fermenter. The composition of the medium (e.g. nutrients, carbon source etc.), temperature and pH are chosen to provide appropriate conditions for growth of the culture and/or production of the biosurfactant. Air or oxygen-enriched air is normally sparged into the medium to provide oxygen for respiration of the culture.
[0099] As used herein, a “fermentation broth composition” refers to cell growth medium that contains a protein of interest, such as hydrophobin. The cell growth medium may include cells and/or cell debris, and may be concentrated. An exemplary fermentation broth composition is hydrophobin-containing, ultrafiltration-concentrated fermentation broth. Microfiltration is conventionally used to retain cell debris and pass proteins, e.g., for cell separation, while ultrafiltration is conventionally used to retain proteins and pass solutes, e.g., for concentration.
[0100] Advantageously, a cross-flow membrane filtration recovery method may allow for a preparation of a hydrophobin concentration as described in PCT Patent Publication WO 2011/019686 which is incorporated by reference. In other embodiments, size exclusion filtration and crystallization may also allow for a preparation of a hydrophobin concentration.
[0101] The invention encompasses a method for purifying a biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, which may comprise adding a precipitation agent to a biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, solution to generate a first precipitate, decanting a supernatant from the precipitation agent/biosurfactant solution and adding the same or different precipitation agent to the supernatant, to generate a second precipitate, wherein the second precipitate may be purified biosurfactant, advantageously a purified hydrophobin, more advantageously purified hydrophobin II. Examples of suitable precipitation agents include, but are not limited to, inorganic salts, organic modifiers, and combinations thereof. The precipitation agent to generate the first precipitate may be the same or different than the precipitation agent to generate the second precipitate. Any combination of suitable precipitation agents may be contemplated by the present invention.
[0102] As used herein, organic modifiers are organic solvents that are miscible in water. One of skill in the art may ascertain as to whether a particular organic modifier is miscible in water using knowledge and/or methods known to those of ordinary skill in the chemical art. For example, the absence of a biphasic mixture when a particular organic modifier is added to water indicates that it is miscible in water. The presence of a biphasic mixture when a particular organic modifier is added to water indicates that it is immiscible in water. Examples of suitable organic modifiers include, but are not limited to, acetonitrile, acetone, alcohols, dimethyl formamide (DMF), dimethyl sulfoxide (DMSO), dioxane, and tetrahydrofuran (THF).
[0103] Advantageously, the precipitation agent is an alcohol, more advantageously a C1-C4 alcohol, most advantageously a C1-C3 alcohol. Alcohols may be monohydric or polyhydric. Examples of C1-C4 alcohols include, but are not limited to, methanol, ethanol, 1-propanol, 2-propanol (isopropanol or isopropyl alcohol), t-butanol, and the like. Examples of C1-C3 alcohols include, but are not limited to, methanol, ethanol, 1-propanol, and 2-propanol (isopropanol or isopropyl alcohol). Advantageously the alcohol is methanol, ethanol or isopropyl alcohol.
[0104] Without being bound by theory, the amount of precipitation agent, preferably an alcohol, more preferably a C1-C4 alcohol, most preferably a C1-C3 alcohol, added would primarily precipitate proteins in the first precipitate. After decanting the supernatant from the precipitation agent/biosurfactant solution and adding the same or different precipitation agent, preferably an alcohol, more preferably a C1-C4 alcohol, most preferably a C1-C3 alcohol, to the supernatant may generate a biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II in a second precipitate.
[0105] A biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II may be precipitated with isopropyl alcohol or isopropanol. About two to three volumes of isopropanol, advantageously about two and a half volumes of isopropanol, may be added to one volume of biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, solution in water to generate a first precipitate, which advantageously may be a brown precipitate. The supernatant may be decanted and a biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, may be precipitated as a second precipitate, which advantageously may be a white precipitate, by adding about one volume of isopropanol.
[0106] Advantageously, the isopropanol is added. Two to three volumes of isopropanol, advantageously two and a half volumes of isopropanol, may be added to one volume of biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, solution in water. The initial precipitate may form after about 15 minutes in a stirred solution, although one of skill in the art may ascertain the formation of an initial precipitate (which may be a brown precipitate). The second precipitation of biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, form after about 10 minutes in a stirred solution, although one of skill in the art may ascertain the formation of a second precipitate, which advantageously may be a white precipitate.
[0107] A biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, may be precipitated with methanol. About one to two volumes of methanol, advantageously about one and a half volumes of methanol, may be added to one volume of biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, solution in water to generate a first precipitate, which advantageously may be a brown precipitate. The supernatant may be decanted and a biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, may be precipitated as a second precipitate, which advantageously may be a white precipitate, by adding about three volumes of methanol.
[0108] Advantageously, the methanol is added at room temperature. One to two volumes of methanol, advantageously one and a half volumes of methanol, may be added to one volume of a biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, solution in water. The initial precipitate may form after about 15 minutes in a stirred solution, although one of skill in the art may ascertain the formation of an initial precipitate, which advantageously may be a brown precipitate. The second precipitation of biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II forms after about 10 minutes in a stirred solution, although one of skill in the art may ascertain the formation of a second precipitate, which advantageously may be a white precipitate.
[0109] A biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, may be precipitated with ethanol. About one to two volumes of ethanol, advantageously about one and a half volumes of ethanol, may be added to one volume of a biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, solution in water to generate a first precipitate, which advantageously may be a brown precipitate. The supernatant may be decanted and biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, may be precipitated as a second precipitate, which advantageously may be a white precipitate, by adding about three volumes of ethanol.
[0110] Advantageously, the ethanol is added at room temperature. One to two volumes of ethanol, advantageously one and a half volumes of ethanol, may be added to one volume of a biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, solution in water. The initial precipitate may form after about 15 minutes in a stirred solution, although one of skill in the art may ascertain the formation of an initial precipitate, which advantageously may be a brown precipitate. The second precipitation of biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, form after about 10 minutes in a stirred solution, although one of skill in the art may ascertain the formation of a second precipitate, which advantageously may be a white precipitate.
[0111] One of skill in the art may ascertain as to whether a particular a precipitation agent, preferably an organic modifier, more preferably an alcohol, as well as determine specific volumes of the particular precipitation agent by determining if an initial precipitate is present and further by determining if a biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, precipitates from the supernatant, as determined by the presence of a second precipitate. Advantageously, the initial or first precipitate is brown and the second precipitate is white. Such observations are within the purview of a skilled artisan.
[0112] A particularly advantageous embodiment of the present invention is that the precipitation agent, preferably an organic modifier, more preferably an alcohol, may be reused or recycled, thereby reducing waste. In other words, the precipitation agent, preferably an organic modifier, more preferably an alcohol, used to precipitate the biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, may be reused or recycled for additional precipitation of the biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II.
[0113] The precipitation may be harvested by centrifugation and lyophilized, which may result in a fine powder. In an advantageous embodiment, the powder is white. The powder may be dissolved in a solvent (such as water, a water/alcohol mix, a water/organic mix (such as water/acetonitrile), an organic solvent, such as DMSO or DMF) and may be frozen.
[0114] The purity of the biosurfactant, advantageously a hydrophobin, more advantageously hydrophobin II, may be assessed by any method known in the art, such as, but not limited to, SDS-PAGE, HPLC, mass spectrometry and amino acid analysis. For example, FIGS. 1-3 and Table 1 are illustrative of the purity of hydrophobin II as isolated by the herein disclosed methods.
[0115] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined in the appended claims.
[0116] The present invention will be further illustrated in the following Example which is given for illustration purposes only and are not intended to limit the invention in any way.
Example
Isopropanol Precipitation of Hydrophobin II
[0117] Unpurified hydrophobin concentrate (200 mL, 150 mg/g) was added to a 1 L glass beaker and slowly mixed with 500 mL (2.5 volumes) isopropanol. The solution was stirred at room temperature for 15 min, resulting in the formation of a brown precipitate. The mixture was centrifuged (5 min, 10,000 rpm, Sorvall Untracentrifuge, SLA-1500 rotor) and the HFBII-containing supernatant was decanted into a clean 1 L glass beaker. Isopropanol (1 volume) was added to the supernatant and stirred for 10 min at room temperature, resulting in fine white precipitate. This precipitate was harvested by centrifugation (10 min, 10,000 rpm), transferred to a 1200 mL lyophilization jar and lyophilized for 62 hours, resulting in a fine white powder. The powder was dissolved in 100 mL deionized water and frozen.
[0118] Dry Solids Analysis.
[0119] The solids content of 1 g of purified HFBII was analyzed by microwave drying (Omnimark μWave Moisture Analyzer), resulting in 7.33% dry solids.
[0120] SDS-PAGE.
[0121] As shown in FIG. 1 , purified HFBII was analyzed SDS-PAGE by diluting the samples in buffer as indicated (10 mM Tris-HCl, pH 8.0, 0.01% Tween-80) and mixing 2:1 with LDS Sample buffer containing 1× Reducing agent (Invitrogen). The samples were incubated at 90° C. for 5 min and 15 μL were loaded into each well of an SDS-PAGE gel (12%, 1 mM Bis-Tris, 10 lane, Invitrogen). The gel was run at 200 V for 35 min in 1×MES buffer (Invitrogen), stained using Coomassie Brilliant Blue, and destained (10% ethanol, 10% acetic acid). The resulting gel image shows a clear band for HFBII in the purified sample and no trace of the non-hydrophobin bands visible in the unpurified concentrate (1/100).
[0122] RP-HPLC.
[0123] As shown in FIG. 2 ., a 1 mg/g solution of HFBII was prepared by diluting the sample in 10% acetonitrile. HFBII was separated by a reverse-phase HPLC system (Agilent) on a C5 column (Supelco Discovery C5, 300 Å, 5 μm, 2.1×100 mm) using a gradient of sodium phosphate buffer (“A”, 25 mM, pH 2.5) and acetonitrile (“B”, 0.05% TFA). The HFBII solution was injected (20 μL) onto the column (60° C.) and eluted by ramping from 10% solvent B to 70% B over 6 min at 0.8 mL/min. The system was returned to 10% B and equilibrated for 2 min before the next injection. HFBII was monitored by absorbance at 222 nm. HFBII elutes from the column at 4.38 min as one large peak and a small shoulder corresponding to the N-terminal phenylalanine truncation. No other peaks are observed in the chromatogram.
[0124] Mass Spectrometry.
[0125] As shown in FIG. 3 ., Purified HFBII (0.5 μL) was spotted onto a stainless steel MALDI plate (Applied Biosystems), mixed with 0.5 μL of a saturated sinapinic acid solution (50% acetonitrile) and dried. The sample was analyzed by MALDI-TOF MS (Voyager, Applied Biosystems), acquiring in the positive mode between 4,000 and 20,000 m/z. The resulting spectrum shows a dominant peak at 7189.8 m/z, which corresponds to the mass of HFBII (calculated m+1=7189.4 m/z). The other peaks can be attributed to a known N-terminal phenylalanine truncation (m+1=7040.49 m/z) and the gas-phase HFBII dimer (14380 m/z).
[0126] Amino Acid Analysis.
[0127] Purified HFBII (1 mL) was analyzed for Amino Acid Analysis in duplicate by an outside laboratory (AAA Services, Inc.). As shown in Table 1, the results indicate that HFBII is present at 63.2 mg/g and is the dominant protein in solution as indicated by the similarity between the calculated and observed amino acid composition.
[0000]
TABLE 1
Amino
known
pMole
EXP
Int.
Acid
Comp
Anal
Comp
Comp
uMoles/ml
CYSO2
0
0
0.00
0
0.0000
HYP (Z)
0
0
0.00
0
0.0000
ASP (D)
6
2695
6.14
6
13.4775
THR (T)
6
2569
6.14
6
12.8453
SER (S)
3
1213
3.04
3
6.0667
GLU (E)
3
1425
3.24
3
7.1239
PRO (P)
5
2145
4.88
5
10.7257
GLY (G)
5
2276
5.18
5
11.3791
ALA (A)
10
4355
9.91
10
21.7754
VAL (V)
6
2664
6.06
6
13.3181
MET (M)
0
0
0.00
0
0.0000
ILE (I)
4
1720
3.92
4
8.6007
LEU (L)
7
3132
7.13
7
15.6609
NLE
0
0
0.00
0
0.0000
TYR (Y)
0
0
0.00
0
0.0000
PHE (F)
3
1278
2.91
3
6.3908
HIS (H)
1
452
1.03
1
2.2578
HLYS
0
0
0.00
0
0.0000
LYS (K)
4
1742
3.97
4
8.7123
ARG (R)
0
0
0.00
0
0.0000
Total AA's
63
Total pMole amino acid
27667
Calc. pMole protein 439
Total pMole hydrolyzed
1757
Conc pMol/ul
8786 uM
Total ugrams
12.6
Conc. mg/ml
63.2
[0128] Alcohol Precipitation Scan.
[0129] Alternative alcohols were assayed for their ability to selectively precipitate HFBII. Co-solvents were added to one volume HFBII concentrate, centrifuged at 14,000 rpm for 5 minutes and assessed for precipitation. Addition of one and two volumes of methanol resulted in a dark brown or light brown precipitate respectively. The supernatant of this solution was mixed with 3 more volumes of methanol (5 total), resulting in a large white precipitate exactly as observed with isopropanol. Similar results were observed with ethanol as the co-solvent. Glycerol was not able to precipitate any protein at a 4:1 ratio. Also, 1-butanol and 1-octanol did not precipitate any proteins and instead form a biphasic mixture. Thus, small-chain (C3 or less) alcohols are effective at selectively precipitating HFBII.
[0130] Having thus described in detail preferred embodiments of the present invention, it is to be understood that the invention defined by the above paragraphs is not to be limited to particular details set forth in the above description as many apparent variations thereof are possible without departing from the spirit or scope of the present invention.
|
The invention relates to a recovery and/or purification process of hydrophobins involving organic solvents and does not require separation techniques. In particular, the invention relates to a method for selective alcohol precipitation of hydrophobin II.
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This is a continuation of application Ser. No. 312,413,filed Dec. 5, 1972, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to the technique of prestressed concrete and more particularly concerns reinforcements and devices for effecting a pretension for the mass-production of prestressed concrete elements. It also relates to such elements and in particular railway sleepers or ties.
Many reinforcing and pretension devices are known of the type comprising: an outer tube constituting the reinforcement proper closed at one end and open at the other; an inner core received in the tube; and means for putting under tension disposed at the open end of the tube and co-operating with the open end and the adjacent end of the core for establishing and maintaining between the tube and core an axial force of given value. Such arrangements are described in French Pat. No. 1,288,878, the first Addition No. 78,223 to French Pat. No. 1,263,984 and the German Pat. No. 522,510.
The first of these references provides means for putting the tube under tension which either weaken the tube in that they require it to be screwthreaded at both ends or are relatively elaborate and do not lend themselves to a profitable production on an industrial scale.
The two other references relate to two structures which employ for the core a material such as sand, mortar or concrete whose use does not lend itself well to mass-production and which does not permit obtaining characteristics that are idential from one element to another.
SUMMARY OF THE INVENTION
An object of the present invention is to overcome these various drawbacks and to provide a reinforcing device whose manufacture and utilization lend themselves particularly well to industrial mass-production and whose performances are substantially improved so that the characteristics of the concrete element in which they are incorporated are also improved.
These results are obtained in a reinforcing device of the type comprising a rigid tube and support surfaces extending roughly radially from the outer surface of the tube, by providing end plates or flanges which define the support surfaces and are secured to the end of the tube, one of the plates defining also an end wall whereas the other is provided with a centre aperture and includes means for putting the reinforcement under tension.
Other important features of the device according to the invention are the following:
the end plates or flanges are friction welded to the ends of the tube;
the tube has a cross-sectional shape which varies along its longitudinal axis.
Another object of the invention is to provide a prestressed reinforced concrete element comprising a reinforcing device such as defined hereinbefore.
A particularly interesting application is in the mass-production of railway sleepers or ties of the composite type, that is, the type comprising two concrete blocks interconnected by a tie member which also acts as a reinforcement in the two blocks. The tie member is then constituted by aa reinforcement according to the invention. Preferably the tube then has, in the regions surrounded by concrete, a cross-sectional shape which is oblong, oval or elliptical, the major dimension of which is roughly horizontal whereas in the free region between the two blocks this section, which is also oblong, oval or elliptical, has its major dimension roughly vertical.
BRIEF DESCRIPTION OF THE DRAWINGS
In a general way, the invention and its advantages will be explained in more detail in the ensuing description with reference to the accompanying drawings, given solely by way of example and in which:
FIG. 1 is a longitudinal sectional view of a reinforcing device according to the invention;
FIG. 2 is a partial sectional view, to an enlarged scale, of one end of this device;
FIG. 3 is a view similar to FIG. 2 of a modification of the device;
FIG. 4 is a view similar to FIG. 2 of another modification of the device;
FIGS. 5 and 6 are respectively a longitudinal sectional view and an end elevational view of a concrete sleeper or tie including a reinforcing device according to the invention:
FIG. 7 is a partial sectional view of a composite sleeper or tie to which the device according to the invention is applied;
FIG. 8 is a diagrammatic longitudinal sectional view of another embodiment of a reinforcing device according to the invention;
FIGS. 9, 10 and 11 are sectional views, to an enlarged scale, respectively taken on lines 2--2, 3--3 and 4--4 of FIG. 1, and
FIG. 12 is a longitudinal sectional view of a composite sleeper or tie for a railway track including an improved reinforcement such as that shown in FIGS. 8-11.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a reinforcing device according to the invention comprising an outer rigid reinforcement unit constituted by a steel tube 1 to the ends of which are secured, for example by friction welding, two plates or flanges 2, 3. The plate 2 defines an unapertured end wall 2 a and a flange 2 b of larger diameter, and the plate 3, which has a diameter in the neighbourhood of the diameter of the flange 2 b , is provided in its centre part with an aperture 3 a which has roughly the same diameter as the inside diameter of the tube 1. A centre pressure transmitting core 4 is disposed inside the tube and may be tubular or solid and has one end abutting the end wall 2 a . Secured to the end plate 3 is a clamping plate 5 which may be moved toward the plate 3 by means of bolts 6 which are screwthreadedly engaged in tapped holes provided in the plate 3.
The active end of the device shown in FIG. 1, namely the end at which the plate 3 and the clamping plate 5 are disposed, is shown in detail in FIG. 2.
It will be understood that by tightening the bolts 6 in a progressive and uniform manner, the clamping plate 5 compresses the core 4 at the centre thereof, whereas the distance between the plates 3 and 5 increases under the effect of the elastic deformation under tension of the tube 1 and the corresponding elastic deformation under compression of the core 4. If d designates the extent to which the core 4 extends beyond the end plane of the plate 3 in the free state (FIG. 2), the distance d must be chosen in such manner that the correct tension of the tube 1 is obtained when the distance d is zero so that this stressing operation may be carried out by unskilled labour. Note that the clearance between the tube 1 and the core 4 is small enough to prevent the buckling or lateral deflection of the core which is subjected to high longitudinal compression, but it is sufficient to enable the core to slide freely inside the tube when it is inserted and subsequently withdrawn from the latter. When this prior tensioning of the tube 1 has been achieved, an assembly is available constituted by the element shown in FIG. 1 which is ready to be placed in position in a mould for the purpose of manufacturing an element of reinforced concrete as will be explained hereinafter in a particular application.
There will now be first described two modifications of the reinforcing device shown in FIG. 1. First, in FIG. 3 there is shown the active end of such a device constituted by the end portion of the tube 11 on which is friction welded a stamped-out plate 12 having radial ribs 13 adapted to improve the anchorage thereof in the concrete. This end plate comprises a tapped tubular portion 14 which receives a bolt 15 adapted to exert a compressive force on the centre core 16. The latter has at its end a tapped aperture 17, or an aperture of any suitable shape, to facilitate the extraction of the core when the bolt 15 has been removed. A washer 18 is also provided.
In the embodiment shown in FIG. 4, an outer rigid reinforcement unit comprises a tube 21 which has at one end a plate 22 constituting an end wall and provided with ribs 22 a , and at its other end a second plate 23 also provided with radial ribs 23 a . These two plates are welded to the tube 21 by friction. Received in the tube is a centre pressure transmitting core 24 having at the end thereof in the vicinity of the plate 23 an enlargement 25 which is screwthreaded and adapted to co-operate with the inner tapped portion of the plate 23. This core terminates in a head portion 26 similar to that of a bolt and a spacer collar 27 may be interposed between this head portion and the outer surface of this plate 23, for example to determine with precision the distance to which the core must be screwed into the tube to obtain the desired tensile force.
In these two embodiments, the tensioning of the tube may be achieved by screwing by means of a rotary hydraulic jack or shifting device, the tensile force being measured by the direct measurement of the tightening torque or of the extent to which the bolt is screwed into the end plate.
There will now be described with reference to FIGS. 5 and 6 an application of the invention to the construction of a beam of prestressed concrete such as a railway sleeper or tie. FIG. 5 shows a mould M in the shape of a trough in which is placed a prestressing reinforcing device such as that described with reference to FIGS. 1 and 2. The rigid reinforcement is disposed between the end walls p 1 , p 2 of the mould in which are formed cavities L for receiving the end plates 2 and 3. In referring to FIG. 6 it can be seen that the mould M is completed at both ends by detachable members A which ensure a seal above and around the plates 2 and 3 and contribute to the maintenance of the reinforcement in the mould during the consequent vibration stage. Means B may also be provided for facilitating the centering of the reinforcement in the mould. When the reinforcement is placed in position in the mould, the tube 1 is under tension by a prior tightening of the bolts 6. Spiral binding hoops or bands F of hard steel are moreover disposed around the tubular reinforcement to reinforce the concrete against outward radial forces which are exerted thereon when it undergoes the prestressing. With the reinforcement in position, the mould M is filled with concrete and then vibrated and compressed. Stripping from the mould may be carried out immediately so that an automatic moulding machine may be employed. When the concrete had reached sufficient strength after having stayed for a sufficiently long period in an oven and/or after storage to achieve a natural hardening, the bolts 6 may be unscrewed and the plate 5 removed so that the centre core 4 can be withdrawn from the tube. It will be understood that when the clamping plate 5 and the centre core are removed, the stressing of the tube is transferred to the mass of concrete partly by adherence and partly through the end plates so that the concrete beam is prestressed. It is then sufficient to close the aperture remaining open at one of the ends of the tube after optionally spraying with a protective produce and/or chemically reducing product to preclude internal corrosion of the reinforcement tube. By way of example, it may be mentioned that in the case of a concrete sleeper or tie intended to withstand a final prestressing of 30 metric tons, the reinforcement may be constituted by a tube having an outside diameter of 42 mm and a wall thickness of 3 mm.
Such a prestressing method meets much better than known methods the requirements of modern industrial organisation and mechanisation in particular for the following reasons: the reinforcement may be prepared in a specialized workshop, for example located at the very source of the tubes, which comprises essentially an automatic rotary friction welding machine employing a very modern method which, apart from its cheapness, has the advantage of being extremely rapid and of not impairing the mechanical characteristics of the steels, even if they have been previously heat treated;
the tensioning of the tube by reaction of the inner core is easily localized and easy to control automatically by measuring the force or elastic elongation of the tube;
the functions of support of the core and reception of the clamping means are performed by the end plates or flanges which also ensure the transmission to the concrete of the prestressing force;
as the tube does not have any screwthreading it is not weakened and may have the minimum required thickness for withstanding the estimated stresses in the contemplated application;
the concrete is easily moulded and stripped from the mould by an automatic moulding machine as though it concerned ordinary reinforced concrete;
the concrete may be prestressed merely at the moment when the beam is withdrawn from the stores for dispatch to the place of use, this prestressing merely consisting of releasing the connection between the tube and core with no measurement or control of the force so that no skilled labour is required;
it is unnecessary to stove the concrete and the moulded product may harden naturally in a storage ground during the required period of time, for example 28 days, which reduces the cost of the plants and improves the final qaulity of the concrete;
note in this respect that the material immobilized during the hardening period is of low value, since it is indeed essentially constituted by the reaction bars or cores and the bolts or like devices which may be used again in the following month.
FIG. 7 shows a part of a composite sleeper or tie constituted by two small concrete blocks interconnected by a tie member E. In this embodiment, the tie member is constituted by a tube 31 whose diameter may be of the order of 60 mm and have a wall thickness of 3.25 mm to possess the required strength, this tube acting in each of the two blocks as a prestressing reinforcement and being pretensioned and placed in position in accordance with the method according to the invention. Bearing in mind that the length of the tube in contact with the concrete is reduced in this case to the length of the block, ridges or other surface unevennesses are also provided on the outer surface of this tube to improve the adherence between the tube and the concrete. There may also be provided flanges, such as 32, which improve the transmission of the compressive forces exerted by the tie member-reinforcement on the concrete. Helical binding bands or hoops 33 are also provided to reinforce the concrete against outward radial forces which are produced when the concrete is prestressed.
FIG. 8 represents another embodiment of an assembly comprising a rigid reinforcement unit constituted by a tube 41 to which end plates 42, 43 are welded and means for placing this reinforcement in a pretensioned state. These means, which are identical to those provided in the embodiment shown in FIG. 3, comprise a centre pressure transmitting core 44, an internal screwthread 45 provided in the plate or flange 43 and a bolt 46 co-operating with the nut constituted by the plate 43.
In this embodiment, the tube 41 does not have the same section throughout its length. In the illustrated embodiment, it has three main portions or sections L 1 , L 2 , L 3 , interconnected by transition regions and having oval cross-sectional shapes which have their major axes oriented in different directions. Thus, the portion L 1 , L 3 have a cross section corresponding to that shown in FIG. 9 whose major axis is horizontal (in the position shown in the drawing), whereas in the portion L 2 the major axis is angularly offset by 90° and is therefore vertical (FIG. 10). In the vicinity of its free ends, the tube has in two portions L 4 , L 5 a circular cross-sectional shape (FIG. 11) so as to permit the friction welding by rotation of the plates 42, 43. In the non-circular sections the length of the minor axis is chosen to be slightly greater than the diameter of the core 44. The latter has a diameter slightly less than the nominal diameter of the tube and can thus easily pass through the bead 47 which is formed by the friction welding of the plates 42, 43 to the tube.
Preferably, the tube 41 is given the shape shown or some other suitable shape by subjecting it in the cold state to a press operation which exerts a pressure along two diametrally opposed generatrices. This deformation can be effected before or after the welding operation carried out on the plates 42, 43.
This embodiment has the following essential advantages:
possibility of modifying and improving the mechanical characteristics of the reinforcement in accordance with the particular contemplated application;
considerably increased adherence and anchoring in the concrete;
reduced overall size in one direction;
a guiding and a lateral maintenance of the centre core when putting the tube under tension.
These very important advantages will be more clear after the description of the application of such a reinforcement to a composite sleeper or tie for a railway track which is diagrammatically shown in FIG. 12. This sleeper comprises two small concrete blocks 51 each of which is adapted to support a rail and are connected by a tie member 52 constituted by a tube such as that shown in FIGS. 8-11. In the free part of the tube 53 between the two concrete blocks the tube has an oblong cross-sectional shape whose major axis or longer side is vertical. This portion of vertically deformed tube may extend if desired a certain distance inside the concrete blocks.
In each of the two regions 54 of the tubular reinforcement inside the blocks, the section of the tube is also oblong but the major axis or longer side extends horizontally. In the illustrated embodiments, these flattened regions have a length which is substantially less than that of the block 51. As in the embodiment shown in FIG. 7, the reinforcement tube is surrounded by at least one spiral hooping 55 of hard steel which completes the reinforcement of the block. However, such a hooping is not necessarily essential.
In this particular application, the very substantial advantages afforded by the device according to the invention are the following:
the moment of inertia and the section modulus of the tube with respect to the horizontal axis, characterizing the stiffness in the vertical plane, have been markedly increased by the oval shape which is very cheap to obtain since the operation is carried out in the cold state on the initially circular tube. This deformation thus permits taking advantage still further of the section of the metal of the tube and increasing the stiffness of the tube in the vertical plane which, in the case of the presently-described application, is advantageous for a composite sleeper in which the tube constitutes the tie member;
the change in the section of the tube which results in a very marked deformation in the vicinity of the entrance of each of the blocks 51 permits considerably increasing the adherence and anchorage of the tube in the concrete when the means for putting the tube under tension have been released to subject the concrete to the prestressing;
this anchoring region of the deformed tube in the concrete may be surrounded by a hard steel spiral reinforcement 55, since the deformation of the tube exert increased radially outward forces owing to the increase in the section and the wedge effect in the vicinity of the vertical plane, that is, upwardly and downwardly in the presently-described application;
the flattening of the tube in the region located under the rails inside the blocks 51 permits a reduction in the thickness of these blocks and an increase in their flexibility without having to reduce the thickness of the concrete extending over and under the reinforcement;
the additional anchoring afforded by the change in the section may be put to use to reduce the dimensions of the outer radial flange of the end anchoring plates;
the deformation of the tube by flattening in successively orthogonal directions afford the advantage of reducing the free length of the core for putting under tension which is inserted in the tube and is subjected to a compression which might cause it to buckle or bend at the moment when the tube is put under tension before placing it in the mould;
the deformations of the tube which are judiciously arranged and multiplied, if necessary, enable the rigid reaction core to be guided inside the tube so as to preclude its buckling or lateral deflection notwithstanding the small effective diameter of this core with respect to its total length between the end plates.
By way of a numerical example justifying the interest of this embodiment, a composite sleeper or tie may be constructed with a tubular tie member having an outside diameter of 60 mm and a wall thickness of 3.5 mm.
By deforming this tube in the manner described hereinbefore so as to impart thereto a small inner axis or a minimum section of passage of a little more than 40 mm instead of 53 mm corresponding to the undeformed circular section of the tube, the moment of inertia of the tie member in the centre part thereof uncovered with concrete is increased from 25 cm 4 corresponding to a circular tube to more than 33 cm 4 for the oval section. The deformation has increased therefore by more than 30 percent the stiffness of the tie member in the desired direction without modifying the weight of the tube.
Likewise, the flattening of the tube under the rails permits, in the presently-described application, a reduction in the thickness of nearly 13 mm while maintaining the same minimum inner sectional passage of 40 mm and with the same layer of concrete above and under the tube.
It is also possible to reduce from 53 to about 40 mm the diameter of the inner reaction core while reducing the risk of buckling or lateral deflection since this core, here guided in three regions, has a free extent considerably reduced with respect to EULER'S formulae for lateral deflection.
The presently-described embodiment of the invention therefore permits taking full advantage of a tubular reinforcement of circular section by deforming it in a judicious manner, so as to modulate the section in accordance with the characteristics to be obtained along the part with minimum weight and volume of high strength steel. The deformations of the cross section of the tube are also employed to increase the anchorage and possibly remedy any insufficient adherence of the concrete to the tube and to guide the inner reaction core inserted in the tube and preclude its buckling, if the part is long with respect to its section, at the moment of putting the tube under tension by compression of the core.
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The invention relates to the technique of prestressed concrete and concerns a reinforcing device comprising a cylindrical metal tube at the ends of which are friction welded two plates or flanges defining radial support surfaces for bearing on the concrete. One of these plates constitutes an end wall against which abuts a metal core for putting the tube under tension. The other plate, which has a centre aperture, comprises means such as screw threading which co-operates with a bolt for achieving said tensioning in an effective and easy manner. Preferably, the tube has a section which varies along its longitudinal axis so as to afford an improved guide for the core and improve the characteristics of the reinforcement. A particularly advantageous application is in the manufacture of composite railway ties.
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FIELD OF THE INVENTION
[0001] The present invention relates to a shield for a breast pump having a breast receiving member to receive the breast of a user. The invention also relates to a breast pump comprising the shield of the invention.
BACKGROUND OF THE INVENTION
[0002] Breast pumps are well known devices for extracting milk from a breast of a user. A breast pump may be used if the baby or infant is not itself able to extract milk from the breast, or if the mother is separated from the baby or infant and is to be fed with breast milk by someone else. Breast pumps typically comprise a rigid, funnel-shaped shield connected to a vacuum pump having a container for collecting the milk.
[0003] The shield of a breast pump is the interface between the user's breast and nipple with the pump and so its sizing is critical to maintaining the user's comfort whilst using the device. It is also important to ensure that the vacuum seal between the breast and the shield is maintained for optimal pumping. A problem with a conventional breast pump is that it has a shield of fixed size, so it can only cater for a limited range of breast and nipple sizes. However, if the shield is too small relative to the nipple, the nipple tends to fill the available space inside the shield and is likely to touch on the sides of the shield, resulting in chafing, friction and discomfort as negative pressure generated during use of the pump draws the nipple into the shield. On the contrary, if the shield is too large relative to the nipple, then there will be more dead space inside the shield which will reduce the efficiency of the pump system and limit the negative pressure achievable. It also introduces the possibility that the nipple will be pulled deeper into the pump and that the skin on areola or breast area surrounding the nipple will be subjected to chafing.
[0004] If the breast shield is not of the optimum size in relation to the size of the breast, there is a tendency for the user to apply greater pressure to the breast pump to urge the breast shield into closer contact with their breast. However, undue pressure on the breast can have a negative effect on the milk production and comfort for the mother. Excessive pressure may also cause the breast shield to block a milk duct resulting in further discomfort and inflammation of the breast tissue. Furthermore, as breast feeding is a delicate matter and is largely influenced by hormones, undue pressure on the breasts can have a negative impact on milk generation and lactation.
[0005] An ill-fitting breast shield can cause further problems for the user. Hormones, created by the body, trigger breast milk production and the creation of these hormones depends greatly on the comfort and confidence of the user. If the user perceives the breast shield to be uncomfortable, either visually or by feel, they may loose confidence and milk production may be impaired.
[0006] Research has shown that nipple diameter and length varies throughout the population and across different geographic regions and also that the size of the nipple can be different before, during and after expressing. Therefore, as fit is an important consideration when attempting to achieve maximum comfort for a user, a breast pump shield for a breast pump that is capable of accommodating a wide range of breast and nipple sizes is desirable. Furthermore, a breast will change shape and size during lactation. It would therefore be desirable to have the ability to adjust the breast shield during use, and without having to remove the shield from the breast, to ensure that the comfort and effectiveness does not deteriorate.
[0007] It is known to provide a breast pump body with a removable shield that may be replaced with another shield of a different size. However, removable shields are generally made from a hard plastic material and do not generally offer the user an enhanced level of comfort whilst using such a device. It is also necessary to store, and have readily accessible, the alternate breast shield, which is not always desirable or convenient. Changing a breast shield is also time consuming and means that the user has to remove their breast from the shield currently in use. As the shields are of finite sizes, they do not allow precise adjustment and it is necessary for a user to be satisfied with a breast shield which is closest in size or shape to that which is actually desired.
[0008] It is also known to provide a soft elastomer liner that may be disposed within a rigid shield of a breast pump and which is designed to adapt to the contour of the breast so as to provide comfort and a vacuum seal necessary for operating the pump. The resilience and compliance of such a liner helps to provide a vacuum and milk seal around the user's breast and also reduces friction on the breast and/or nipple when the negative pressure draws the breast and nipple in a direction into the pump. A cushion or insert may be formed from silicon or thermoplastic elastomer (TPE) which, in addition to providing an enhanced level of comfort, can also provide a warmer feeling to the breast.
[0009] Although a liner may improve the comfort for a user, a breast pump shield equipped with a liner still suffers from the problem that the liner will only accommodate a relatively small range of breast and/or nipple sizes resulting in a poor fit between the breast and/or the nipple with the insert for a relatively large number of breastfeeding women, causing discomfort and poor vacuum pressure generation.
[0010] The present invention seeks to overcome or substantially alleviate the aforementioned problems.
SUMMARY OF THE INVENTION
[0011] It is known, for example from EP 2,172,236 A1, to provide a shield for a breast pump comprising a body attachable to a breast pump, a resilient, flexible insert received in the body and configured to receive a user's breast, the insert being mountable to a body and an adjuster operable by a user to alter the shape of the insert, wherein the body has a narrow, inner end for attachment to a breast pump body and a wider, outer end through which a breast is inserted into the shield, a first end of the flexible insert being immovably mounted to the wider, outer end of the body with a second end of the insert extending through the body towards its inner end.
[0012] According to the present invention, there is provided a breast shield for a breast pump characterised in that the adjuster is configured to move the second end of the insert towards said wider, outer end of the body to axially compress, and thereby change the shape of, the insert. As the shape of the insert is adjustable, the user may adapt the insert to suit the shape of their breast and so have a more comfortable pumping experience.
[0013] Adjustment of the breast shield prevents the need for interchanging breast shields for different shapes and sizes of breast. This reduces the number of components that need to be sold with a breast pump making it easier to use and cheaper to produce.
[0014] The adjuster may comprise a collar received on the inner end of the body, said second end of the insert being in contact with said collar which is configured such that rotation relative to the body in one direction moves it axially towards said wider, outer end of the body to axially compress, and thereby change the shape of, the insert. This configuration provides an easy way for a user to simply and quickly adjust the shape of the insert to suit their requirements and provides a wide range of adjustment. Preferably, the collar is configured such that rotation relative to the body in the opposite direction moves it axially away from said wider, outer end of the body, the resilience of the insert causing it to expand in an axial direction and thereby change the shape of the insert. This enables the user to simply adjust the shape of the insert back to its original form, i.e. the user is quickly able to appreciate that the shape can be adjusted simply by turning the collar in opposite directions.
[0015] The collar may be threadingly received on the inner end of the body. This enables rotation of the collar by the user to be translated into axial movement of the second end of the insert towards, and away from, the first end of the insert.
[0016] Preferably, a thread is formed on an inner surface of the collar and at least one radially extending thread follower on the outside of the body, the follower cooperates with the thread to enable the collar to rotate relative to the body. The thread follower may simply be a post extending outwardly from the body which locates in a helically shaped groove in the collar.
[0017] In a preferred embodiment, the collar extends beyond the inner end of the body and comprises a radially inwardly extending shoulder, said second end of the insert being in contact with said shoulder. The second end of the insert is in contact with the collar, but is not attached to the body. This means that the second end of the insert will move axially within the body in response to rotation of the collar in either direction, thereby moving it towards, or away from, the fixed first end of the insert. This movement has the result of deforming or changing the shape of the insert.
[0018] Preferably, the body has a generally conical portion that narrows from its wider outer end in a direction towards its inner end and a substantially cylindrical portion that extends from said conical portion to said inner end, said insert also narrowing in the same direction and having a substantially cylindrical tubular section extending through the substantially cylindrical portion of the retaining element. The generally conical portion of the body supports the conical portion of the insert. Similarly, the cylindrical portion receives the collar and guides movement of the second end of the insert within the body.
[0019] The substantially cylindrical portion of the body may have openings therein. In which case, the tubular section of the insert may also have radially outwardly extending protrusions. The protrusions locate in said openings when the insert is received in the body. This prevents rotation of the insert relative to the body when adjustment is being carried out as a result of rotation of the collar.
[0020] Preferably, the generally conical portion of the body comprises a circular frame to which the first end of the insert is attached and a plurality of arms extending radially inwardly towards each other at an angle away from said frame, the substantially cylindrical portion comprising generally axially extending tips to the end of each arm, said openings being formed by spaces between said tips. As the body is formed from a frame, the amount of material used in its construction is reduced. It is also lighter and easier to clean.
[0021] The section of the insert that narrows from the wider, outer end of the body towards its tubular section may comprise a series of ribs in the wall of the insert, each rib being parallel to each other and to a plane extending across the wider outer end of the retaining element. This increases the flexibility of the insert, which can fold more easily between the ribs when its shape is being adjusted.
[0022] A flexible liner may be removably receivable in the insert. As the liner will form the material that makes direct contact with the breast tissue, it may further provide the user with an enhanced level of comfort and as it can be removed easily will also make the breast pump easier to clean.
[0023] According to the invention, there is also provided a pump body having a milk receiving inlet, including a shield according to the invention for attachment to said milk receiving inlet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0025] FIG. 1 shows an exploded view of a first embodiment of the breast shield according to the invention.
[0026] FIG. 2 a shows a side view of the embodiment described in FIG. 1 , the breast shield is adjusted to a first maximum position.
[0027] FIG. 2 b shows a side view of the embodiment described in FIG. 1 and FIG. 2 a , the breast shield is adjusted to a second maximum position.
[0028] FIG. 3 shows an example of a breast shield for background information only.
[0029] FIG. 4 shows a cross-sectional view of an example of a breast shield, for background information only showing two different states of adjustment.
DETAILED DESCRIPTION
[0030] Referring to the drawings, FIG. 1 shows a first embodiment of the adjustable breast shield 1 , comprising a rigid body 2 , a flexible insert 3 , an adjuster including an adjusting collar 4 and a removable liner 5 .
[0031] The rigid body 2 comprises a wider, outer end defined by a frame having a ring 6 and three arms 7 extending downwardly from the upper ring 6 at an angle towards the axis of the upper ring 6 to form a generally conical or funnel-like shape. The distal ends 8 of the arms 7 each have tips 9 that extend substantially axially to form a tubular-shaped portion with a smaller internal diameter than the upper ring 6 . The tips 9 terminate at a second, inner end of the body 2 which can be rigidly, and releasably, connected to a milk inlet of a breast pump body (not shown).
[0032] The adjustment collar 4 comprises an annular body 10 with an internal thread 11 and a radially inwardly extending internal lip or shoulder 12 at its lower end. The opposite end of the collar couples to the body 2 over the tips 9 and extends beyond the second, inner, end of the body 2 with the lip 12 extending radially inwardly across the second end of the body 2 and beyond an inner surface of each of the tips 9 .
[0033] The tips 9 of the body 2 comprise thread engagement protrusions or members 13 extending radially outwardly from their outer surface that engage with an internal thread 11 formed on an inner surface of the adjusting collar 4 so that, when the adjusting collar 4 is turned, the thread 11 and the thread engagement members 13 cooperate so that the collar 4 moves in an axial direction along the tips 9 of the body 2 , the direction of axial movement depending on the direction of rotation of the collar 4 relative to the body 2 .
[0034] Rotation of the collar 4 is limited, in one direction, as a result of the tips 9 coming into contact with the lip 12 on the adjusting collar 4 and, in the other direction, by an end of the threaded part 11 formed on the adjusting collar 4 .
[0035] The flexible insert 3 comprises a deformable cone 14 having a first end immovably and releasably coupled to the wider, outer end of the body 2 . The insert 3 extends through the body 2 towards its second end and narrows into a tubular section 15 . The deformable cone 14 may comprise a plurality of folds 24 that open and close to provide increased flexibility in the cone 14 . These folds may be formed between a series of circular ribs parallel to each other and to a plane extending across the wider, outer end of the body 2 .
[0036] When assembled, the first end of the insert 3 is attached to the outer end of the body 2 and the second end extends into the body 2 with the tubular section 15 of the flexible insert 3 being slideably received through, and guided by, the tubular portion 9 of the rigid body 2 , formed by the tips 9 . The second end of the insert 3 contacts the internal lip 12 of the adjusting collar 4 that protrudes radially inwardly beyond the inner surface of the tips 9 .
[0037] The tubular section 15 comprises a plurality of radially extending ribs 18 on its external face that each extend longitudinal to the axis of the tubular section 15 and are positioned so that they locate in the gaps between the tips 9 . The ribs 18 engage side edges 19 of the tips 9 and prevent rotation of the flexible insert 3 with respect to the rigid body 2 .
[0038] The arrangement is such that, as the adjustment collar 4 is turned in a first direction, the collar 4 moves axially towards the outer end of the body 2 . As the second end of the insert 3 is in contact with the collar 4 , via the lip 12 , the insert 3 is resiliently deformed under axial compression, i.e. the distance between its fixed first end, and its movable second end is reduced. This changes the shape of the deformable cone 14 of the insert 3 from a position, as shown in FIG. 2 a , in which it generally lies against and conforms to the shape of the body 2 , into the shape shown in FIG. 2 b , in which the conically shaped portion 14 has been substantially flattened.
[0039] Similarly, when the adjustment collar 4 is turned in the opposite direction, it moves axially towards the inner end of the body 2 . This increases the distance between the first and second ends of the insert 3 , releasing the insert 3 and allowing it to regain its original shape, as shown in FIG. 2 a.
[0040] The collar 4 may be a friction fit on the tips 9 of the body 2 , so that the insert 3 may be positioned at any location between the two extremes shown by FIGS. 2 a and 2 b , thereby enabling a user to select the most appropriate shape for the insert 3 to accommodate their breast size.
[0041] As the ribs 18 cooperate with the side edges of the tips 9 , rotation of the flexible insert 3 is prevented.
[0042] The removable liner 5 is made of a flexible material and is inserted into the insert 3 so as to cover the inner face of the flexible insert 3 . The liner 5 provides the direct interface to the breast and provides a removable part for cleaning purposes, although the entire shield may be also be disassembled for replacement of parts or for cleaning The liner 5 comprises a conical portion 20 and a cylindrical portion 21 and closely matches the interior form of the flexible insert 3 . The peripheral edge 22 of the liner 5 has a folded over lip 23 that is hooked over the edge 16 of the flexible insert 3 to fix the liner 5 and the outer edge 16 of the cone 14 of the flexible insert 3 to the upper ring 16 .
[0043] FIG. 3 shows an example of an adjustable breast shield which is described for background information only. The adjustable breast shield 30 comprising a flexible conical body portion 31 , a tubular portion 32 extending from the smaller end of the conical body 31 and an adjustable diameter collar 33 around the larger end of the conical body 31 .
[0044] The adjustable diameter collar 33 comprises an incomplete loop with ends 34 , 35 and a mechanism 36 to either pull together or push apart the ends 34 , 35 of the incomplete loop, so changing the diameter of the loop. As the diameter of the outer collar 33 is adjusted the shape of the conical body 31 will change in a radial direction. If the diameter is made larger then the cone becomes flatter, and vice versa. The limits of the screw mechanism 36 limit the amount of adjustment possible. The conical body 31 is made of an elastically deformable material and is at the smallest adjustment size when in its natural state, i.e. not under any force. The mechanism 36 can be adjusted to increase the diameter of the outer ring 33 and elastically stretch the conical body 31 until the required breast shield shape is achieved. The mechanism is finger operated and an adjustment knob can be turned by a user to change the size of the insert.
[0045] The breast shield 30 is attachable to a supporting body (not shown in FIG. 3 ).
[0046] FIG. 4 shows another example of an adjustable breast shield 40 which is described for background information. More specifically, it shows a sectional view of two halves at different stages of adjustment.
[0047] The adjustable breast shield of FIG. 4 comprises a flexible conical body 41 , a tubular portion 42 extending from the smaller end of the conical body 41 and an adjustable diameter ring 43 on the larger, outer edge of the conical body 41 . In this example the adjustable diameter ring comprises an inflatable tube 44 that is attached to, or integrally formed with, the larger edge of the conical body 41 . Means for inflating the tube 44 may be a hand, or small electric, air pump or the tube 44 may be inflated by a one-way mouth air valve. It is envisaged that a release valve is included to allow the tube 44 to be deflated when required.
[0048] The conical body 41 is made of an elastically deformable material. The right hand side of FIG. 4 shows the third example of the adjustable breast shield 40 with little or no inflation of the adjustable diameter ring 43 . In this state the conical body 41 is in its natural state with no elastic deformation. This is the smallest size of adjustment that can be achieved. The left hand side of the example of FIG. 4 shows the adjustable breast shield when the adjustable diameter ring 43 has been inflated, showing the increase in the size of the breast shield. The conical body 41 has been elastically enlarged.
[0049] Although FIG. 4 has been described with reference to an inflatable ring 43 that is integral with the conical body 41 , it will be appreciated that the inflatable element may be entirely separate from both the body and the insert and form a separate component that is received between the body and the insert and is inflated in order to change the shape of the insert.
[0050] The breast shield 40 is attachable to a supporting body (not shown in FIG. 4 ).
[0051] It will be appreciated that the term “comprising” does not exclude other elements or steps and that the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to an advantage. Any reference signs in the claims should not be construed as limiting the scope of the claims.
[0052] Although claims have been formulated in this application to particular combinations of features, it should be understood that the scope of the disclosure of the present invention also includes any novel features or any novel combinations of features disclosed herein either explicitly or implicitly or any generalisation thereof, whether or not it relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as does the parent invention. The applicants hereby give notice that new claims may be formulated to such features and/or combinations of features during the prosecution of the present application or of any further application derived therefrom.
[0053] Other modifications and variations falling within the scope of the claims hereinafter will be evident to those skilled in the art.
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A shield for a breast pump is disclosed. It comprises a resilient, flexible insert configured to receive a user's breast, and an adjuster operable by a user to alter the shape of the insert.
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BACKGROUND
1. Field of the Invention
This invention relates to innovative needles for facilitating the performance of peripheral nerve blocks and, more particularly, to a novel, atraumatic needle apparatus and method for reducing risks of injury and time associated with administering local anesthetic to a peripheral nerve.
2. Background
A peripheral nerve block is a well-established medical procedure that involves injecting a dose of local anesthetic near and around the nerve or nerve plexus that serves a surgical area. A peripheral nerve block is often used as part of a multimodal analgesia technique where the block is combined with additional medications and methods of medication delivery to target pain at several levels. Peripheral nerve blocks specifically target nociceptive impulses transmitted along peripheral nerves. Other analgesics, for example, nonsteroidal anti-inflammatory drugs (“NSAIDs”) and opioids, may be used to control pain at the injury site and/or to modify the perception of pain at the cortical level.
Peripheral nerve blocks are highly advantageous for continuous pain relief for several reasons. First, narcotic related side effects are less frequently reported in patients receiving continuous peripheral nerve blocks than in patients receiving epidural or intravenous analgesia. Second, urinary catheters are less frequently required in patients receiving peripheral nerve blocks compared to patients receiving epidural analgesia. Third, patient satisfaction is higher in patients having peripheral nerve blocks than in patients utilizing other analgesic methods. Fourth, the ability of a peripheral nerve block to provide site-specific relief contributes to the overall mobilization of the patient after surgery. Indeed, there is strong clinical evidence that peripheral nerve blocks, especially those administered to the lower extremity, provide superior analgesia compared to other types of analgesia and often result in earlier discharge from the hospital after major joint surgery.
In light of these and other advantages, it is somewhat surprising that only 20-30% of practicing anesthesiologists utilize peripheral nerve blocks as a standard method of analgesia. The most common reasons for avoiding such techniques are time constraints, fear of inadequately anesthetizing an affected nerve, and fear of injuring the affected nerve. Indeed, prior art techniques require a peripheral nerve block needle to be touching or in very close proximity to the affected nerve, without penetrating the nerve or a proximate artery or vein. Positioning the needle in this exact location can be both technically challenging and time consuming.
The major nerves of the lower extremity, including the sciatic and femoral nerves, are unique in that they are contained within well defined fascial compartments. Such lower extremity nerves may be successfully blocked by simply injecting anesthetic into the fascial compartment containing the nerve. Correctly identifying this fascial compartment, however, can be quite challenging.
Accordingly, what is needed is an improved needle for accurately administering anesthetic within a fascial compartment containing an affected lower extremity nerve. Further what is needed is an improved needle for efficiently administering anesthetic within a fascial compartment containing an affected lower extremity nerve. Finally what is needed is a method for properly locating and anesthetizing a fascial compartment containing an affected lower extremity nerve while avoiding intravascular injection and/or inadvertent penetration of the affected nerve.
SUMMARY AND OBJECTS OF THE INVENTION
This invention is a method and apparatus for facilitating peripheral nerve block procedures. A needle comprises a plurality of fenestrations that enable local anesthetic to be administered simultaneously at several points surrounding an affected nerve. A needle further comprises a needle hub attached to a proximal end of the needle in which a backflow of fluid may be observed. A stylet is slidably disposed within the needle and needle hub apparatus such that selectively withdrawing the stylet from the apparatus enables a backflow of fluid into the needle hub, from which proper localization of the apparatus may be verified prior to administering the local anesthetic. In this manner, local anesthetic may be effectively and efficiently administered to a peripheral nerve with reduced risk of injury to a patient.
It is an object of certain embodiments of the present invention to facilitate proper delivery of local anesthetic with respect to an affected peripheral nerve.
Another object of certain embodiments of the present invention is to provide a method for performing a peripheral nerve block that enables effective delivery of local anesthetic to an affected peripheral nerve within a short period of time.
It is yet another object of certain embodiments of the present invention to reduce the risks related to nerve injury and intravascular injection traditionally associated with administration of a peripheral nerve block.
It is yet another object of certain embodiments of the present invention to provide a peripheral nerve block needle apparatus having a stylet that is easily inserted and manipulated.
These and other objects and features of the present invention will become more readily apparent from the following description in which preferred and other embodiments of the invention have been set forth in conjunction with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and features of the present invention 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 of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1 is a perspective of a needle apparatus in accordance with the present invention;
FIG. 2 is a cross-sectional view of a human thigh depicting the location of the sciatic nerve within a fascial compartment;
FIG. 3 is a side view of the stylet associated with the needle apparatus of the present invention;
FIG. 4 is a side view of the needle and needle hub of the present invention;
FIG. 5 is a perspective view of the stylet cap and stylet partially inserted and in alignment with the needle hub and needle of the present invention;
FIG. 6 is a perspective view of the needle hub with the user's finger in contact with the raised portions for verifying the orientation of fenestrations present on a needle; and
FIG. 7 is an enlarged perspective view of the needle hub with a magnifying window and inserted stylet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
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 that come within the meaning and range of equivalency of the claims are to be embraced within their scope. The presently preferred embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
As used in this specification, the terms “anesthetic” and “analgesia” are used to indicate a chemical composition to induce a loss of sensation with or without loss of consciousness. The term “fenestration” refers to an opening along the surface of a needle that enables a flow of fluid between the needle and a patient. The term “fascial compartment” refers to a intermuscular compartment defined by the fascial layers of at least one muscle.
Referring to FIG. 1 , certain embodiments of the present invention comprise a needle apparatus to facilitate peripheral nerve block procedures. A needle apparatus 10 comprises three main components: a hollow needle component 12 , a needle hub component 40 , and a stylet component 60 . A hollow needle component 12 may comprise a plurality of fenestrations 20 disposed longitudinally thereon to permit a flow of fluid between the needle 12 and a patient. Fenestrations 20 are preferably located proximate a distal end 16 of a needle 12 . For example, fenestrations 20 located on a needle 12 5.0 inches in length are preferably contained along a distance measured from the tip 14 to about 1.785 inches along the length of the needle 12 .
A hollow needle hub component 40 may be coupled to a needle 12 mechanically by heat, an adhesive, a retaining mechanism, a secure pressure fit, or by any other means known to those in the art. A stylet component 60 , comprising a stylet 70 and a stylet cap 62 , may be freely inserted, removed and rotated within the combined needle 12 and needle hub 14 structure, and may be selectively retained therein by a pressure fit, a selective release mechanism, or by any other means known to those in the art.
Referring now to FIG. 2 , a fascial compartment 30 containing lower extremity nerves may comprise only a few millimeters in width. For example, a discrete fascial compartment 30 of only a few millimeters is located between the semitendinosis muscle 32 and the biceps femoris muscle 34 . This fascial compartment 30 houses the sciatic nerve 36 , one of two major lower extremity nerves. Fenestrations 20 are spaced at relatively small intervals along the needle 12 in order to maximize an even distribution of local anesthetic to any particular fascial compartment 30 , including particularly narrow compartments such as that housing the sciatic nerve 36 . Fenestrations 20 are preferably located within 0.17 inches, and most preferably within within one to two millimeters, of each other for this purpose. Additionally, fenestrations 20 may occupy alternating sides of a needle 12 to facilitate even distribution of local anesthetic to an affected peripheral nerve.
As fascial compartments 30 are less resistant to the flow of local anesthetic than surrounding muscle, a greater efflux of local anesthetic is observed through fenestrations 20 corresponding to fascial compartments than through fenestrations 20 located intramuscularly. Once introduced into a fascial compartment 30 , local anesthetic passively flows to a peripheral nerve contained therein. In this manner, the needle apparatus 10 of the present invention may be introduced into a dermal area roughly corresponding to a desired fascial compartment, while ensuring effective and safe administration of local anesthetic to an appropriate peripheral nerve. Indeed, since a precise location of a peripheral nerve need not be pinpointed in order to effectively anesthetize the nerve so long as a portion of the fascial compartment 30 containing the nerve is penetrated, and since local anesthetic introduced into an appropriate fascial compartment 30 passively flows to the nerve contained therein even absent locating the needle 12 immediately adjacent the nerve, it is possible to administer a peripheral nerve block without incurring substantial risk of injury to the nerve. A peripheral nerve block may also be accomplished in less time since only a rough determination of the location of the fascial compartment 30 containing the appropriate peripheral nerve is required. These features of the present invention are highly beneficial to practitioners performing lower extremity peripheral nerve block procedures and to their patients, as the time and risks associated with such procedures are greatly reduced.
Referring now to FIG. 3 , a stylet component 60 comprises a stylet 70 having a proximal end 72 and a distal end 74 . The term proximal as used herein connotes proximate to the “main body” of needle apparatus 10 , or in other words, nearer the portion of needle apparatus 10 that connects to a syringe. The term “distal” connotes a position removed from the main body of needle apparatus 10 or in other words, nearer the tip 14 of the needle apparatus 10 . A stylet 70 has a diameter and a length. The length and diameter of the stylet 70 are sufficient to occlude a hollow needle 12 and its associated fenestrations 20 when the stylet 70 is inserted into the needle 12 .
A stylet cap 62 has a generally spherical shape with raised portions 64 and flat areas 66 distributed throughout its surface. The generally uniform shape of the stylet cap 62 allows the stylet cap 62 to be gripped with a conventional or uniform grip from almost any angle. Raised portions 64 and flat areas 66 of a stylet cap 62 allow the stylet cap 62 to be manipulated more easily, even when the user is wearing surgical gloves. A stylet cap 62 has a cap nose component 68 disposed around the stylet 70 where the stylet 70 communicates with the stylet cap 62 . A cap nose component 68 is frusco-conical in shape with the broader base of the cone being adjacent to the stylet cap 62 . The diameter of a cap nose 68 allows it to slide into and fit securely with hollow needle hub 40 , as shown in FIGS. 6 and 7 . A stylet cap 62 and needle hub 40 create a pressure fit that allows a stylet 70 to be rotated about its axis and still be secured by a pressure fit with the needle hub 40 . A stylet cap 62 does not need to be rotated to a particular orientation to create the pressure fit.
The stylet component 60 of the present invention offers several advantages. First, the stylet 70 reinforces a hollow needle 12 as the needle 12 is being inserted, positioned or retracted. Second, as mentioned above, a stylet 70 occludes fenestrations 20 on the needle 12 . Occlusion of fenestrations 20 is particularly necessary in cases where the needle 12 must be repositioned during a procedure. Additionally, the stylet 70 , when withdrawn, indicates whether the needle 12 was bent during entry.
In addition to the advantages above, the stylet 70 of the present invention provides a stylet cap 62 that makes it easier to see and manipulate the stylet 70 than prior art stylet caps. The stylet cap 62 of the present invention reduces the likelihood that an anesthesiologist or other practitioner will mishandle or fumble with the stylet 70 , thereby reducing both the incidence of unnecessary trauma to tissue and the time required to complete a procedure. For example, during a peripheral nerve block procedure, an anesthesiologist or other practitioner may need to withdraw and reinsert the needle 12 until he or she can verify that the needle 12 is not located intravascularly. Once verified, the anesthesiologist or other practitioner may need to promptly reinsert the stylet 70 to occlude fenestrations 20 . The stylet cap 62 of the present invention facilitates the anesthesiologist's efforts to respond promptly, once the anesthesiologist has verified proper needle placement. The stylet cap 62 provides improved handling of the stylet 70 and allows the stylet 70 to be more quickly positioned. The stylet 70 does not have to be aligned in a particular position relative to needle hub 40 , as do prior art devices.
The stylet 70 slides inside a hollow needle 12 through a needle hub 40 until the stylet cap 62 contacts the needle hub 40 . The cap nose component 68 slides into and contacts interior walls of the needle hub 40 , thereby creating a pressure fit between the cap nose 68 and the broad opening 46 of the needle hub 40 . The spherical shape of the stylet cap 62 obstructs the broad opening 46 of the needle hub 40 .
Referring now to FIG. 4 , the needle apparatus 10 of the present invention further comprises a hollow needle 12 having a length and diameter suitable for injection of anesthetic into a fascial compartment surrounding a peripheral nerve. The length of a needle is bounded by an occluded tip 14 at a distal end 16 , and an intake opening 22 at a proximal end 18 . Fenestrations 20 are longitudinally disposed along the length of the needle 12 , and are preferably isolated on a distal end 16 of the needle 12 to facilitate an effective amount of efflux into a desired fascial compartment or other area proximate an affected peripheral nerve. Fenestrations 20 may be isolated along one side of a needle 12 , may alternate between sides of a needle 12 , or may occupy more than one side of a needle 12 . A needle hub 40 is disposed around the proximal end 18 of the needle 12 , and is configured to receive a syringe.
A needle hub 40 is hollow, defined by a funnel 42 having two openings, a first narrow opening 48 communicating with the needle intake opening 22 , and a broad opening 46 at the hub's proximate end. A cap nose component 68 of a stylet cap 62 may be inserted into the broad opening 46 of the funnel 42 by a pressure fit. The broad opening 46 comprises a shape corresponding to the stylet cap nose 68 to allow such a pressure fit. In one embodiment, the broad opening 46 is substantially cylindrical and tubular, thereby allowing a frusco-conical shaped stylet cap nose 68 to form a pressure fit therein. A needle hub 40 may also provide an extended opening 50 .
A needle hub 40 further comprises a finger grip 52 disposed about the funnel 42 . A finger grip 52 may comprise a plurality of sides and a length and diameter which allows the finger grip 52 to be easily manipulated between the thumb and forefinger. The sides of the finger grip 52 can be slightly concave to facilitate handling. Additionally, a needle hub 40 may incorporate a magnifying window 44 . Such magnifying window 44 reveals the content of the needle hub 40 in magnified view. In one embodiment, the funnel 42 is magnified so that any fluid passing into or out of the funnel 42 is more easily viewed by the user.
In one embodiment of the present invention, a needle hub 40 also provides fenestration indicators 56 and 58 . Fenestration indicators 56 and 58 comprise raised portions of the needle hub 40 that correspond to the relative position of fenestrations 20 located along a particular side of a needle 12 . In this manner, orientation of fenestrations 20 can be observed even when fenestrations 20 are not in view. This allows a user to remain aware of the direction of the release or uptake of fluid through fenestrations 20 . In a preferred embodiment, fenestration indicators 56 and 58 are raised from the surface of the needle hub 40 to provide visual and/or tactile verification of fenestration 20 orientation, as shown in FIG. 5 .
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A peripheral nerve block needle for facilitating a peripheral nerve block procedure. A needle has several fenestrations along its length to allow an efflux of local anesthetic into a particular fascial compartment to treat a corresponding peripheral nerve despite only roughly approximating the location of such fascial compartment. A needle hub may be attached to the needle so that a backflow of fluid may be observed. A stylet is slidably disposed within the needle and needle hub such that selectively withdrawing the stylet from the apparatus enables a backflow of fluid into the needle hub, from which proper localization of the apparatus may be verified prior to administering local anesthetic. In this manner, local anesthetic may be effectively and efficiently administered to a peripheral nerve with reduced risk of injury to a patient.
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This application is a continuation of application Ser. No. 08/063,640, filed May 18, 1993, now abandoned.
BACKGROUND OF THE INVENTION
A. Field of the Invention
The present invention relates to chemically synthesized catalysts which are capable of catalyzing chemical reactions heretofore only efficiently catalyzed using naturally-occurring molecules. In particular, the invention pertains to catalytic compositions of matter and to catalyst chemical structures, to methods of producing the kinds of catalysts described, and to chemical reactions in which the catalytic compositions can be applied.
B. Description of the Related Art
For almost a century, catalytic macromolecules have occupied center-stage in life sciences and medicine because they catalyze many of the important chemical processes carried out in living organisms. In fact, one of the principal achievements of the modem pharmaceutical industry is the production of large quantities of such molecules for use in health care. More recently, the application of these catalysts in non-biological chemical processes has received the increasing interest of industrial chemists.
Entire enzyme molecules have been synthesized as a result of major advances in the knowledge of protein structure and solid-phase peptide chemistry. Some of these whole molecules retained the catalytic nature of the naturally-occurring enzyme. However, the molecules upon which the synthetic molecules were modeled were relatively small and the yields of the correct structures were extremely low due to the inherent limitations of solid-phase peptide synthesis. These failures made it evident that synthesizing whole enzymes merely to achieve the catalytic capability of the naturally occurring molecule was not a viable approach for the construction of commercial quantities of catalysts. Neither is this approach at all useful for larger enzymes which may comprise several hundreds of amino acid residues in their chains. Clearly, it would be highly desirable if it were possible to obtain the desired chemical activity without synthesizing the entire enzyme structure.
A short peptide was previously designed by the Applicant using surface-simulation synthesis to mimic the substrate-binding site of trypsin. This peptide was shown to possess the expected binding activities of the native enzyme with substrates and inhibitors (Atassi, M. Z., "Surface-Simulation Synthesis of the Substrate-Binding Site of an Enzyme," Biochem. J. Vol. 226, pp. 477-485 1985!). However, although the synthetically produced peptide had the ability to bind to substrates and competitive inhibitors, it exhibited no significant catalytic activity.
More recently and representative of one type of current approach to synthetic catalyst design, an attempt was made to synthesize a portion of an enzyme molecule which would have a desired chemical activity. K. W. Hahn et al., "Design and Synthesis of a Peptide Having Chymotrypsin-Like Esterase Activity," Science, Vol. 248, pp. 1544-1547 (1990), describe the construction of a catalytic molecule in which four helical peptides were assembled in a bundle which contained at its amino ends, serine, histidine and aspartic acid in a spatial arrangement similar to that present in chymotrypsin (αCT). This assembled-helical design molecule contained 73 residues representing a major portion of and derived from the whole enzyme and was capable of binding to ester substrates of αCT. The assembled-helical design molecule was limited to hydrolyzing an acetyltyrosine ethyl ester for about 100 turnovers and was limited to a rate of catalysis which was only about 0.02% that of the native αCT. Importantly, the sequences in the marginally catalytic synthetic structure derived from the whole enzyme were substantially the same as the equivalent sequences found in the native enzyme.
Quite different approaches to attaining the chemical advantages of enzymes without having to rely on the native molecule have involved a unique use of immunological molecules. Monoclonal antibodies with catalytic activity have been prepared by using transition-state intermediates of the substrate as the immunizing antigen. Again, these molecules demonstrate binding of substrate but possesses only marginal activity.
However, no synthetic catalytic structure representing significantly less than, but designed to structurally imitate, an enzyme has functioned like a true enzyme. Specifically, no chemically synthesized, low molecular weight catalyst comprising a peptide has been produced which is capable of hydrolyzing a substrate in a specific manner at pre-selected bonds, at a useful rate of catalysis and for a useful period of time.
SUMMARY OF THE INVENTION
In accordance with the present invention, Applicant has constructed relatively low molecular weight, synthetic catalysts having the functional characteristics of naturally occurring enzymes. The synthetic catalysts of the invention represent molecules which are significantly smaller than, but designed to structurally imitate, an enzyme to the degree that they function like the native enzyme. These catalysts are capable of hydrolyzing a substrate of the native enzyme upon which they are modeled in a highly specific manner, at pre-selected chemical bonds, at commercially useful rates of catalysis and for commercially useful periods of time. In some instances, the synthetic catalysts actually improve upon the characteristics of the native molecule when comparisons of specificity, turnover rates, temperature sensitivity and the like are carried out.
The synthetic catalysts of the invention generally comprise a sterically-constrained peptide comprising amino acids. Herein, the term amino acid refers generally to L-amino acids routinely encountered in native enzymes as well as to analogs of these naturally occurring compounds including D-amino acids, imino acids and the like.
Further, the sterically-constrained catalyst comprises, in part, those amino acids which are in the active site of the naturally occurring enzyme. For the purposes of this invention, an active site amino acid is one which interacts with a substrate, substrate analog or competitive inhibitor of the native enzyme. The interaction may be one which achieves the goal of binding the substrate to the catalytic surface of the enzyme. The interaction may also be one which actually causes the conversion of the substrate to product, such as by temporary donation of electrons to cause the cleavage of a bond in the substrate. Not uncommonly, the nature of the interaction may be a hybrid interaction where both binding and conversion of substrate to product occurs.
This interaction may comprise a very tight interaction such as through one or more covalent bonds shared, however briefly, between the substrate and the active site amino acid. The interaction between the substrate and the active site amino acid may be of a weaker nature such as through hydrogen bonding, hydrophobic bonding or other weak inter-molecular interactions. Regardless of the actual interaction, be it mere binding, conversion or a combination of the two, or be it of a strong or weak character, for the purposes of the invention, such interactions with the substrate cause an amino acid residue to fall within the definition of an active site amino acid.
Identification of active site amino acids is routinely carried out on enzymes for which 3-dimensional structural information is known. In certain cases, substrate analogs are utilized which allow the protein chemist to determine which of the amino acids exposed to the catalytic surface (active site) of the enzyme interact with the substrate. Typically these interactions are detected using analytical techniques such as X-ray crystallography, mass spectroscopy, nuclear magnetic resonance and the like.
In certain instances, having applied one or more of these techniques, it will be known precisely which one of the amino acid residues exposed to the catalytic surface actually cause the substrate to be bound to the catalytic surface of the enzyme. Similarly, it may be known precisely which one of the amino acid residues exposed to the catalytic surface actually cause the substrate to be converted to product. More typically, however, the actual site of interaction of the substrate with the catalytic surface residues win be narrowed down to a defined region comprising sequences and/or amino acid residues that are in close proximity to one another in 3-dimensional structure but distant in primary structure among which are the actually interacting residues. For the purposes of the invention, each of the sequences and amino acid residues in such a region among which are the actually interacting residues are considered to be active site amino acid residues. This is particularly the case since it is not unlikely that each residue in such a region may coordinately participate in the binding or conversion of the substrate, leaving no one residue among them to be singled out as the actually interacting residue.
Additionally, it will be understood by those of skill in the art that certain enzymatic reactions are catalyzed indirectly by ligands bound to the enzyme active site, which ligands themselves are bound by interactions with the amino acid residues in the enzyme chain. In such instances, the amino acids which bind the ligand which in turn interacts with the substrate are expressly included within the definition of the active site amino acids of the invention.
Selection of the active site amino acids to be included in the synthetic catalysts of the invention may actually involve the isolation, purification and 3-dimensional analysis to a sufficiently detailed degree of resolution of a protein for which the substrate interactions with the catalytic surface are unknown. The techniques for doing so are known well by those of skill in the art. Even so, the obtaining of such data routinely involves substantial investments of research time and effort. Fortunately, however, the structural information of the degree of resolution necessary to allow selection of the active site amino acids is known for a large number of enzymes. As more enzymes are subjected to 3-dimensional analysis and included in the relevant databases, synthetic catalysts modeled after such enzymes may be constructed in a straightforward manner using the methods of the invention.
A number of sources are available for both the 3-dimensional structural information as well as the amino acid sequence information which may be used in designing the catalysts of the invention. In the United States, a useful source is the Protein Data Bank, Chemistry Department, Building 555, Brookhaven National Laboratory, Upton, N.Y. 11973. Protein Data Bank Service Association member centers are located worldwide and include Canadian Scientific Numeric Data Base Service, Dutch National Facility for Computer Assisted Chemistry, NE Italy Interuniversity Computing Center, European Molecular Biology Laboratory, Japan Association for International Chemical Information, National Center for Supercomputing Applications, Osaka University, Pittsburgh Supercomputing Center, Prophet, San Diego Supercomputing Center, and SEQNET. Addresses, phone numbers, and access to magnetic media at the parent facility as well as the member centers may be obtained through the Protein Data Bank.
Moreover, in many cases, enzymes fall into classes which allow certain structural generalizations to be made in the selection of the active site amino acids. Thus, enzymes may be classified into classes according to the substrates they convert--proteases digest proteins, lipases attack lipids, and so on. Subclasses of proteins also exist--serine proteases possess a serine in their active sites useful in the cleaving of peptide bonds in proteins. Even more useful is the fact that many proteins, especially those falling into the same classes and subclasses, exhibit a great deal of amino acid sequence homology. Thus, trypsin and chymotrypsin, both of which are serine proteases, share many of the same or chemically similar amino acid residues at or near the same positions in each enzyme chain. Chemically similar substrates (for example, protein substrates of proteases) impose very similar structural requirements on the catalytic surfaces in the active sites of the enzymes which convert the substrates to products (i.e., serine proteases cleaving peptide bonds of protein substrates, albeit at different positions).
Therefore, the catalyst designer having designed a synthetic catalyst based on the known 3-dimensional structure of one enzyme in a given class, can justifiably rely on such homology in selecting the active site amino acids of another enzyme of the same class for which there is substantial homology. This approach has been successfully utilized by the Applicant to design a synthetic trypsin-like catalyst based upon the homology of trypsin with chymotrypsin. Thus, active site amino acids may also be defined by their homology with the same or similar residues in an enzyme for which the 3-dimensional structure is known. If an active site residue has been defined in the enzyme for which the 3-dimensional structure is known, and an homologous region of a related, closely homologous enzyme with undetermined 3-dimensional structure is known, then by analogy those residues failing within the homologous region may be justifiably considered to be active site residues. Such residues are, therefore, included within the definition of active site amino acid for purposes of the invention.
By design methods as detailed herein, after the identification of the active site amino acids, these residues are arranged to have a 3-dimensional spacial relationship which is essentially equivalent to that of the naturally occurring enzyme. Chiefly, this entails measurements of the distances between the active site residues from α-carbon to α-carbon in the peptide bond. Thus, if the α-carbon of active site residue A is spatially separated from the α-carbon of active site residue B by 10 angstroms, it will be understood that the resulting design must provide a similar distance to be achieved in the synthetic catalyst. In the first instance, the 3-dimensional relationship may be promoted using spacers such as catalytically inactive amino acids between the active site amino acids. The bond lengths of representative spacers are detailed in the Examples to follow. By way of continuing example, however, if active site residues A and B above were to be linked by spacers, the linear distance of 10 angstroms would determine the number and the nature of the spacers to be used. As used herein, a catalytically inactive amino acid is any amino acid which does not fall within the definition of an active site amino acid as defined supra. Other spacers which would not fall within the definition of amino acids as used herein but which would function structurally and chemically in a similar fashion will find usefulness, as well.
Steric constraint of the catalyst may take several forms. Certainly, the Applicant has found that cyclization of the catalyst achieves the goal of steric constraint admirably. However, the goal of steric constraint may be achieved by other means as well. Thus, co-terminal attachment of the N- and C-termini of the linear peptide to a surface in close proximity to one another is such a means of sterically constraining the catalyst. For the purposes of the present invention, any means which sterically constrains the catalyst in a manner which allows the requisite flexibility of the chain to conform to the substrate yet which eliminates a large portion of the non-productive (non-catalytic) conformations which would result from a strictly linear, freely mobile chain in solution are expressly included in this definition.
Cyclization of the linear catalyst may take a number of forms as well. The means for cyclization must meet at least two criteria. First, the means for cyclizing the catalyst must maintain the interchain distances necessary for attaining the proper orientation of active site residues around the substrate in a fashion similar to that occurring in the native enzyme. Second, the means for cyclicizing the catalyst must be at least stable enough under the conditions of the reaction with the substrate to maintain the cyclic nature of the catalyst. Certainly, the Applicant has found that a simple yet effective means for cyclicizing the catalyst is to include at its N- and C-termini, a cysteine residue in order to allow the formation of a disulfide bond between the terminal residues thereby closing the linear catalyst into a cyclic structure. Other intermolecular disulfide linkages work as well. Alternatively and preferably where a bond such as the disulfide linkage may be susceptible to being reduced, intermolecular cyclization may be achieved via peptide bonding between any two terminal amino acids so long as the proper interchain distances are maintained. Other interchain bonding, including bonding to and between non-amino acid substituents of the catalyst may be used to cyclize the catalyst so long as the means achieve the two criteria detailed supra.
Thus, the catalysts of the invention may achieve steric constraint by constructing a cyclized catalyst containing an end-to-end joint between N- and C-termini of the catalyst. In certain embodiments, the end-to-end joint further comprises a disulfide bond, a peptide bond or a linking molecule which is not an amino acid (e.g., sugars, lipids, carbon-carbon bonds, and the like).
Since there is no a priori reason for closing the synthetic peptide catalyst chain at a particular site along its linear structure, it is possible to construct the linear catalyst using standard peptide synthesis chemistry or through recombinant DNA techniques as any of a number of possible linear configurations. Some of these linear configurations may be preferable to others for purposes of synthesis, especially where it is desired to use disulfide linkages to cyclize the catalyst and the interchain distances limit the placement of the disulfide linkage to one or only a few potential sites within the linear catalyst. Where cyclization is affected by means other than disulfide linkages, the order of synthesis is more flexible.
Thus, claimed herein are synthetic catalysts capable of catalyzing reactions of substrates in a manner similar to that of naturally-occurring enzymes. The catalysts generally comprise sterically-constrained peptides, which peptides are themselves made up of, at least in part, amino acids. The amino acids which are used to synthesize the peptide further comprise at least some of the active site amino acids known to exist in the naturally-occurring enzyme upon which the catalyst is modeled. The catalyst is also made up of one or more spacers variously interspersed during synthesis of the linear peptide between the active site amino acids.
The active site amino acids are arranged during the synthesis of the linear peptide to achieve a linear relationship along the length of the catalyst such that, when contorted properly in 3-dimensional space, the catalyst is capable of assuming a 3-dimensional spacial relationship amongst these active site amino acids. The 3-dimensional spacial relationship is essentially equivalent to that present in the naturally-occurring enzyme in its catalytically active state. Unlike this essential equivalency of 3-dimensional spatial intermolecular distances, the linear relationship between the active site amino acids along the length of the synthetic catalyst is substantially different from that of the naturally-occurring enzyme. In many cases, the linear relationships established in the synthetic catalysts of the invention will be substantially altered and even reversed from that observed in the native molecule. Thus, the catalysts have molecular weights substantially less than that of the naturally-occurring enzyme upon which they are modeled.
The catalysts of the invention display reaction kinetics that are enzyme-like for substrates, substrate analogs and competitive inhibitors of the correlate enzymes. The substrates are converted in an essentially equivalent manner to that of the correlate enzyme. Herein, binding specificity is meant to refer to substrate preference. As seen herein, a mere four alterations in the active site residues of the chymotrypsin-like synthetic catalyst causes the resulting trypsin-like catalyst to no longer bind to or cleave proteins at chymotrypsin cleavage sites, rather it then only binds and cleaves proteins at trypsin cleavage sites. Binding constant is meant to refer to the Michaelis-Menten constant (K m ). In certain embodiments, the catalysts of the invention have binding constants for their respective substrates which are approximately 90% of or better than that of the naturally-occurring enzyme. In preferred embodiments, the binding constant of the synthetic catalyst will be essentially equivalent to that of the native molecule. Similarly, the preferred catalysts have rates of catalysis (k cat ) which are approximately 1% of or better than that of the naturally-occurring enzyme. In preferred embodiments, the rate of catalysis of the synthetic catalyst will be essentially equivalent to that of the native molecule. In highly preferred embodiments, the rates of catalysis of the synthetic catalysts will be superior to that of the native molecule, especially where the catalysis takes place in a reaction environment unfavorable for the native enzyme such as with elevated and depressed temperatures or other situations where the native structure is susceptible to denaturing. In certain instances, as shown in the examples to follow, the turnover number (the cycles of catalysis) of the synthetic catalysts of the invention exceed that of the native enzyme to such a degree that it remains undetermined how many turnovers are theoretically possible with the synthetic molecules.
The catalysts of the invention, as noted previously, have molecular weights substantially less than that of the native enzymes. This is a function of the need to incorporate and link together only the active site residues of the enzyme into the constructed design. The size of the catalysts is therefore dictated to a large degree by the size of the active site of the modeled enzyme. In any case, the numbers of amino acid residues of certain preferred synthetic catalysts will rarely exceed approximately 30% of that of the naturally-occurring enzyme.
Of course, the skilled artisan will recognize that there may be additions to the minimal synthetic catalyst made for other reasons which would add to the mass of the molecule. Thus, for instance, it may be possible to add allosteric regions to the basic catalytic molecule in order to regulate the catalysis. Additionally, it is likely that multimers of the synthetic peptide catalysts may exhibit preferred characteristics and would thereby add additional mass to such catalysts. For instance, it is readily apparent that mixed function synthetic catalysts may be constructed using the methods and compositions of the present invention. A trypsin-like synthetic catalyst may be coupled to a chymotrypsin-like catalyst to achieve a combined catalyst which will act on either protein substrate by covalently bonding two distinct synthetic catalyst molecules via, for instance, the side chains present in either molecule's amino acid residues. In certain instances, it may be desirable to increase the solubility or serum life of a catalyst of the invention by attaching it to a solubilizing agent or stabilizing agent, such as lysozyme, polyethylene glycol, polyvinyl alcohol or the like, adding mass to the catalyst in the process. Also, where a ligand is bound and is involved in catalysis, mass increases are possible. Thus, while it is anticipated that the basic synthetic peptide catalyst will be substantially reduced in molecular weight compared to the native enzyme, synthetic constructions which add mass to this basic configuration are expressly anticipated.
The spacers which may further comprise catalytically inactive amino acids will be recognized by one of skill in the art to meet certain criteria. Chiefly, such amino acid spacers will be amino acids which have a minimal steric hindrance capacity as it relates to movement of the peptide in all dimensions. Additionally, the spacer amino acids will typically lack such side groups as might interfere in catalysis such as reactive, hydrophilic, hydrophobic groups or other such moieties. Typically, such amino acid spacers will be glycyl or alanyl residues. However, in certain instances, it may be desirable to use one or more spacers selectively introduced into the catalyst design to impart a desired conformational constraint on the design, such as by using proline residues to introduce a kink. Such chain kinks may help to further sterically constrain the synthetic catalyst to additionally limit the non-catalytic conformations which the cyclic molecule takes in solution.
In certain preferred embodiments of the invention, the catalysts of the invention were modeled upon naturally-occurring enzymes selected from the group of enzymes consisting of chymotrypsin, trypsin, lysozyme and ribonuclease. These were the enzymes which the Applicant chose to be representative of the wide utility of the present invention in constructing synthetic catalysts. This selection was made in order to demonstrate in the one instance that while a 3-dimensional structure is advantageous and ultimately necessary to construct the synthetic catalysts of the present invention, where amino acid sequences exist which are highly homologous to a known 3-dimensional structure, substitution of the relevant catalytic residues was carried out to alter the catalytic specificity of the resulting catalyst. Thus, trypsin residues were shown in the examples to follow to be replaced for chymotrypsin residues in a 3-dimensional catalyst based only upon the chymotrypsin X-ray coordinates. In the second instance, these exemplary enzymes were diversely selected to demonstrate that the compositions of matter and methods of the invention were not limited to enzymes catalyzing only certain classes of substrate. While both chymotrypsin and trypsin are proteolytic enzymes, lysozyme is a polysaccharide digesting enzyme and ribonuclease hydrolyzes the bonds of RNA. These selections were only exemplary. The approaches and designs detailed herein allow any one of skill in the art with the requisite 3-dimensional data necessary (or homologous to) to design a peptide capable of assuming that 3-dimensional structure.
More specifically, representative catalysts are disclosed which indicate the utility and scope of the present invention across a wide range of natural enzyme models. One preferred catalyst is modeled on chymotrypsin and consists essentially of the cyclic amino acid catalyst (SEQUENCE ID NO:1):
cyclo(-S-cystinyl-glycyl-phenylalanyl-histidyl-phenylalanyl-glycyl-glycyl-seryl-aspartyl-glycyl-methionyl-glycyl-seryl-seryl-glycyl-glycyl-valyl-seryl-tryptophanyl-glycyl-isoleucyl-glycyl-glycyl-aspartyl-glycyl-alanyl-alanyl-histidyl-cystinyl-S);
wherein "cyclo" refers to the cyclic nature of the peptide and the residues "-S-cystinyl" and "-cystinyl-S" indicate that the peptide was cyclized through the use of a disulfide bond between the two cysteine residues. Another preferred catalyst is modeled on trypsin and consists essentially of the cyclic amino acid catalyst (SEQUENCE ID NO:2):
cyclo(-S-cystinyl-glycyl-tyrosyl-histidyl-phenylalanyl-glycyl-glycyl-seryl-aspartyl-glycyl-glutamyl-glycyl-seryl-aspartyl-glycyl-glycyl-valyl-seryl-tryptophanyl-glycyl-leucyl-glycyl-glycyl-aspartyl-glycyl-alanyl-alanyl-histidyl-cystinyl-S).
Another preferred catalyst is modeled on lysozyme and consists essentially of (SEQUENCE ID NO:3):
cyclo(-S-cystinyl-threonyl-asparagyl-arginyl-asparagyl-glycyl-glycyl-aspartyl-glycyl-glycyl-leucyl-glutamyl-isoleucyl-asparagyl-glycyl-tryptophanyl-tryptophanyl-glycyl-glycyl-isoleucyl-glycyl-aspartyl-glycyl-aspartyl-glycyl-alanyl-tryptophanyl-valyl-alanyl-glycyl-arginyl-glycyl-phenylalanyl-glutamyl-seryl-asparagyl-cystinyl-S).
Another preferred catalyst is modeled on ribonuclease and consists essentially of (SEQUENCE ID NO:4):
cyclo(-S-cystinyl-glutamyl-glycyl-valyl-histidyl-phenylalanyl-aspartyl-alanyl-seryl-glycyl-glycyl-threonyl-asparagyl-valyl-prolyl-lysyl-glcyl-glycyl-glutamyl-histidyl-glycyl-phenylalanyl-lysyl-cystinyl-S).
It will be recognized, however, by those of skill in the art that the catalysts described above and those claimed in general may contain functionally equivalent amino acid substitutions. The importance of the hydropathic index of amino acids in conferring biological function on a protein is generally known by those of skill in the art. It has been found by many researchers that certain amino acids may be substituted for other amino acids having a similar hydropathic index or score and still retain similar if not identical biological activity. As displayed below, amino acids are assigned a hydropathic index on the basis of their hydrophobicity and charge characteristics. It is believed that the relative hydropathic character of the amino acid determines the secondary structure of the resultant protein, which in turn defines the interaction of the protein with the substrate molecule. It is proposed that biological functional equivalence may typically be maintained where amino acids are exchanged having no more than a ±1 to 2 difference in the index value, and more preferably within a ±1 difference.
______________________________________AMINO ACID HYDROPATHIC INDEX______________________________________Isoleucine 4.5Valine 4.2Leucine 3.8Phenylalanine 2.8Cysteine/Cystine 2.5Methionine 1.9Alanine 1.8Glycine -0.4Threonine -0.7Tryptophan -0.9Serine -0.8Tyrosine -1.3Proline -1.6Histidine -3.2Glutamic Acid -3.5Glutamine -3.5Aspartic Acid -3.5Asparagine -3.5Lysine -3.9Arginine -4.5______________________________________
Thus, for example, isoleucine, which has a hydropathic index of +4.5, can be substituted for valine (+4.2) or leucine (+3.8), and might still obtain a protein having similar biological activity. Alternatively, at the other end of the scale, lysine (-3.9) can be substituted for arginine (-4.5), and so on.
Accordingly, these amino acid substitutions are generally based on the relative similarity of R-group substituents, for example, in terms of size, electrophilic character, charge, and the like. In general, although these are not the only such substitutions, the preferred substitutions which take various of the foregoing characteristics into consideration include the following:
______________________________________ORIGINAL RESIDUE EXEMPLARY SUBSTITUTIONS______________________________________alanine glycine; serinearginine lysineasparagine glutamine; histidineaspartic acid glutamic acidcysteine serineglutamine asparagineglycine alaninehistidine asparagine; glutamineisoleucine leucine; valineleucine isoleucine; valinelysine arginine; glutamine; glutamic acidmethionine leucine; tyrosineserine threoninethreonine serinetryptophan tyrosinetyrosine tryptophan; phenylalaninevaline isoleucine; leucine______________________________________
The invention also relates to methods of synthesizing a catalyst capable of catalyzing a reaction of a substrate in a manner similar to that of a naturally-occurring enzyme. These methods generally comprise first selecting certain amino acids to be included in the catalyst from at least some of the active site amino acids in the naturally-occurring enzyme. As noted above, the Protein Data Bank readily provides an excellent source of such information in the form of both 3-dimensional structure, probable active site residues, sequences and sequence homologies between related enzymes. Where the designer chooses to base the design of the catalyst on a known 3-dimensional structure of an enzyme, reference is first made to such a source for the distances separating and the identity of the active site residues on the catalytic surface of the enzyme. If the design is to be based upon the sequence homology of an enzyme for which the 3-dimensional structure is unknown but which unknown enzyme is related to an enzyme of known 3-dimensional structure, then a first step includes design of a first catalyst modeled after the known 3-dimensional structure enzyme. This step is followed by substitutions of active site amino acids where the unknown 3-dimensional structure enzyme differs with that of the known enzyme as determined by sequence homologies.
The elements of the design first require the identification of the active site residues and the α-carbon to α-carbon distances separating them. This is based on the structural homology with the known reference enzyme. Next, a selection is made of one or more spacers to be variously interspersed between the active site amino acids selected in the first step. The distances determined in the first step between the active site residues guide the selection of a proper atomic bridging structure in the form of a spacer to be used. Reference should be made to the detailed examples herein for representative spacers and their atomic dimensions. Of course, the spacers used herein are but exemplary and may be readily substituted by any spacer of suitable dimensions and chemical compatibility.
Having selected the substituents of the synthetic catalyst, a next step will typically include synthesizing a linear peptide by stepwise addition of either the active site amino acids or the spacers to the growing peptide to achieve the proper linear arrangement and distances. While the Applicant has demonstrated the utility and ease by which this may be accomplished using synthetic peptide chemistry, it is certainly possible and, in some cases, advisable to achieve the synthesis of the peptide using recombinant DNA technology. Either approach is permissible. In either case, the preferred order of synthesis will typically be dictated by the position deemed best for cyclization. Thus, where a disulfide linkage is to be used to cyclize the catalyst, synthesis will typically begin with a cystinyl residue and end with a cystinyl residue. Alternatively, where a peptide bond is used to cyclize the peptide, less concern need be placed on the specific starting point synthesis.
Having so constructed the linear peptide, this establishes a linear relationship along the peptide such that the peptide is capable of assuming a 3-dimensional spacial relationship amongst the active site amino acids. The 3-dimensional spacial relationship is essentially equivalent to that present in the naturally-occurring enzyme in its catalytically active state. Conversely, the linear relationship is substantially different from that of the naturally-occurring enzyme. As a result of the unique linear bridging of active site residues, there is no need to include vast amounts of the amino acids typically found along the native polypeptide chain nor is there a need to maintain the order of sequence found along the native polypeptide chain. The result of this cutting out of most of the non-catalytic residues found in the native polypeptide is that the catalyst has a molecular weight substantially less than that of the naturally-occurring enzyme. As a final step, the linear peptide is sterically-constrained by one or another of the techniques discussed above.
A process using the synthetic catalysts of the invention to catalyze a reaction of a substrate in a manner similar to that of a naturally-occurring enzyme is also provided. Typically, the synthetic peptide catalysts of the invention are used in exactly the same manner and under identical conditions for which the native enzyme is known to function best. Thus, buffered solutions at given temperatures and given concentrations which conform to equivalent molar ratios of catalyst to substrate are preferred. However, since the catalysts of the invention may exhibit enhanced ability to function under conditions which would denature or otherwise reduce the catalytic ability of the native enzyme, in some instances the synthetic catalysts of the invention may be used under conditions different from those that are maximal for the native molecules. In any case, no special conditions over those routinely utilized by those of skill in the art of enzymology are necessary when using the catalysts of the invention. Products produced using the catalytic processes of the invention are also provided.
In addition to the terms and definitions discussed above, the following abbreviations are used herein: BTEE, N-benzoyl-L-tyrosine ethyl ester; BPTI, bovine pancreatic trypsin inhibitor; ChPepz, peptide designed by surface-stimulation synthesis to mimic the active site of α-chymotrypsin; DIFP, diisopropyl fluorophosphate; PMSF, phenylmethylsulfonyl; TAME, N-tosyl-L-arginine methyl ester; TPCK, L-1-p-tosylamino-2-phenylethyl chloromethyl ketone; and TrPepz, surface-stimulation synthetic peptide designed to mimic the active site of trypsin; DTT, dithiothreitol; LyPepz, peptide designed by surface-simulation synthesis to mimic the active site of hen egg lysozyme; LYZ, hen egg lysozyme; RNASE, bovine ribonuclease A; RnPepz, surface-simulation synthetic peptide designed to mimic the active site of bovine ribonuclease A.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1. Time-course hydrolysis of BTEE by αCT and ChPepz. Hydrolyses were carried out, a s described in the test, on 200 μg (0.638 μmole) of BTEE, and monitored on a recording spectrophotometer by increase in absorbance at 256 nm, using (a) 1.5 μg (6.05×10 -5 μmole) αCT; (b) 7.06 μg (2.65×10 -3 μmole) ChPepz; and (c) 4.71 μg (1.77×10 -1 μmole) ChPepz. Curve (d) represents the following reactions, all of which had zero activity and superimposed on the x axis: ChPepz (7.06 μg) inhibited with TPCK or with DIFP; ChPepz (7.06 μg) made acyclic by reduction of the disulfide bond; Trypsin or TrPepz action on BTEE; αCT or ChPepz action on TAME; and action of un related peptide controls on BTEE.
FIG. 2. Examples of Lineweaver-Burk plots for BTEE hydrolysis by ChPepz (), and αCT (Δ). Assays were carried out at pH 7.8 and 25° C., in 306 replicates at six different substrate concentrations as described in the text. The K m and k cat values obtained from these plots are given in Table 1 together with the kinetic constants for the action of trypsin and TrPepz on TAME.
FIG. 3. Hydrolysis of TAME by trypsin and TrPepz. Reactions were done on 240 μg (0.634 μmole) of TAME at 25° C., pH 8.0, in a total reaction of 1 ml and monitored at 247 nm on a recording spectrophotometer, as described in the text. Hydrolyses were done with: (a) trypsin (2.1×10 -5 μmoles); (b) 6.84 μg of TrPepz (2.53×10 -3 μmoles), both in the presence and absence of 10 molar excess of TPCK (the two curves superimposed) (c) 4.55 μg of TrPepz (1.69×10 -3 μmoles); (d) several reactions superimposed on this zero activity curve. These are: action of ChPepz (7.0 μg) on TAME, effect of control cyclic and linear peptides (unrelated to TrPepz or ChPepz) on TAME, TrPepz (6.84 μg) inactivated by reduction with DTT or inhibited by 10 molar excess of PMSF, DIFP, BPTI or human α 1 -antitrypsin.
FIG. 4. Maps of the peptides obtained from (1) myoglobin and (2) casein by hydrolysis with αCT or ChPepz. (1a) myoglobin peptides obtained with αCT; (1b) myoglobin peptides obtained with ChPepz; (2a) Casein peptides obtained with αCT; (2b) casein peptides obtained with ChPepz. Peptide maps were done, as described in the text, by chromatography in the descending dimensions followed by high voltage paper electrophoresis (from left to right).
FIG. 5. Fingerprints of the myoglobin and casein peptides obtained by hydrolysis with trypsin or TrPepz. (1) myoglobin peptides obtained by hydrolysis with: (1a) trypsin, or (1b) TrPepz; (2) casein peptides obtained with (2a) trypsin, or (2b) TrPepz. Peptide maps were done by paper chromatography in the ascending dimension, followed by high voltage paper electrophoresis (from left to right). For details, see the text.
FIG. 6. Stereodiagram showing the active site residues of (A) bovine αCT and (B) bovine trypsin. Four residues in the active site of αCT are substituted in trypsin (Phe-39 to Tyr, Ile-99 to Leu, Ser-189 to Asp, Met-192 to Gln) and shown in heavy lines in (B).
FIG. 7. Design of the surface-simulation synthetic peptides mimicking the active sites of α-chymotrypsin (ChPepz) and trypsin (TrPepz). (a) shown the contact residues of the active site in the shaded areas and the distances (C.sup.α -to-C.sup.α, in Å) separating the appropriate residues. Residue numbers are based on bovine chymotrypsinogen sequence. (b) indicates the surface-simulation synthetic peptides designed to mimic the active sites. The residues in the shaded areas are the actual active site residues of bovine αCT while those linking these shaded areas are glycine spacers introduced to achieve appropriate distances of separation between the respective residues and regions of the site. (Cter) is the C-terminal Cys and (Nter) denotes the N-terminal Cys of the peptides which are cyclized by the disulfide between the two Cys residues. The outer sequence differs from ChPepz in four positions only: Phe-39 to Tyr, Ile-99 to Leu, Ser-189 to Asp, Met-192 to Gln.
FIG. 8. Time-course hydrolysis of M. lysodeikticus by LYZ and LyPepz. Hydrolyses were carried out, as described in the text, on 140 μg of substrate and monitored on a recording spectrophotometer by decrease in absorbance at 450 nm using (a) 1.5 μg (1.04×10 -4 μmole) of LYZ and (b) 5.6 μg (1.51×10 -3 μmole) of LyPepz. Curves (c) represent the following reactions all of which had near zero hydrolytic activity: LyPepz (5.6 μg) inhibited by 10 molar excess of imidazole, histamine or tryptamine; LyPepz after reduction of the intramolecular disulfide bond; and action of unrelated peptide controls (RnPepz and other cyclic peptides).
FIG. 9. Lineweaver-Burk plots for M. lysodeikticus hydrolysis by LyPepz (Δ), and LYZ (▴). Assays were carried out at 25° C. in 0.125M NaCl using nine different substrate concentrations in 3-6 replicates as described in the text. The K m and k cat , values obtained from these plots are given in Table 2.
FIG. 10. Time-course hydrolysis of yeast RNA by RNase and RnPepz. Reactions were done at 25° C. on 700 μg of yeast RNA. The decrease in absorbance at 300 nm was monitored continuously on a recording spectrophotometer. The curves show: (a) hydrolysis by 1.5 μg (1.095×10 -4 μmole) of RNase; (b) hydrolysis by 5.8 μg (2.42×10 -3 mole) of RnPepz; (c) RnPepz inhibited by 250 μg of denatured DNA, or 10 molar excess of AgNO 3 ; and RnPepz rendered acyclic by reduction of the disulfide bond. Also superimposed on curve (c) is the action of unrelated peptide controls (LyPepz and other cyclic peptides) on yeast RNA.
FIG. 11. Lineweaver-Burk plots for yeast RNA hydrolysis by RnPepz (⋄), and RNase (,∘). Assays were carried out in 0.1M sodium acetate at pH 5.0 and 25° C. in 3-6 replicate analyses of different substrate concentrations, as described in the text. The kinetic constants derived from these plots are given in Table 2.
FIG. 12. A diagram of the spatial disposition of the active site residues of LYZ.
FIG. 13. Design of the surface-simulation peptide mimicking the active site of LYZ. (a) Shows the active site residues in the shaded areas and the C.sup.α -to-C.sup.α distances (in Å) separating the appropriate residues. (b)) Gives the surface-simulation synthetic peptide designed to mimic the active site of LYZ. The shaded areas, representing the actual active site residues of LYZ, were linked by glycine spacers which were introduced to achieve appropriate spacing between the regions and the residues of the active site. (Cter) denotes the C-terminal Cys and (Nter) is the N-terminal Cys of the peptide. A disulfide bridge between these half cystine residues is used to cyclize the peptide.
FIG. 14. A diagram of the spatial disposition of the essential residues of the active site of RNase.
FIG. 15. Design of the surface-simulation peptide mimicking the active site of RNase. (a) The active site residues shown in the shaded areas and the C.sup.α -to-C.sup.α distances separating them are given in Å. (b) Structure of the surface-simulation synthetic peptide designed to mimic the active site of RNase. The shaded areas are the actual site residues and the glycine residues in between are spacers. A disulfide bridge between the Cys residues at the C-terminal (Cter) and the N-terminal (Nter) is used to cyclize the peptide.
DESCRIPTION OF PREFERRED EMBODIMENTS
INTRODUCTION
The Applicant has now constructed a number of catalytically active synthetic peptide catalysts that duplicate the catalytic activities and specificities of various enzymes. The ability to construct at will fully functional peptide enzymes having the activity and specificity chosen by the investigator should find vast applications.
The disclosure describes two catalyst designs that mimic the activities and specificities of αCT and trypsin, both enzymes being proteases. Two 29-residue peptides were prepared, one of which (ChPepz) was designed by surface-simulation synthesis to mimic the active site of a-chymotrypsin (a-CT), while the other (TrPepz), which contained four substitutions relative to ChPepz, was fashioned after the active site of trypsin. The peptides were each cyclized by a disulfide bond. The ChPepz monomer effected hydrolysis of the ester group in N-benzoyl-L-tyrosine ethyl ester (BTEE), an αCT substrate, with K m and k cat values that were comparable to those of αCT. ChPepz was completely inactivated by diisopropyl fluorophosphate (DIFP), L-1-p-tosylamino-2-phenylethyl chloromethyl ketone (TPCK) or reduction of the disulfide bond. It had no catalytic activity on N-tosyl-L-arginine methyl ester (TAME), a trypsin substrate. On the other hand, TrPepz, which had no effect on BTEE, hydrolyzed TAME with a K m value that was essentially identical to that of trypsin, while its k cat value was almost half that of the enzyme. TrPepz was fully inactivated by reduction of the disulfide bond, by DIFP or by PMSF but not by TPCK. It was also completely inhibited by soybean trypsin inhibitor, bovine pancreatic trypsin inhibitor and human α 1 -antitrypsin. ChPepz and TrPepz hydrolyzed proteins (myoglobin and casein) to give panels of peptides that were similar to those of the same protein obtained with the respective enzyme. However, TrPepz was more efficient than trypsin at hydrolysing the C-bonds of two or more consecutive lysine and/or arginine residues. Finally, like the esteratic activity, the proteolytic activity of ChPepz was inhibited by DIFP or TPCK while that of TrPepz was inhibited by DIFP or PMSD but not by TPCK.
To ensure that the ability to construct peptide enzymes was not restricted to the two aforementioned proteolytic enzymes, Applicant synthesized two catalysts which were designed by surface-simulation to mimic the active sites of hen egg lysozyme (LYZ) and bovine ribonuclease A (RNase). The former (LyPepz), a 37-residue peptide cyclized by an intramolecular disulfide bond, exhibited the muramidase activity and specificity typical of LYZ. LyPepz was able to effect complete hydrolysis of the cell wall of Micrococcus lysodeikticus with a K m value that compared well with that of LYZ, while its k cat value was 6.7 times lower than that of the whole enzyme. Like LYZ, LyPepz was inhibited by imidazole, tryptamine and histamine. LyPepz became completely inactive when rendered acyclic by reduction of the disulfide bond. The 24-residue cyclic (by a disulfide bond) peptide, RnPepz, designed to mimic the active site of RNase was able to completely hydrolyze yeast RNA with a K m value that was essentially identical to that of RNase, while its k cat value was considerably lower than that of the enzyme. The cyclic structure of RnPepz was important for its activity because the latter was completely lost upon reduction of the disulfide bond. Like RNase, RnPepz was inhibited by heavy metals and by denatured DNA. Finally, LyPepz had no activity on RNA and conversely RnPepz had no muramidase activity.
CHYMOTRYPSIN AND TRYPSIN
General Materials and Methods
Materials. Myoglobin was the major chromatographic component (No. 10) isolated from crystallized sperm-whale myoglobin as described (Atassi, M. (1964) Nature (London) 202, 496-498; to the extent that such references provide disclosure which would enhance the ability of the skilled practitioner to practice the invention described herein, all references provided herein are specifically incorporated by reference). BTEE and TAME were obtained from Aldrich Chemical Company. αCT, TPCK-trypsin, BPTI and soybean trypsin inhibitor were from Worthington Biochemical Corporation. Bovine milk β-casein (which contained about 10% α-casein), DIFP, PMSF, and human al-antitrypsin were from Sigma Chemical Co. Reagents for peptide synthesis and Nα-Fmoc amino acids were obtained from Vega Biotechnologies.
Peptide Synthesis. The rationale for the design of the peptides is given in the Examples. The peptides, ChPepz and TrPepz, were prepared by solid phase synthesis on a benzyloxybenzyl alcohol resin to which 9-fluorenylmethylcarbonyl (Fmoc)-S-tert-butylcysteine had been coupled. The side-chain protecting groups were: aspartic, β-tert-butyl ester; cysteine, S-tert-butyl; histidine, im-trityl; lysine, ε-tert-butoxycarbonyl; serine and tyrosine, O-tert-butyl. The peptides were synthesized and cleaved from the resin by the procedures described elsewhere in detail Atassi, M. Z., Manshouri, T. and Sakata, S. (1991) Proc. Natl. Acad. Sci. USA 88, 3613-3617.
Cyclization of the Peptide and Purification of the Monomer. A portion (50 mg) of the synthetic product was dissolved in 2 ml of 8.0M urea containing 5% 2-mercaptoethanol, preadjusted to pH 8.5 with triethylamine. The solution was stirred gently on a magnetic stirrer for 3 hrs at room temperature, after which it was applied on a column (90×1.6 cm) of Sephadex G15, which was eluted with 0.025M acetic acid, to remove the urea and mercaptoethanol. The fractions containing the peptide were pooled and diluted with 3 liters of 0.025M acetic acid and the pH was adjusted to 8.0 on the pH meter by the addition of triethylamine. The solution was stirred magnetically at room temperature for 4 days and then freeze-dried. The dry peptide was dissolved in 1 ml of 0.25M acetic acid and subjected to ascending chromatography on two columns (90×2.5 cm each) of G50-fine, connected in series and eluted with 0.25M acetic acid. The fractions (2 ml) were monitored by absorbance at 280 nm. The peak of the monomer, eluting at 523 ml, was well resolved from the oligomers which eluted as a single peak at 438 ml. The oligomers were saved for reduction and re-cyclization to obtain more monomer. The tubes containing the monomeric species were pooled and freeze-dried (yields: ChPepz, 26.7%; TrPepz, 33.2%). The monomer was further purified by HPLC on a 5 μm C 18 column (10 mm ID×25 cm) using a gradient of 0.05% acetic acid-triethylamine pH 5.5, and acetonitrile in 0.05% acetic acid (9:1 vol/vol). The fractions were monitored by absorbance at 256 nm and by their hydrolytic activity toward BTEE (for ChPepz) or TAME (for TrPepz). The active fraction was freeze-dried and reapplied on the same column using a gradient of 0.1% acetic acid and acetonitrile in 0.1% acetic acid (9:1 vol/vol). The catalytically-active fractions (yields: ChPepz, 12.1%; TrPepz, 11.5%, of the monomer) were homogeneous by high voltage paper electrophoresis and by analytical HPLC and their amino acid compositions were in excellent agreement with those expected from their covalent structures.
Measurement of Catalytic Activity
Chymotryptic activity. The catalytic activity of αCT and ChPepz was determined by hydrolysis of BTEE in 0.08M Tris buffer, pH 7.8 containing 0.01M CaCl 2 as described (Hummel, B. C. W. (1959) Can. J. Biochem. Physiol. 37, 1393-1399). Assays were done at 25° C. using 8.06×10 -4 μmoles of αCT or 7.49×10 -4 μmoles of ChPepz and different substrate concentrations (from 3 to 6 mM) in a total reaction volume of 1.0 ml. The change of absorbance at 256 nm was monitored on a recording spectrophotometer against a reference cuvette containing 1 ml of the same concentration of BTEE, but without αCT or ChPepz. Controls included trypsin, TrPepz (which are inactive against BTEE) and several linear and cyclic peptides from Applicant's peptide library although any such controls would work equally as well.
Tryptic activity. Measurement of tryptic activity was done in 0.046M Tris-HCl buffer, pH 8.0, containing 0.0115M CaCl 2 as described (Hummel, B. C. W. (1959), id) using TAME as the substrate. For the assays, 8.4×10 -4 μmoles of αCT or 1.6 c 10 -3 μmoles of TrPepz were allowed to hydrolyze different amounts of substrate at 25° C. in a total reaction volume of 1.0 ml. Hydrolysis was monitored on a recording spectrophotometer by change in absorbance at 247 nm against a reference cuvette containing the same concentration of TAME, but without trypsin or TrPepz. αCT, ChPepz (which do not hydrolyze TAME) and several linear and cyclic peptides from Applicants library were used as controls although others would work as well. Kinetic constants for hydrolysis of BTEE and TAME were determined from the linear plots of 1/initial velocity (Vi in μmoles/min) versus 1/substrate concentration as described (Lineweaver, H. and Burk, D. (1934) J. Amer. Chem. Soc. 56, 658).
Inhibition of Enzymatic Activity. The effects of inhibitors or disulfide bond reduction on enzymatic activities were done as described above except that the enzyme were pre-mixed (3 hrs, 25° C.) with 10 molar excess of inhibitor (or DTT) prior to addition to the substrate (140-150 molar excess relative to the catalyst). Activities were monitored spectrophotometrically as above and were compared to uninhibited controls.
Hydrolysis of Proteins by Enzymes or Peptide Enzyme Catalysts. Hydrolyses were done at 37° C. on aliquots (200 μl) containing 1 mg of myoglobin (5.6×10 -2 μmoles) or casein (4.2×10 -2 μmoles) in 0.1M triethylamine-acetic acid buffer, pH 8.0 with 51 μg of αCT (2.06×10 -3 μmoles) and 2.9 μg of ChPepz (1.1×10 -3 moles) for 31/2 hrs or with 49 μg trypsin (2.06×10 -3 μmoles) and 5.0 μg TrPepz (1.87×10 -3 μmoles) for 8 hrs. The samples were then acidified (to pH 3.0) with 0.1M HCl freeze-dried and redissolved in 100 μl of H 2 O at pH 3.0, and the entire sample was applied as a single spot to Whatman No. 3MM paper and subjected, in the first dimension, to ascending chromatography in n-butanol-acetic acid-water (4:1:5, vol/vol) followed by high voltage electrophoresis (3000 volts, 55 min), in the second dimension, in pyridine-acetic acid-water (1:10:289, vol/vol), pH 3.65, as described (Atassi, M. Z. and Saplin, B. J. (1968) Biochemistry 7, 688-698). The papers were then dried, steamed and stained with 0.2% ninhydrin in ethanol and the color was allowed to develop at room temperature. The papers were photographed 48 hrs after staining.
Chymotrypsin and Trypsin Examples
EXAMPLE I
Hydrolysis of Ester Substrates by αCT and ChPepz
Like αCT, the action of ChPepz on BTEE caused hydrolysis of the ester bond (FIG. 1). Lineweaver-Burk plots (FIG. 2) of experiments at different substrate concentrations showed that the kinetic constants of the hydrolysis of BTEE by αCT and by ChPepz were comparable (Table 1). The values of K m (a measure of substrate affinity) for ChPepz and αCT were almost identical, while the k cat value for ChPepz was only slightly lower than that of αCT. The specificity constants k cat /K m ) for BTEE with αCT and ChPepz were also quite comparable (Table 1). The activity of ChPepz was completely inhibited by the αCT inhibitors, TPCK and DIFP, and also completely lost when rendered acyclic by reduction of the disulfide bond. ChPepz had no hydrolytic activity on TAME (which is a trypsin substrate) and, as mentioned (below, BTEE was not hydrolyzed by TrPepz or by control cyclic and linear peptides that are not related to αCT.
TABLE 1______________________________________Kinetic constants for hydrolysis of BTEE by αCT and ChPepzand of TAME by trypsin and TrPepz.sup.1,2 K.sub.m k.sub.cat k.sub.cat /K.sub.m (M × 10.sup.-3) (sec..sup.-1) (M.sup.-1 Sec.sup.-1)______________________________________Hydrolysis of BTEE by:ChPepz 1.11 ± 0.15 147 ± 8.5 1.32 × 10.sup.5αCT 1.07 ± 0.16 185 ± 10.3 1.72 × 10.sup.5Hydrolysis of TAME by:TrPepz 2.42 ± 0.09 85 ± 2.6 3.5 × 10.sup.4Trypsin 2.56 ± 0.16 221 ± 9.7 8.6 × 10.sup.4______________________________________ .sup.1 Values of the constants for ChPepz and αCT were obtained at pH 7.8 and 25° C. while those for TrPepz and trypsin were derived from measurements at pH 8.0 and 25° C. For details, see the text. .sup.2 Note that BTEE is not hydrolysed by trypsin or TrPepz and TAME is not hydrolysed by αCT or ChPepz.
EXAMPLE II
Activity of TrPepz on Ester Substrates
In its action on TAME, TrPepz exhibited an activity which was very much like that of trypsin. Lineweaver-Burk plots of reactions at different substrate concentrations showed that TrPepz had an affinity for the substrate (K m ) which was similar to that of trypsin. It hydrolyzed TAME at a rate which was about 40% relative to the rate obtained with the enzyme itself (Table 1). The hydrolytic activity of TrPepz on TAME was completely lost by reduction of the disulfide bond. The activity of TrPepz on TAME was completely lost by reduction of the disulfide bond. The activity was also inhibited entirely by DIFP, PMSF, soybean trypsin inhibitor, BPTI and human α-antitrypsin (FIG. 3). On the other hand, the activity was not affected by TPCK. TrPepz had no effect on BTEE and, an mentioned above, TAME was not hydrolyzed by ChPepz or by control unrelated (to trypsin) cyclic or linear peptides. Thus, the replacement of residues converted the catalyst activity from chymotryptic to tryptic.
EXAMPLE III
Proteolytic Activity of ChPepz
To confirm that the ability of the two synthetic catalysts to hydrolyze, in a specific manner, the correct amino acid ester substrate was a true proteolytic activity, it was necessary to examine their action on peptide and protein substrates. The action of ChPepz on Mb and casein resulted in the hydrolysis of the respective protein by αCT (FIG. 4). The hydrolysis of the proteins by ChPepz was quite efficient and was achieved in a time-frame that was enzyme-like. The activity of ChPepz on protein substrates was completely inhibited by TPCK.
EXAMPLE IV
Proteolytic Activity of TrPepz
In order to further ascertain that TrPepz behaved like trypsin in activity and possessed its specificity, it was tested on model peptides and proteins. Its action (3 hrs; molar ratio of substrate/TrPepz, 95) on the peptide Gln-Leu-Glu-Pro-Ser-Thr-Ser-Ser-Ala-Val-Pro-Leu-Ile-Gly-Lys-Gly (SEQUENCE ID NO:5) resulted in almost complete (over 95%) hydrolysis of the Lys-Gly bond. The lysozyme sequences: Ala-Ala-Met-Lys-Arg-His-Gly-Leu-Asp-Asn (SEQUENCE ID NO:6), Asp-Asn-Tyr-Arg-Gly-Tyr-Ser-Leu-Gly (SEQUENCE ID NO:7), Ala-Lys-Lys-Ile-Val-Ser-Asp-Gly (SEQUENCE ID NO:8) were completely cleaved by TrPepz at the C-bond of the lysine and arginine residues indicated. No other products were obtained. The proteolytic activity of TrPepz was investigated on two proteins, myoglobin and casein. In each case, the peptide pattern of the TrPepz hydrolysate was essentially the same as the pattern of the respective protein obtained by tryptic hydrolysis (FIG. 5). However, TrPepz was in fact more efficient at hydrolyzing Lys-Lys, Lys-Lys-Lys, Arg-Lys and Lys-Arg bonds as evident from the higher yields of lysine and arginine in hydrolyses by Trpepz, as compared to those by trypsin. Finally, the proteolytic action of TrPepz, like that of trypsin, was completely inhibited by DIFP or PMSF while TPCK had no effect.
Design of the Synthetic Peptide Catalysts
EXAMPLE V
Surface Simulation of Chymotrypsin Active Site
The essential residues of the active sites of αCT and trypsin are shown in FIG. 6. These residues have been implicated as essential parts of the active site by chemical and crystallographic evidence which has been reviewed (Atassi, M. Z. (1985) Biochem. J. 226, 477-485). FIG. 7 shows that position of the contact residues in the sequence (using bovine chymotrypsinogen sequence numbers) and the distances (in Å) separating them. The sequence was obtained from reference (Meloun, B., Kluh, I., Kosta, V., Moravek, L., Prusik, Z., Vanecek, J., Keil, B. and Sorm, F. (1966) Biochim. Biophys. Acta 130, 543-546) and the X-ray coordinates are known to 1.68 Å resolution (Tsukada, H. and Blow, D. M. (1985) J. Mol. Biol. 184 703 (Protein Data Bank) entry code 4CHA). In order to determine the appropriate length of spacers to be used for linking the active site residues, we calculated the average (of 15) Cα-to-C.sup.α distances in single peptide bonds and two and three consecutive peptides bonds. These were: one peptide bond (C.sup.α -to-C.sup.α), 3.80±0.20 Å; two peptide bonds (distance between the first and the third α carbons in C.sup.α -C.sup.α -C.sup.α), 6.20±1.00 Å; three peptide bonds (distance between the first and the fourth a carbons in C.sup.α -C.sup.α -C.sup.α -C.sup.α), 7.94±2.07 Å. Therefore, the distances separating the contact residues (FIG. 7A) could be well accommodated by the glycine spacers shown in FIG. 7B. In surface-simulation synthesis, glycine residues have been found (Atassi, M. Z. (1986) in Protein Engineering, Applications in Science, Medicine and Industry (Inouye, M. and Sarma, R., Eds.) pp. 125-153, Academic Press, Orlando, Fla.) to be most suited for use as spacers, probably because of their flexibility and the fact that they provide no interfering side chains. The cyclic design, which is crucial for activity, requires closure. The Applicant measured several disulfide bonds in proteins and found that the C.sup.α -to-C.sup.α distance in Cys-S-S-Cys is 5.5±0.4 Å (range 5.11-5.93 Å). Closure of the peptide (to obtain a cyclic structure) could be achieved anywhere an appropriate space occurs in the structure provided the bond angles in the disulfide bridge do not interfere or induce undue distortion in the orientation of essential active site residues. The best design was that obtained by closure between Cys-58 and Phe-39 (or Tyr in TrPepz) which are separated by 13.16 Å (C.sup.α -to-C.sup.α). This is satisfied by a Gly-Cys spacer which, with the S-S bond, would give an effective separation of 11.7±1.4 Å. The inner sequence in FIG. 7b was designed to mimic the active site of αCT, while the outer sequence (which differs from the inner sequence by four residues: Phe-39→Tyr, Ile-99→Leu, Ser-189→Asp and Met-192→Gln) mimicked the active site of trypsin. The amino acid sequence of bovine trypsin and the X-ray coordinates for its active site were from references (Mikes, O., Holeysovsky, V., Tomasek, V. and Sorm, F. (1966) Biochem. Biophys, Res. Commun. 24, 346-352) and (Marquart, M., Walter, J., Deisenhofer, J., Bode, W. and Huber, R. (1983) Acta Crystallogr., Section B 39, 480 (Protein Data Bank entry 2PTN)), respectively.
EXAMPLE VI
Functional Behavior of the Synthetic Catalyst
The surface-simulation synthetic peptide, ChPepz, which was designed to mimic the active site of αCT behaved functionally very much like the enzyme itself. The kinetic constants for hydrolysis of BTEE by ChPepz and by αCT were comparable (Table 1). The affinity of ChPepz for the substrate, as evidenced from the K m value, was very similar to that of the whole enzyme. The k cat values indicated that ChPepz effected hydrolysis at a rate which was in the same order of magnitude as, and only slightly lower than, that of the whole enzyme. Our k cat value (185 sec -1 ) for BTEE hydrolysis by αCT is similar to the value of 193 sec -1 reported in the literature (Hartley, B. S., 1964) at pH 7.9 and 25° C. The values of the specificity constant (k cat /K m ) of ChPepz and αCT were also comparable indicating that BTEE functioned equally well as a substrate for both ChPepz and αCT. The similarity of the kinetic constants of αCT and ChPepz, and the inhibition of the ChPepz catalytic activity by DIFP (a serine esterase inhibitor) and by TPCK (an αCT inhibitor) suggest that the catalytic process by ChPepz must employ the same mechanism as αCT. The decrease in the rate of catalysis of ChPepz is probably caused by the flexibility of the peptide as it searches, through an equilibrium of conformational states and induced fit, for a catalytically-productive conformation. The virtual loss of catalytic activity when the peptide is rendered acyclic (by reduction of the disulfide bond) is most probably due to the inability of the open-chain structure to achieve such a conformation. This would explain why the first generation of Applicant's synthetic active sites, which employed an open-chain design (Atassi, M. Z. (1985) Biochem. J. 226, 477-485) exhibited binding but did not possess measurable catalytic activity. The inability of ChPepz to hydrolyze TAME, which is a trypsin substrate, further confirmed that this peptide had an αCT-like specificity. But the most compelling performance of ChPepz was its ability to hydrolyze proteins producing, from a given protein, peptides that were essentially the same as those produced by αCT.
In addition, test were performed which compared the activity of the two proteases under differing temperature parameters. If temperatures were changed to a lower 10° C. or a higher 48° C., and all other parameters being equal, each of the two synthetic catalysts were compared to their enzyme parent molecule, an interesting pattern is demonstrated as shown below.
______________________________________% Activity of Native Enzyme at 35° C.Temp. Chymotrypsin ChPepz Trypsin TrPepz______________________________________48 0 3.5 67 approx. 5035 100 100 100 approx. 4010 6.8 12.6 4.5 7.4______________________________________
Thus, not only do the synthetic catalysts exhibit activity at temperatures at which the native enzyme fails to do so, but also the synthetic catalysts may actually exhibit improved activity over that seen for the synthetic catalyst at standard temperatures.
EXAMPLE VII
Surface Simulation of Trypsin Active Site
To further confirm that an enzymically-active peptide design had been achieved, an analog was synthesized in which four residues were substituted to obtain a peptide (TrPepz) that would then mimic the active site of trypsin. Trypsin does not hydrolyze BTEE but hydrolyzes TAME. TrPepz behaved precisely like trypsin, exhibiting an almost identical substrate dissociation constant (K m and its k cat and k cat /K m values were about half the corresponding values of the enzyme (Table 1). The values of trypsin K m (2.56×10 -3 M) and k cat (221 sec -1 ) found here were in agreement with the reported values of 2.76×10 -3 M (Lorand, L. et al., 1961) and 187 sec -1 (Martin, C. J., Golubow, J. and Axelrod, A. E. (1959) J. Biol. Chem. 234, 1718-1725), respectively, at pH 8.0 and 25° C. The activity of TrPepz was completely inhibited by DIFP, PMSF, soybean trypsin inhibitor and human α- 1 -antitrypsin, all known to be inhibitors of trypsin. Like ChPepz, the cyclic structure of TrPepz was essential for activity. The most striking finding was the exquisite specificity of TrPepz for cleavage of the C-peptide bonds of arginine and lysine residues in peptides and proteins. Its action on myoglobin or casein resulted in hydrolysis of each protein into peptide fragments that were similar to those obtained by hydrolysis with trypsin itself. In fact, TrPepz was more efficient than trypsin at hydrolyzing Lys-Lys, Lys-Arg, Arg-Lys and Lys-Lys-Lys bonds. Thus, the substitution of four amino acid residues in the ChPepz design caused an unequivocal functional conversion from a chymotryptic to a tryptic activity.
LYSOZYME AND RIBONUCLEASE
General Materials and Methods
Materials. Hen egg lysozyme, Micrococcus lysodeikticus, bovine pancreatic ribonuclease A and yeast RNA were obtained from Worthington Biochemical Corp. Imidazole was purchased from Eastman Organic Chemicals. Tryptamine, histamine and dithiothreitol were from Aldrich Chemical Co. Silver nitrate, analytical grade, was from Fisher Scientific and herring testes DNA from Sigma Chemical Co. Reagents for peptide synthesis and N.sup.α -Fmoc-amino acids were obtained from Vega Biotechnologies.
Synthesis and Purification. The rationale for the design of the peptides and their structures are given in the examples below. The peptides, LyPepz and RnPepz, were prepared by solid phase synthesis on a benzyloxybenzyl alcohol resin to which 9-fluorenylmethyl-carbonyl (Fmoc)-S-ter-butyl cysteine had been coupled. The methods for synthesis, cyclization and isolation of the monomer have been described above. The oligomeric species was saved for reduction and re-cyclization. The monomeric species was further purified by HPLC on a 5 μm C18 column (10 mm ID×25 cm) using the following gradients: LyPepz, solvent A, 0.1% acetic acid-triethylamine, pH 5.5, and solvent B acetonitrile-0.1% acetic acid (9:1 vol/vol); RnPepz, solvent A, 0.1% trifluoroacetic acid (4:1, vol/vol). The fractions were monitored by absorbance at 256 nm and by their hydrolytic activity toward M. lysodeikticus (for LyPepz) or yeast RNA (for RnPepz). The active fraction was freeze-dried and applied on the same column using the same respective solvents but employing gradients that were less steep. The active site fractions (yields: LyPepz, 12.9%; RnPepz 12.2% of the monomer) were homogeneous by high voltage paper electrophoresis and by analytical HPLC, and their amino acid compositions were in excellent agreement with those expected from their covalent structures. Cyclic peptides, which are unrelated to LYZ or RNase and which were used as negative controls in the enzymic assays, were from Applicant's library of synthetic peptides as described above.
Measurement of Catalytic Activity
Measurement of Lysozyme Activity. The kinetics of the catalytic activity of LYZ and LyPepz were determined by hydrolysis of M. lysodeikticus as described (Neville, W. M. and Eyring, H. (1972) Proc. Natl. Acad. Sci. USA 88, 3613-3617). Assays were done at 25° C. in 0.125M NaCl using 1.5 μg (1.04×10 -4 μmole) of LYZ and 4.25 μg (1.13×10 -3 μmole) of LyPepz and different amounts of cell suspension (in the range 330 to 100 μg/ml) in a total reaction volume of 1.10 ml. The decrease in turbidity was measured at 450 nm on a recording spectrophotometer. Reaction mixtures that contained no catalyst or had RnPepz or other cyclic peptides that are unrelated to LYZ (instead of LyPepz) were used as controls. Kinetic constants were determined from the linear plots of 1/initial velocity (in change of absorbance/min) against 1/substrate concentration in mg/ml as described (Lineweaver, H. and Burk, D. (1934) J. Amer. Chem. Soc. 56, 658-666). To study the effect of reduction of the disulfide bond on the catalytic activity, LyPepz (5.6 μg=1.51×10 -3 μmole) or LYZ (1.5 μg=1.04×10 -4 mole) were mixed with 10 molar excess of dithiothreitol. After reaction at room temperature for 3 hr, the reduced cyclic synthetic peptide catalyst or LYZ were each added to 140 μg of M. lysodeikticus (total reaction volume, 1 ml of 0.125M NaCl) and the activity was measured by the decrease of absorbance at 450 nm as described above. The effects of the lysozyme inhibitors, imidazole, tryptamine and histamine were also determined by pre-mixing the synthetic catalyst or LYZ for 3 hr at room temperature with a 10 molar excess of each inhibitor before addition to the cells, using the same amounts of catalysts and cells, as described for the effect of dithiothreitol.
Measurement of Ribonuclease Activity. The catalytic activity of RNase and RnPepz were determined by their hydrolytic effects on yeast RNA (Kunitz, M. (1946) J. Biol. Chem. 164, 563-569; Gutte, B. and Merrifield, R. B. (1971) J. Biol. Chem. 246, 1922-1941). RNase (1.5 μg=1.095×10 -1 μmol) and RnPepz (2.9 μg=1.21×10 -3 μmole) were each mixed with different amounts of yeast RNA (from 500 to 180 μg/ml) in a total reaction volume of 1 ml of 0.1M sodium acetate at pH 5. The decrease in absorbance at 300 nm with time was measured on the recording spectrophotometer. Reaction mixtures that contained no catalyst as well as mixtures containing LyPepz or other cyclic peptides unrelated to RNase were used as controls. The kinetic parameters of the hydrolytic activities were determined by Lineweaver-Burk plots (Lineweaver, H. and Burk, D. (1934) J. Amer. Chem. Soc. 56, 658-666) of 1/absorbance change per minute against 1/substrate concentration in mg per ml.
The effects of disulfide-bond reduction on RNase and RnPepz activities were determined by premixing each catalyst (RNase, 1.095×10 -4 μmole; RnPepz, 2.42×10 -3 μmole) with 10 molar excess of DTT for 3 hr at room temperature, followed by addition to 600 μg of yeast RNA (total reaction volume, 1 ml. of 0.1M sodium acetate pH 5.0). The reactions were monitored by the decrease in absorbance at 300 nm as above. The effects of inhibitors (denatured DNA or Ag + ) on activities were also done by pre-mixing RNase or RnPepz with denatured DNA (250 μg) or with 10 molar excess of AgNO 3 prior to addition to RNA, using the same amounts of catalyst and substrate described for DTT. Denaturation of DNA was done by boiling a solution in water (1 mg/ml) for 10 min, then chilling immediately in ice.
Lysozyme and Ribonuclease Examples
EXAMPLE VIII
Hydrolysis of M. lysodeikticus by LYZ and LyPepz
In its action on M. lysodeikticus, LyPepz exhibited a lysozyme-like activity, causing complete hydrolysis of the cell wall of the organism (FIG. 8). The activity was specific since RnPepz had no hydrolytic activity on the cell wall. The kinetic constants were determined from experiments at different substrate concentrations (FIG. 9). Because it is not possible to express substrate concentrations in molar quantities, the constants were based on mg/ml and initial velocities in OD change/min. These results showed that the K m values of LyPepz and LYZ were quite comparable. The turn-over rate of LYZ, however, was about 7 times higher than that of LyPepz. The synthetic catalyst, like LYZ, was completely inhibited by imidazole, tryptamine or histamine (FIG. 8). The hydrolytic activity of LyPepz was completely lost by reduction of the disulfide bond with DTT (FIG. 8). It should be noted that RnPepz and other control peptides had no hydrolytic activity on M. lysodeikticus. Both LyPepz and LYZ showed an optimum temperature for activity between 30° C.-35° C. and there was no significant change in their activities to one another in the range 10° C.-45° C.
EXAMPLE IX
Hydrolysis of yeast RNA by RNase and RnPepz
Like Rnase, RnPepz was able to hydrolyze yeast RNA completely (FIG. 9), while LyPepz (used as a control) had no effect on this substrate. Because it is difficult to express substrate concentrations in molar quantities, the kinetic constants were calculated using substrate concentration values in mg/ml. Also, velocities of hydrolysis were measured in decrease in OD/min. Lineweaver-Burk plots of the hydrolytic reactions (FIG. 4) showed that the K m value for RnPepz was almost identical to that of RNase. RnPepz, however, exhibited a k cat value which was considerably lower than that of the whole enzyme. The activity of RnPepz was completely destroyed by reduction of the disulfide bond. The temperature optimum for the hydrolytic activity of RnPepz was around 25° C., while the optimum for the enzyme was closer to 35° C. In the range 17.5° C.-45° C., RnPepz and RNase showed little change in their relative activities. At 10° C. neither RnPepz nor RNase had any measurable hydrolytic activity on yeast RNA. Like RNase, RnPepz was completely inhibited by Ag + or denatured DNA. It should be noted that LyPepz, lysozyme and other synthetic cyclic peptides that are unrelated to RNase had no effect on yeast RNA.
Design of the Synthetic Peptide Catalysts Based on Ribonuclease and Lysozyme
Lysozyme (muramidase) catalyzes cleavage of the N-acetylmuramic acid-N-acetylglucosamine β-1,4-linkages that occur in the cell-wall polysaccharide of some organisms (e.g. M. lysodeikticus). The LYZ amino acid sequence (Canfield, R. E. (1963) J. Biol. Chem. 238, 2869; Jolles, J., Jauregui-Adell, J., Bernier, I. and Jolles, P. (1963) Biochim. Biophys. Acta 78, 668-698) and three-dimensional structure (Blake, C. C. F., Mair, G. A., North, A. C. T., Phillips, D. C. & Sharma, V. R. (1967) Proc. Roy. Soc. B167, 365; as well as its interactions with substrate analogs and inhibitors (Blake, C. C. F., Mair, G. A., North, A. C. T., Phillips, D. C. and Sarma, V. R. (1967) Proc. Roy. Soc. B167, 365-377; Imoto, T., Johnson, L. N., North, A. C. T., Phillips, D. C. and Rupley, J. A. (1972) in The Enzymes (Boyer, P. D., ed) Vol. 7, pp. 665-868) have been determined. For the present work, the X-ray coordinates were from Diamond, R. and Phillips, D. (1975) Protein Data Bank, Entry Identification Code 6LYZ; Kelly, J. and James, M. (1979) Protein Data Bank, Entry Identification Code 9LYZ. Ribonuclease A effects hydrolysis of the phosphodiester bond between the 5'-ribose of a nucleotide linked to the 3'ribose of a pyrimidine nucleotide. Its amino acid sequence (Smyth, D. G., Stein, W. H. and Moore, S. (1963) J. Biol. Chem. 238, 227-234.) and three-dimensional structure (Kartha, G., Bello, J. and Harker, D. (1967) Nature (London) 213, 862) are known. The RNase X-ray coordinates employed in the present studies were from Nachman, J. and Wlodawer, A. (1989) Protein Data Bank, Entry codes 8RSA and 9RSA.
EXAMPLE X
Lysozyme
The essential residues of the active site of LYZ are shown in FIG. 10. The elements of the design of LyPepz are outlined in FIG. 11, which shows (in FIG. 11a) the sequence positions of the LYZ active site residues together with the C.sup.α -to-C.sup.α distances (in Å separating them and (in FIG. 11b) the structure of the peptide designed to mimic the active site. FIG. 12 shows the essential residues of the active site of RNase. The distances separating these residues and the structure of the peptide designed to mimic the active site of RNase are given in FIG. 13. The appropriate numbers of glycine spacers used in the design of each synthetic catalyst were based on the finding (13) (Atassi, M. Z., (1993) Proc. Nat. Acad. Sci. USA 90:8282-8286) that the average C.sup.α -to-C.sup.α distances were: one peptide bond (C.sup.α -to-C.sup.α), 3.80±0.20 Å; two peptide bonds (distances between C.sup.α 1 and C.sup.α in C.sup.α 1 -C.sup.α 2 -C.sup.α 3 ), 6.20±1.00 Å; three peptide bonds (distance between C.sup.α 1 and C.sup.α 4 in C.sup.α 1 -C.sup.α 2 -C.sup.α 3 -C.sup.α 4 ), 7.94±2.07 Å. Glycine residues were found (12) (Atassi, M. Z., (1986) in Protein Engineering, Applications in Science, Medicine and Industry (Inouye M. and Sarma, R., Eds.) pp. 125-153, Academic Press, Orlando, Fla.) to be most suitable for use as spacers in surface-simulation synthesis, probably because they are flexible and do not have a side chain that might potentially interfere in the activity of the peptide. To prepare the cyclic structure which is essential for activity, the peptides were cyclized by an intramolecular disulfide bond. The latter was placed in each synthetic catalyst in a position that would closely maintain the appropriate spacing and cause no interference or undue distortion in the orientation of the essential site residues. The C.sup.α -to-C.sup.α distance in Cys-SS-Cys was found (Atassi, M. Z. et al. (1993), id) to be 5.52±0.41 Å. The best design, which fulfilled these requirements was obtained by a disulfide bridge between Asn-37 and Thr-43 in LyPepz and between Lys-7 and Glu-1 tin RnPepz (see FIGS. 11 and 12).
The peptide LyPepz possessed a catalytic activity which was similar to that of the protein itself. The affinity of LyPepz for the substrate was quite similar to that of LYZ as evidenced by their comparable K m values. The K m value obtained here for LYZ (121 mg/liter) in 0.125M NaCl is similar to the value of 129 mg/liter reported (Neville, W. M. et al. (1972), id) in the same solvent. The k cat values showed that LyPepz hydrolyzed the cell wall of M. lysodeikticus in a time-frame that was very much enzyme-like. The finding that LyPepz was almost completely inhibited by imidazole, histamine or tryptamine, which are known to inhibit LYZ by forming charge-transfer complexes with the tryptophan residues in the enzyme (Shinitzky, M., Katchalski, E., Grisaro, V. and Sharon, N. (1966) Arch. Biochem. Biophys. 116, 332-343; Swan, I. D. A. (1972) J. Mol. Biol. 65, 59-62), would indicate that LyPepz employs the same mechanism of catalysis as that used by LYZ. The inability of RnPepz and other control peptides to hydrolyze M. lysodeikticus cell wall demonstrated that the action of LyPepz on the cell wall is a true muramidase activity.
EXAMPLE XI
Ribonuclease
In their hydrolysis of yeast RNA, RnPepz and RNase, exhibited near-identical K m values (Table 2), indicating that the two catalysts possessed comparable affinities for the substrate. The K m value found here for RNase (1.25 mg/ml) in 0.1M sodium acetate buffer, pH 5.0, is in agreement with the reported values of 1.20 mg/ml (Gutte, B. et al. (1971), id) and 1.25 mg/ml (Edelhock, H. and Coleman, J. (1956) J. Biol. Chem. 219, 351-363). The k cat values of RnPepz and RNase showed that the synthetic catalyst effected hydrolysis at a rate which was considerably lower than that of the enzyme. Nevertheless, RnPepz was quite efficient and was in fact able to effect complete hydrolysis of RNA in an enzyme-like time frame. The specificity of the hydrolytic action of RnPepz on RNA was evident from its inability to hydrolyze the cell wall of M. lysodeikticus and conversely from the lack of action of LyPepz and other control peptides on RNA. The complete inhibition of RnPepz by heavy metals and by DNA, which are known to inhibit RNase (Sekine, H., Nakano, E. and Sakaguchi, K. (1969) Biochim. Biophys. Acta 174, 202-210), would suggest that the synthetic catalyst employs a similar catalytic mechanism to that of the enzyme.
EXAMPLE XII
Design Problem Areas
The lower rate of catalysis by the synthetic catalysts, relative to their respective enzymes, is most likely caused by the existence of each peptide in an equilibrium of conformational states influenced by substrate-induced fit. The peptide will display activity when a catalytically-productive conformation is achieved. The finding that integrity of the cyclic structure was crucial for the activity of both LyPepz and RnPepz (as evidenced from the total loss of activity on reduction of the disulfide bond) is probably due to the inability of the acyclic form to assume such a conformation. This is similar to the findings with the two proteolytic synthetic catalysts which mimicked the activities of trypsin and α-chymotrypsin (Atassi, et al. (1993), id). The presence in RnPepz of two segments (residues 7-8 and 41-45), possessing the retro-sequence to their counterparts in native RNase may have also contributed to the decrease in the rate of hydrolysis by RNPepz. A synthetic analog in which these two segments were made by D-amino acids did not show any significant changes in the rate of hydrolysis (data not shown).
TABLE 2______________________________________Kinetic constants for hydrolysis of M. lysodeikticus byLYZ and LyPepz and of yeast RNA by RNase and RnPepz k.sub.cat K.sub.m (OD units/ (mg/liter) μmole/sec)______________________________________Hydrolysis of M. lysodeikticus by:LyPepz 133.4 ± 2.6 1.38 ± 0.01LYZ 120.6 ± 4.0 9.26 ± 0.12Hydrolysis of yeast RNA by:RnPepz 1238 ± 228 0.559 ± 0.01RNase 1254 ± 460 14.05 ± 6.85* * * * * * * *______________________________________
The present invention has been described in terms of particular embodiments found or proposed to comprise preferred modes for the practice of the invention. It will be appreciated by those of skill in the art that, in light of the present disclosure, numerous modifications and changes can be made in the particular embodiments exemplified without departing from the intended scope of the invention. Thus, it will be understood by those of skill in the art that any enzyme sequence and 3-dimensional information which is available will serve admirably well as a model. In certain instances, where the sequence is known but the 3-dimensional structure of the chosen enzyme is not known, a homologous protein whose 3-dimensional structure and sequence are known can be used as a model. For example, the structure of trypsin can be used to model peptide catalysts designed to possess the activity of urokinase and tissue plasminogen activator. In addition, as demonstrated by the substitution of the trypsin residues for those of chymotrypsin herein, substitutions of active site residues can be used to modulate, alter or to improve catalytic function. Additionally, it is anticipated that certain designs will be useful even where there is not a particularly impressive correlation with the native enzyme kinetics at maximal conditions since the synthetic catalysts may exhibit desirable characteristics under conditions where the native enzyme fails to function. All such modifications are intended to be included within the scope of the appended claims.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 8(2) INFORMATION FOR SEQ ID NO: 1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 29 amino acids(B) TYPE: amino acid(D) TOPOLOGY: circular(ii) MOLECULE TYPE: protein(iii) HYPOTHETICAL: NO(iii) ANTI-SENSE: NO(v) FRAGMENT TYPE: not applicable(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 1:CysGlyPheHisPheGlyGlySerAspGlyMetGlySerSerGlyGly151015ValSerTrpGlyIleGlyGlyAspGlyAlaAlaHisCys2025(2) INFORMATION FOR SEQ ID NO: 2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 29 amino acids(B) TYPE: amino acid(D) TOPOLOGY: circular(ii) MOLECULE TYPE: protein(iii) HYPOTHETICAL: NO(v) FRAGMENT TYPE: not applicable(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 2:CysGlyTyrHisPheGlyGlySerAspGlyGluGlySerAspGlyGly151015ValSerTrpGlyLeuGlyGlyAspGlyAlaAlaHisCys2025(2) INFORMATION FOR SEQ ID NO: 3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 37 amino acids(B) TYPE: amino acid(D) TOPOLOGY: circular(ii) MOLECULE TYPE: protein(iii) HYPOTHETICAL: NO(v) FRAGMENT TYPE: not applicable(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 3:CysThrAsnArgAsnGlyGlyAspGlyGlyLeuGluIleAsnGlyTrp151015TrpGlyGlyIleGlyAspGlyAspGlyAlaTrpValAlaGlyArgGly202530PheGluSerAsnCys35(2) INFORMATION FOR SEQ ID NO: 4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 24 amino acids(B) TYPE: amino acid(D) TOPOLOGY: circular(ii) MOLECULE TYPE: protein(iii) HYPOTHETICAL: NO(v) FRAGMENT TYPE: not applicable(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 4:CysGluGlyValHisPheAspAlaSerGlyGlyThrAsnValProLys151015GlyGlyGluHisGlyPheLysCys20(2) INFORMATION FOR SEQ ID NO:5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 16 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(v) FRAGMENT TYPE: not applicable(xi) SEQUENCE DESCRIPTION: SEQ ID NO: 5:GlnLeuGluProSerThrSerSerAlaValProLeuIleGlyLysGly151015(2) INFORMATION FOR SEQ ID NO:6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 10 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(v) FRAGMENT TYPE: not applicable(xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:AlaAlaMetLysArgHisGlyLeuAspAsn1510(2) INFORMATION FOR SEQ ID NO:7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 9 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(v) FRAGMENT TYPE: not applicable(xi) SEQUENCE DESCRIPTION: SEQ ID NO:7:AspAsnTyrArgGlyTyrSerLeuGly15(2) INFORMATION FOR SEQ ID NO:8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 8 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(iii) HYPOTHETICAL: NO(iv) ANTI-SENSE: NO(v) FRAGMENT TYPE: not applicable(xi) SEQUENCE DESCRIPTION: SEQ ID NO:8:AlaLysLysIleValSerAspGly15__________________________________________________________________________
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Pepzymes, chemically synthesized cyclic peptides, modeled on lysozyme and ribonuclease have been prepared which efficiently catalyze the same reaction as the native enzyme being modeled. The synthetic pepzymes have a sequence of amino acids which is substantially shorter than the naturally occurring enzymes. Methods of producing these pepzymes are described. Pepzymes may be useful catalysts under conditions where the native enzymes are inactive.
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TECHNICAL FIELD
[0001] The present invention relates to an industrially advantageous production method of an imidazole derivative.
BACKGROUND OF THE INVENTION
[0002] It is known that an imidazole derivative represented by the following formula (Ia):
[0000]
[0000] wherein n is an integer of 1 to 3, and Ar is an aromatic ring optionally having substituent(s),
or a salt thereof has high safety and superior steroid C 17-20 lyase inhibitory activity, and is useful for the prophylaxis or treatment of diseases for which androgen or estrogen is an aggravating factor (patent document 1).
[0003] As the production method of the above-mentioned imidazole derivative, the methods described in patent document 1 and patent document 2 are known.
[0004] However, there is a demand for an advantageous production method of the imidazole derivative, which is suitable for industrial production.
DOCUMENT LIST
Patent Document
[0000]
Patent Document 1: WO 02/40484
Patent Document 2: WO 03/059889
SUMMARY OF THE INVENTION
Problems to be Solved by the Invention
[0007] In the production method of patent document 2, the synthetic reaction of the following formula (Ib):
[0000]
[0000] wherein Ar is an aromatic hydrocarbon group optionally having substituent(s), and PG is an imidazole-protecting group, which is an intermediate for synthesizing the above-mentioned formula (Ia), needs to be carried out in the presence of an organic lithium compound at an ultralow temperature of −65° C.
[0008] In view of such situation, an object of the present invention is to provide a novel production method of an imidazole derivative represented by the above-mentioned formula (Ia), particularly 6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide or a salt thereof, which is suitable for efficient and convenient industrial production. In addition, another object of the present invention is to provide a production method of a compound useful as an intermediate for synthesizing 6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide or a salt thereof, specifically the below-mentioned compound (VI) and compound (IX), which is suitable for efficient and convenient industrial production.
Means of Solving the Problems
[0009] The present inventors have conducted intensive studies in an attempt to solve the above-mentioned problems and found that the synthetic reaction of a compound represented by the above-mentioned formula (Ib), particularly the below-mentioned compound (VI), can proceed under mild conditions by using an organic magnesium compound together with an organic lithium compound, which resulted in the completion of the present invention.
[0010] Accordingly, the present invention is as follows;
[1] A method of producing a compound represented by the formula:
[0000]
[0000] wherein PG is a protecting group,
or a salt thereof (hereinafter sometimes to be referred to as compound (VI)), which comprises
Step (1): a step of reacting a compound represented by the formula:
[0000]
[0000] wherein R 1 is an iodine atom or a bromine atom,
(hereinafter sometimes to be referred to as compound (I)) with a compound represented by the formula:
[0000] R 2 —MgX (II)
[0000] wherein R 2 is a C 1-6 alkyl group or a C 6-12 aryl group; and X is a chlorine atom, a bromine atom or an iodine atom,
(hereinafter sometimes to be referred to as compound (II)), or a compound represented by the formula:
[0000] R 2 R 2′ —Mg (III)
[0000] wherein R 2′ is a C 1-6 alkyl group or a C 6-12 aryl group; and R 2 is as defined above,
(hereinafter sometimes to be referred to as compound (III)), and a compound represented by the formula:
[0000] R 3 —Li (IV)
[0000] wherein R 3 is a C 1-6 alkyl group or a C 6-12 aryl group,
(hereinafter sometimes to be referred to as compound (IV)),
and then reacting the resulting compound with a compound represented by the formula:
[0000]
[0000] wherein PG is as defined above,
or a salt thereof (hereinafter sometimes to be referred to as compound (V)).
[2] A method of producing 6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide or a salt thereof, which comprises
Step (1): a step of reacting a compound represented by the formula:
[0000]
[0000] wherein R 1 is an iodine atom or a bromine atom, with a compound represented by the formula:
[0000] R 2 —MgX (II)
[0000] wherein R 2 is a C 1-6 alkyl group or a C 6-12 aryl group; and X is a chlorine atom, a bromine atom or an iodine atom,
or a compound represented by the formula:
[0000] R 2 R 2′ —Mg (III)
[0000] wherein R 2′ is a C 1-6 alkyl group or a C 6-12 aryl group; and R 2 is as defined above,
and a compound represented by the formula:
[0000] R 3 —Li (IV)
[0000] wherein R 3 is a C 1-6 alkyl group or a C 6-12 aryl group,
and then reacting the resulting compound with a compound represented by the formula:
[0000]
[0000] wherein PG is a protecting group, or a salt thereof;
Step (2): a step of subjecting a compound represented by the formula:
[0000]
[0000] wherein PG is as defined above,
or a salt thereof, (hereinafter sometimes referred to as compound (VI)), which is obtained in Step (1), to oxidation;
Step (3): a step of reacting a compound represented by the formula:
[0000]
[0000] wherein PG is as defined above,
or a salt thereof (hereinafter sometimes to be referred to as compound (VII)), which is obtained in Step (2), with a compound represented by the formula:
[0000] BrZnCH 2 CO 2 —R 4 (VIII)
[0000] wherein R 4 is a C 1-6 alkyl group,
(hereinafter sometimes to be referred to as compound (VIII));
Step (4): a step of subjecting a compound represented by the formula:
[0000]
[0000] wherein each symbol is as defined above,
or a salt thereof (hereinafter sometimes to be referred to as compound (IX)), which is obtained in Step (3), to reduction; and
Step (5): a step of subjecting a compound represented by the formula:
[0000]
[0000] wherein PG is as defined above,
or a salt thereof (hereinafter sometimes to be referred to as compound (X)), which is obtained in Step (4), to cyclization and deprotection.
[3] A method of producing of a compound represented by the formula:
[0000]
[0000] wherein PG is a protecting group; and R 4 is a C 1-6 alkyl group,
or a salt thereof, which comprises
Step (3a): a step of reacting a compound represented by the formula:
[0000]
[0000] wherein PG is as defined above,
or a salt thereof, with a compound represented by the formula:
[0000] BrZnCH 2 CO 2 —R 4 (VIII)
[0000] wherein R 4 is as defined above,
and then adding citric acid to the obtained reaction mixture.
[4] A method of producing of 6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide or a salt thereof, which comprises
Step (3a): a step of reacting a compound represented by the formula:
[0000]
[0000] wherein PG is a protecting group,
or a salt thereof, with a compound represented by the formula:
[0000] BrZnCH 2 CO 2 —R 4 (VIII)
[0000] wherein R 4 is a C 1-6 alkyl group,
and then adding citric acid to the obtained reaction mixture;
Step (4): a step of subjecting a compound represented by the formula:
[0000]
[0000] wherein each symbol is as defined above,
or a salt thereof, which is obtained in Step (3a), to reduction; and
Step (5): a step of subjecting a compound represented by the formula:
[0000]
[0000] wherein PG is as defined above,
or a salt thereof, which is obtained in Step (4), to cyclization and deprotection.
[5] The method of any of the above-mentioned [1] to [4], wherein PG is trityl.
[6] The method of any of the above-mentioned [1] to [4], wherein PG is tosyl, benzenesulfonyl or N,N-dimethylaminosulfonyl.
[7] The method of the above-mentioned [2], wherein Step (3) is
Step (3a): a step of reacting a compound represented by the formula:
[0000]
[0000] wherein PG is a protecting group,
or a salt thereof, with a compound represented by the formula:
[0000] BrZnCH 2 CO 2 —R 4 (VIII)
[0000] wherein R 4 is a C 1-6 alkyl group,
and then adding citric acid to the obtained reaction mixture.
Effect of the Invention
[0012] The production method of the present invention using, as organic metal reagents, an organic lithium compound and an organic magnesium compound, for the production of compound (VI) does not require the reaction to be carried out at an ultralow temperature (for example, −65° C.)
[0013] In addition, work-up of the reaction mixture by adding citric acid after completion of the reaction in the production of compound (IX) suppresses decomposition of compound (IX) as well as the amount of the zinc remaining in the reaction mixture. As a result, the yield and purity of compound (IX) can be improved, and the yield and purity of the final product, 6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide or a salt thereof, and the object product in each step up to the final product can also be improved.
[0014] Accordingly, the production method of the present invention is a method of producing 6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide or a salt thereof, which is suitable for efficient and convenient industrial production.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 shows a powder X-ray diffraction pattern of 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide 1 hydrate.
[0016] FIG. 2 shows a powder X-ray diffraction pattern of 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide anhydride.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In the present specification, the “C 1-6 alkyl group” means methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-pentyl, isopentyl, neopentyl, 1-ethylpropyl, n-hexyl, isohexyl, 1,1-dimethylbutyl, 2,2-dimethylbutyl, 3,3-dimethylbutyl, 2-ethylbutyl or the like, and is preferably a C 1-4 alkyl group.
[0018] In the present specification, the “C 1-4 alkyl group” means methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl or the like.
[0019] In the present specification, the “C 6-12 aryl group” means phenyl, 1-naphthyl, 2-naphthyl or the like.
[0020] In the present specification, the “protecting group” means a nitrogen-protecting group (e.g., a formyl group, a C 1-6 alkyl-carbonyl group, a C 1-6 alkoxy-carbonyl group (e.g., tert-butoxycarbonyl), a benzoyl group, a C 7-10 aralkyl-carbonyl group (e.g., benzylcarbonyl), a C 7-14 aralkyloxy-carbonyl group (e.g., benzyloxycarbonyl, 9-fluorenylmethoxycarbonyl), a trityl group, a phthaloyl group, an N,N-dimethylaminomethylene group, a substituted silyl group (e.g., trimethylsilyl, triethylsilyl, dimethylphenylsilyl, tert-butyldimethylsilyl, tert-butyldiethylsilyl), a C 2-6 alkenyl group (e.g., 1-allyl), a substituted C 7-10 aralkyl group (e.g., 2,4-dimethoxybenzyl), a C 1-6 alkylsulfonyl group (e.g., methanesulfonyl), a C 6-12 arylsulfonyl group (e.g., benzenesulfonyl, tosyl (toluenesulfonyl)), an N,N-di-C 1-6 alkylaminosulfonyl group (e.g., N,N-dimethylaminosulfonyl) etc.). The protecting group is optionally substituted by 1 to 3 substituents selected from a halogen atom, a C 1-6 alkoxy group and a nitro group.
[0021] R 1 is preferably a bromine atom.
[0022] R 2 is preferably a C 1-6 alkyl group, more preferably a C 1-4 alkyl group, more preferably isopropyl.
[0023] R 2′ is preferably a C 1-6 alkyl group, more preferably a C 1-4 alkyl group.
[0024] R 3 is preferably a C 1-4 alkyl group, more preferably butyl.
[0025] R 4 is preferably a C 1-4 alkyl group, more preferably ethyl.
[0026] X is preferably a chlorine atom.
[0027] PG is preferably trityl. In another embodiment, PG is preferably tosyl, benzenesulfonyl or N,N-dimethylaminosulfonyl.
[0028] Each step in the production method of the present invention is explained in the following.
[Step 1]
[0029] In Step 1, compound (VI) is obtained by reacting compound (I) with compound (II) or compound (III), and compound (IV), and then reacting the resulting compound with compound (V).
[0030] First, compound (I) is reacted with compound (II) or compound (III), and compound (IV) (Step 1a). Since the intermediate produced by the reaction has a magnesiated methylamido group, and therefore, it is stabilized, and the next reaction with compound (V) can be carried out under a mild condition.
[0031] Examples of the compound (II) include C 1-6 alkylmagnesium halides such as methylmagnesium chloride, ethylmagnesium chloride, isopropylmagnesium chloride, methylmagnesium bromide, ethylmagnesium bromide, isopropylmagnesium bromide and the like; and C 6-12 arylmagnesium halides such as phenylmagnesium chloride, phenylmagnesium bromide and the like. Among them, C 1-4 alkylmagnesium halides are preferable. The halide means chloride, bromide or iodide, preferably chloride or bromide, more preferably chloride. Compound (II) is preferably isopropylmagnesium chloride.
[0032] Examples of the compound (III) include di-C 1-6 alkylmagnesiums. Among them, di-C 1-4 alkylmagnesiums are preferable. Compound (III) is preferably dibutylmagnesium.
[0033] Examples of the compound (IV) include C 1-6 alkyllithiums such as n-butyllithium, sec-butyllithium, tert-butyllithium and the like; and C 6-12 aryllithiums. Among them, C 1-4 alkyllithiums are preferable. Compound (IV) is preferably n-butyllithium.
[0034] The amount of compound (II) or compound (III) to be used is generally about 0.1 to about 10 equivalents, preferably about 0.1 to about 3 equivalents, relative to compound (I).
[0035] The amount of compound (IV) to be used is generally about 1 to about 10 equivalents, preferably about 1 to about 3 equivalents, relative to compound (I).
[0036] To improve the yield and purity of the object product, the reaction is preferably carried out by adding (preferably adding dropwise) compound (II) or compound (III) to compound (I), and then adding (preferably adding dropwise) compound (IV) to the obtained mixture.
[0037] The reaction is generally carried out in a solvent.
[0038] The solvent is not particularly limited as long as it does not adversely influence the reaction, and examples thereof include aromatic hydrocarbons such as benzene, toluene, xylene and the like; aliphatic hydrocarbons such as hexane, pentane, heptane and the like; ethers such as diethyl ether, diisopropyl ether, tert-butyl methyl ether, cyclopentyl methyl ether, tetrahydrofuran, dioxane, 1,2-dimethoxyethane, bis(2-trimethoxyethyl)ether and the like; aromatic halogenated hydrocarbons such as chlorobenzene, dichlorobenzene, benzotrifluoride and the like; and the like. These may be used alone or in a mixture of two or more kinds thereof at an appropriate ratio. Among them, the above-mentioned ethers and aliphatic hydrocarbons are preferable, and tetrahydrofuran, hexane, heptane and toluene are more preferable.
[0039] The amount of the solvent to be used is generally 1 to 100-fold, preferably 10 to 80-fold, relative to compound (I).
[0040] The reaction temperature is generally about −40° C. to about 200° C., preferably about −40° C. to about 40° C. When compound (II) or compound (III) is added to compound (I) and then compound (IV) is added to the obtained mixture, the addition of compound (II) or compound (III) is generally carried out at about −40° C. to about 200° C., preferably about −10° C. to about 40° C., and the addition of compound (IV) is generally carried out at −40° C. to about 200° C., preferably about −40° C. to about 10° C.
[0041] While the reaction time varies depending on the kinds of compound (I)—compound (IV) and the reaction temperature, it is generally about 5 min to about 48 hr, preferably about 1 hr to about 12 hr.
[0042] After completion of the reaction, the reaction product is used for the next reaction with compound (V) as the reaction mixture. Step 1a is preferably carried out under an inert condition such as a nitrogen atmosphere and the like.
[0043] Compound (I)-compound (IV), which are starting materials, can be produced according to a method known per se, for example, the method described in WO 03/059889.
[0044] Second, compound (VI) is obtained by reacting the reaction product obtained in Step 1a with compound (V) (Step 1b).
[0045] The amount of compound (V) to be used is generally about 0.1 to about 10 equivalents, preferably about 1 to about 3 equivalents, relative to compound (I).
[0046] The reaction is preferably carried out by adding (preferably adding dropwise) compound (V) to the reaction product obtained in Step 1a.
[0047] The reaction is generally carried out in a solvent. Examples of the solvent include those similar to the solvent exemplified in Step 1a.
[0048] The reaction temperature is generally about −40° C. to about 200° C., preferably about −40° C. to about 40° C.
[0049] While the reaction time varies depending on the kinds of compound (V) and the reaction temperature, it is generally about 5 min to about 48 hr, preferably about 1 hr to about 12 hr.
[0050] After completion of the reaction, the obtained compound (VI) can be used for the next reaction as the reaction mixture or as a crude product, or can also be isolated according to a conventional method from the reaction mixture, and can also be easily purified according to a conventional separation means (e.g., recrystallization, distillation, chromatography).
[0051] Compound (V) can be produced according to a method known per se.
[Step 2]
[0052] In Step 2, compound (VII) is obtained by subjecting compound (VI) to oxidation.
[0053] The oxidation is generally carried out using an oxidant in a solvent.
[0054] Examples of the oxidant include chromic acid-acetic acid, Jones reagent, anhydrous chromic acid-pyridine complex, manganese dioxide, silver carbonate-Celite, dimethyl sulfoxide-oxalyl chloride, aluminum alkoxide-ketone, tetrapropylammonium-perruthenate, ruthenium tetraoxide, hypochlorous acid-acetic acid, periodinane compounds, dimethyl sulfoxide-acetic anhydride, 2,2,6,6-tetramethylpiperidine-1-oxyradical-hypochlorous acid, benzenesulfenamide-N-halogenated succinimide, N-halogenated succinimide, bromine, sodium hydride and the like. Among them, manganese dioxide and sodium hydride are preferable, and manganese dioxide is particularly preferable.
[0055] The amount of the oxidant to be used is generally about 1 to about 30 equivalents, preferably about 1 to about 10 equivalents, relative to compound (VI).
[0056] The solvent is not particularly limited as long as it does not adversely influence the reaction, and examples thereof include aromatic hydrocarbons such as benzene, toluene, xylene and the like; aliphatic hydrocarbons such as hexane, pentane, heptane and the like; esters such as ethyl acetate, n-butyl acetate and the like; ethers such as diethyl ether, diisopropyl ether, tert-butyl methyl ether, cyclopentyl methyl ether, tetrahydrofuran, dioxane, 1,2-dimethoxyethane, bis(2-trimethoxyethyl)ether and the like; aliphatic halogenated hydrocarbons such as dichloromethane, chloroform, dichloroethane, carbon tetrachloride and the like; aromatic halogenated hydrocarbons such as chlorobenzene, dichlorobenzene, benzotrifluoride and the like; ketones such as acetone, methyl ethyl ketone and the like; and aprotic polar solvents such as acetonitrile, N,N-dimethylformamide, N,N-dimethylacetamide, N-methylpyrrolidone, dimethylsulfoxide and the like. These may be used alone or in a mixture of two or more kinds thereof at an appropriate ratio. Among them, the above-mentioned aliphatic halogenated hydrocarbons, ethyl acetate, N,N-dimethylformamide and N,N-dimethylacetamide are preferable.
[0057] The amount of the solvent to be used is generally 1 to 100-fold, preferably 5 to 80-fold, relative to compound (VI).
[0058] The reaction temperature is generally about −40° C. to about 200° C., preferably about 0° C. to about 100° C.
[0059] While the reaction time varies depending on the kinds of compound (VI) and oxidant and the reaction temperature, it is generally about 5 min to about 48 hr, preferably about 1 to about 12 hr.
[0060] After completion of the reaction, the resultant product can be used for the next reaction as the reaction mixture or as a crude product, or can also be isolated according to a conventional method from the reaction mixture, and can also be easily purified according to a conventional separation means (e.g., recrystallization, distillation, chromatography).
[Step 3]
[0061] In Step 3, compound (IX) is obtained by reacting compound (VII) with compound (VIII).
[0062] Compound (VIII) is prepared from a compound represented by the formula:
[0000] BrCH 2 CO 2 —R 4 (VIIIa)
[0000] wherein R 4 is as defined above,
(hereinafter sometimes to be referred to as compound (VIIIa)) and zinc.
[0063] The preparation is generally carried out by reacting compound (VIIIa) with zinc in the presence of an activator, in a solvent.
[0064] The zinc is used in the form of powder, flake, wire or foil, particularly preferably in the form of powder. Zinc may be subjected to a conventional pre-treatment by washing with an acid, or a commercially available product may be directly used.
[0065] The amount of the zinc to be used is preferably an excess amount relative to compound (VIIIa). Specifically, it is preferably 1 equivalent or more, more preferably 1 to 50 equivalents, still more preferably 1 to 5 equivalents, particularly preferably 1 to 3 equivalents, relative to compound (VIIIa).
[0066] Examples of the activator include hydroiodic acid, 1,2-dibromoethane, halogenated copper, halogenated silver, trimethylsilyl chloride and molecular sieve. Among them, trimethylsilyl chloride is preferable. In addition, zinc-copper couple, Rieke-Zn, zinc-silver-graphite, zinc chloride-lithium, zinc chloride-lithium naphthalide, zinc and zinc compound each activated by ultrasonication, and the like can be used.
[0067] The amount of the activator to be used is generally about 0.01 to about 1 equivalent, preferably about 0.01 to about 0.2 equivalent, relative to compound (VIIIa).
[0068] To improve the yield and purity of the object product, the reaction is preferably carried out by adding an activator to zinc, and then adding (preferably adding dropwise) compound (VIIIa) to the obtained mixture.
[0069] The solvent is not particularly limited as long as it does not adversely influence the reaction, and examples thereof include aromatic hydrocarbons such as benzene, toluene, xylene and the like; aliphatic hydrocarbons such as hexane, pentane, heptane and the like; esters such as ethyl acetate, butyl acetate and the like; ethers such as diethyl ether, diisopropyl ether, tert-butyl methyl ether, tetrahydrofuran, dioxane, cyclopentyl methyl ether, 1,2-dimethoxyethane, bis(2-methoxyethyl)ether and the like; aliphatic halogenated hydrocarbons such as methylene chloride, chloroform, dichloroethane, carbon tetrachloride and the like; aromatic halogenated hydrocarbons such as chlorobenzene, dichlorobenzene, benzotrifluoride and the like; and aprotic polar solvents such as acetonitrile, N,N-dimethylformamide, N,N-dimethylacetamide, N-methylpyrrolidone, dimethylsulfoxide and the like. These may be used alone or in a mixture of two or more kinds thereof at an appropriate ratio. Among them, the above-mentioned aliphatic hydrocarbons, aromatic hydrocarbons and ethers are preferable, and cyclopentyl methyl ether and tetrahydrofuran are more preferable. A smaller amount of water is preferably contained in the solvent, and the amount is particularly preferably 0.005% or less. When an ether such as tetrahydrofuran and the like is used as a solvent, a stabilizer (e.g., 2,6-di-t-butyl-4-methyl-phenol etc.) may be added thereto if desired.
[0070] The amount of the solvent to be used is generally 1 to 100-fold, preferably 5 to 30-fold, relative to compound (VIIIa).
[0071] The addition of the activator is generally carried out at about −40° C. to about 100° C., preferably 0° C. to about 60° C. While the reaction time varies depending on the kinds of the activator and the reaction temperature, it is generally about 5 min to about 10 hr, preferably about 5 min to about 2 hr.
[0072] The addition of compound (VIIIa) is generally carried out at about −40° C. to about 100° C., preferably about 0° C. to about 60° C. While the reaction time varies depending on the kinds of compound (VIIIa) and the reaction temperature, it is generally about 5 min to about 10 hr, preferably about 5 min to about 2 hr.
[0073] Compound (VIIIa) can be produced according to a method known per se.
[0074] Compound (VIII) thus prepared is used for the next reaction with compound (VII) as the reaction mixture.
[0075] The amount of compound (VIII) to be used is generally about 1 to about 10 equivalents, preferably about 1 to about 5 equivalents, relative to compound (VII).
[0076] In addition, an amine may be added to compound (VIII) in order to promote the reaction. Examples of the amine include aromatic amines such as pyridine, lutidine, quinoline, bipyridyl and the like; and tertiary amines such as triethylamine, tripropylamine, tributylamine, cyclohexyldimethylamine, 4-dimethylaminopyridine, N,N-dimethylaniline, N-methylpiperidine, N-methylpyrrolidine, N-methylmorpholine, N,N′-tetramethylethylenediamine and the like.
[0077] The amount of the amine to be used is generally about 1 to about 20 equivalents, preferably about 1 to about 10 equivalents, relative to compound (VII).
[0078] The solvent is not particularly limited as long as it does not adversely influence the reaction, and examples thereof include aromatic hydrocarbons such as benzene, toluene, xylene and the like; aliphatic hydrocarbons such as hexane, pentane, heptane and the like; esters such as ethyl acetate, butyl acetate and the like; ethers such as diethyl ether, diisopropyl ether, tert-butyl methyl ether, tetrahydrofuran, dioxane, cyclopentyl methyl ether, 1,2-dimethoxyethane, bis(2-methoxyethyl)ether and the like; aliphatic halogenated hydrocarbons such as methylene chloride, chloroform, dichloroethane, carbon tetrachloride and the like; aromatic halogenated hydrocarbons such as chlorobenzene, dichlorobenzene, benzotrifluoride and the like; and aprotic polar solvents such as acetonitrile, N,N-dimethylformamide, N,N-dimethylacetamide, N-methylpyrrolidone, dimethylsulfoxide and the like. These may be used alone or in a mixture of two or more kinds thereof at an appropriate ratio. Among them, the above-mentioned aliphatic hydrocarbons, aromatic hydrocarbons and ethers are preferable, and cyclopentyl methyl ether and tetrahydrofuran are more preferable.
[0079] The reaction temperature is generally about −80° C. to about 150° C., preferably −40° C. to about 20° C.
[0080] While the reaction time varies depending on the kinds of compound (VII) and compound (VIII) and the reaction temperature, it is generally about 5 min to about 20 hr, preferably about 30 min to about 5 hr.
[0081] After completion of the reaction, an acid is preferably added to the reaction mixture. The zinc which has been mixed up with compound (VIII) (the zinc which is remaining in the reaction mixture of compound (VIII)) can be removed by the addition of the acid to the reaction mixture. In addition, compound (IX) can be obtained in high yield by the addition of the acid to the reaction mixture.
[0082] Examples of the acid include inorganic acids such as hydrochloric acid, hydrobromic acid, nitric acid, sulfuric acid, phosphoric acid and the like; and organic acids such as formic acid, acetic acid, trifluoroacetic acid, phthalic acid, fumaric acid, oxalic acid, tartaric acid, maleic acid, citric acid, succinic acid, malic acid, methanesulfonic acid, benzenesulfonic acid, p-toluenesulfonic acid and the like. Among them, citric acid, tartaric acid, succinic acid, malic acid, fumaric acid and maleic acid are preferable, and citric acid is particularly preferable, since the zinc which has been mixed up with compound (VIII) can be efficiently removed and decomposition of the reaction product, compound (IX), can be prevented.
[0083] The amount of the acid to be used is generally about 1 to about 100-fold, preferably about 5 to about 20-fold, relative to compound (VIII).
[0084] After the addition of the acid, the obtained compound (IX) can be used for the next reaction as the reaction mixture or as a crude product, or can also be isolated according to a conventional method from the reaction mixture, and can also be easily purified according to a conventional separation means (e.g., recrystallization, distillation, chromatography).
[0085] The optically active compound (IX) can be obtained by reacting compound (VII) with compound (VIII) in the presence of an asymmetric ligand.
[0086] Examples of the asymmetric ligand include optically active aminoalcohol derivatives, optically active alcohol derivatives and optically active amine derivatives. Examples of the optically active aminoalcohol derivative include cinchona alkaloids such as cinchonine, cinchonidine, quinidine, kinin and the like; N-methylephedrine, norephedrine, 3-oxo-(dimethylamino)isoborneol, 1-methyl-2-pyrrolidinemethanol, 1-benzyl-2-pyrrolidinemethanol, 2-[hydroxy(diphenyl)methyl]-1-methylpyrrolidine and 2,2′-{benzene-1,3-diylbis[methanediyl(methylimino)]}bis(1-phenylpropan-1-ol). Examples of the optically active alcohol derivative include 1,2-binaphthol. Examples of the optically active amine derivative include strychnine and sparteine. Compound (IX) having a desired steric configuration can be obtained depending on the selection of the asymmetric ligand.
[0087] The amount of the asymmetric ligand to be used is generally about 0.01 to about 5 equivalents, preferably about 0.01 to about 2 equivalents, relative to compound (VII).
[0088] Step 3 can also be performed using compound (VIII) wherein the bromine atom is replaced by an iodine atom, instead of compound (VIII).
[Step 4]
[0089] In Step 4, compound (X) is obtained by subjecting compound (IX) to reduction.
[0090] The reaction is generally carried out in the presence of a metal hydride complex compound, in a solvent. A metal halide may be added for this reaction.
[0091] Examples of the metal hydride complex compound include alkali metal hydride complex compounds such as sodium borohydride, lithium borohydride, potassium borohydride, sodium cyanoborohydride and the like; and zinc borohydride. Among them, alkali metal hydride complex compounds such as sodium borohydride, lithium borohydride, potassium borohydride and the like are preferable, sodium borohydride and potassium borohydride are more preferable, and sodium borohydride is particularly preferable.
[0092] The amount of the metal hydride complex compound to be used is generally 1 to 50 mol, preferably 2 to 10 mol, per 1 mol of compound (IX).
[0093] Examples of the metal halide include halogenated aluminums such as aluminum chloride, aluminum bromide and the like; halogenated lithiums such as lithium iodide, lithium chloride, lithium bromide and the like; halogenated magnesiums such as magnesium chloride, magnesium bromide and the like; halogenated calciums such as calcium chloride, calcium bromide and the like; halogenated zincs such as zinc chloride, zinc bromide and the like; iron chloride, tin chloride and boron fluoride. Among them, halogenated calciums such as calcium chloride, calcium bromide and the like; and halogenated zincs such as zinc chloride, zinc bromide and the like are preferable, halogenated calciums such as calcium chloride, calcium bromide and the like are more preferable, and calcium chloride is particularly preferable.
[0094] The amount of the metal halide to be used is generally 0.1 to 10 mol, preferably 0.1 to 5 mol, per 1 mol of compound (IX).
[0095] The solvent is not particularly limited as long as it does not adversely influence the reaction, and examples thereof include aromatic hydrocarbons such as benzene, toluene, xylene and the like; aliphatic hydrocarbons such as hexane, pentane, heptane and the like; ethers such as diethyl ether, diisopropyl ether, tert-butyl methyl ether, tetrahydrofuran, dioxane, 1,2-dimethoxyethane, bis(2-methoxyethyl)ether and the like; aliphatic halogenated hydrocarbons such as methylene chloride, chloroform, dichloroethane, carbon tetrachloride and the like; aromatic halogenated hydrocarbons such as chlorobenzene, dichlorobenzene, benzotrifluoride and the like; alcohols such as methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 2-methyl-1-propanol and the like; and aprotic polar solvents such as acetonitrile, N,N-dimethylformamide, N,N-dimethylacetamide, N-methylpyrrolidone, dimethylsulfoxide and the like. These may be used alone or in a mixture of two or more kinds thereof at an appropriate ratio. Among them, the above-mentioned ethers and alcohols are preferable, mixed solvents of ethers-alcohols are more preferable, and a mixed solvent of tetrahydrofuran-ethanol, and a mixed solvent of tetrahydrofuran-methanol are particularly preferable.
[0096] The amount of the solvent to be used is 1 to 50-fold, preferably 10 to 30-fold, relative to compound (IX).
[0097] The reaction temperature is generally about −80° C. to about 200° C., preferably about −40° C. to about 40° C.
[0098] While the reaction time varies depending on the kinds of compound (IX), the metal hydride complex compound and metal halide and the reaction temperature, it is generally about 5 min to about 48 hr, preferably about 3 to about 24 hr.
[0099] After completion of the reaction, the obtained compound (X) can be used for the next reaction as the reaction mixture or as a crude product, or can also be isolated according to a conventional method from the reaction mixture, and can also be easily purified according to a conventional separation means (e.g., recrystallization, distillation, chromatography).
[Step 5]
[0100] In Step 5,6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide or a salt thereof is obtained by subjecting compound (X) to cyclization and deprotection.
[0101] This reaction is generally carried out in a solvent, by (i) reacting compound (X) with an agent for conversion of hydroxyl to a leaving group, and (ii) reacting the resulting compound with a base (cyclization and deprotection).
[0102] The reactions of the above-mentioned (i) and (ii) may be carried out simultaneously or stepwisely in no particular order.
[0103] Examples of the agent for conversion of hydroxyl to a leaving group include halogenated sulfonyls such as methanesulfonyl chloride, p-toluenesulfonyl chloride and the like; and halogenating agents such as carbon tetrachloride-triphenylphosphine, N-chlorosuccinimide-triphenylphosphine, thionyl chloride, lithium chloride, carbon tetrabromide-triphenylphosphine, N-bromosuccinimide-triphenylphosphine, phosphorus tribromide, phosphorus bromide, sodium bromide, sodium iodide, imidazole-iodine-triphenylphosphine and the like. Among them, halogenated sulfonyls such as methanesulfonyl chloride, p-toluenesulfonyl chloride and the like are preferable, and methanesulfonyl chloride is particularly preferable.
[0104] The amount of the agent for conversion of hydroxyl to a leaving group to be used is generally 1 to 10 equivalents, preferably 1 to 5 equivalents, particularly preferably 1 to 2 equivalents, relative to compound (X).
[0105] Examples of the base include organic bases and inorganic bases. Examples of the organic base include tertiary amines such as triethylamine, diisopropylethylamine, tri(n-propyl)amine, tri(n-butyl)amine, cyclohexyldimethylamine, N-methylpiperidine, N-methylpyrrolidine, N-methylmorpholine and the like; and aromatic amines such as pyridine, lutidine, N,N-dimethylaniline and the like. Among them, tertiary amines such as triethylamine, diisopropylethylamine and the like are preferable. Examples of the inorganic base include hydroxides of alkali metal or alkaline earth metal such as sodium hydroxide, potassium hydroxide, lithium hydroxide, calcium hydroxide, barium hydroxide and the like; carbonates of alkali metal or alkaline earth metal such as sodium carbonate, potassium carbonate, cesium carbonate, sodium hydrogen carbonate, potassium hydrogen carbonate and the like; and phosphates such as disodium monohydrogenphosphate, dipotassium monohydrogenphosphate, trisodium phosphate, tripotassium phosphate and the like. Among them, sodium carbonate and potassium hydrogen carbonate are preferable.
[0106] The amount of the base to be used is generally 0.1 to 10 equivalents, particularly preferably 1 to 2 equivalents, relative to compound (X). The base to be used may be alone or in combination of two or more. For example, when the base is used in combination of two or more, an amine may be added in the reaction of compound (X) with an agent for conversion of hydroxyl to a leaving group, and an inorganic base may be added in the reaction (cyclization and deprotection) of the resultant product by the above-mentioned reaction with the base presented in the reaction mixture.
[0107] The solvent is not particularly limited as long as it does not adversely influence the reaction, and examples thereof include aromatic hydrocarbons such as benzene, toluene, xylene and the like; aliphatic hydrocarbons such as hexane, pentane, heptane and the like; ethers such as diethyl ether, diisopropyl ether, tert-butyl methyl ether, cyclopentyl methyl ether, tetrahydrofuran, dioxane, 1,2-dimethoxyethane, bis(2-methoxyethyl)ether and the like; aliphatic halogenated hydrocarbons such as methylene chloride, chloroform, dichloroethane, carbon tetrachloride and the like; aromatic halogenated hydrocarbons such as chlorobenzene, dichlorobenzene, benzotrifluoride and the like; alcohols such as methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 2-methyl-1-propanol and the like; aprotic polar solvents such as acetonitrile, N,N-dimethylformamide, N,N-dimethylacetamide, N-methylpyrrolidone, dimethylsulfoxide and the like; and water. These may be used alone or in a mixture of two or more kinds thereof at an appropriate ratio. Among them, the above-mentioned aromatic hydrocarbons, ethers, aprotic polar solvents and water are preferable, toluene, tetrahydrofuran, acetonitrile and water are more preferable, tetrahydrofuran, methanol, acetonitrile and water are still more preferable, and a mixed solvent of tetrahydrofuran-water is particularly preferable.
[0108] The amount of the solvent to be used is 1 to 50-fold, preferably 5 to 30-fold, relative to compound (X).
[0109] After completion of the reaction, the obtained 6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide can be isolated according to a conventional method from the reaction mixture, and can also be easily purified according to a conventional separation means (e.g., recrystallization, distillation, chromatography). For example, the purification is performed by dissolving the crude product in water-methanol, and adding dropwise water to the obtained solution under cooling.
[0110] In the present specification, 6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide encompasses 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide and 6-((7R)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide.
[0111] 6-(7-Hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide may be in the form of a salt, preferably a pharmacologically acceptable salt. Examples of the salt include salts with an inorganic base, salts with an organic base, salts with an inorganic acid, salts with an organic acid, and salts with a basic or acidic amino acid.
[0112] Preferable examples of the salts with an inorganic base include alkali metal salts such as sodium salt, potassium salt and the like; alkaline earth metal salts such as calcium salt, magnesium salt and the like; an aluminum salt; and an ammonium salt.
[0113] Preferable examples of the salts with an organic base include salts with trimethylamine, triethylamine, pyridine, picoline, ethanolamine, diethanolamine, triethanolamine, tromethamine[tris(hydroxymethyl)methylamine], tert-butylamine, cyclohexylamine, benzylamine, dicyclohexylamine or N,N-dibenzylethylenediamine.
[0114] Preferable examples of the salts with an inorganic acid include salts with hydrochloric acid, hydrobromic acid, nitric acid, sulfuric acid or phosphoric acid.
[0115] Preferable examples of the salts with an organic acid include salts with formic acid, acetic acid, trifluoroacetic acid, phthalic acid, fumaric acid, oxalic acid, tartaric acid, maleic acid, citric acid, succinic acid, malic acid, methanesulfonic acid, benzenesulfonic acid or p-toluenesulfonic acid.
[0116] Preferable examples of the salts with a basic amino acid include salts with arginine, lysine or ornithine.
[0117] Preferable examples of the salts with an acidic amino acid include salts with aspartic acid or glutamic acid.
[0118] In the present specification, 6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide may be in the form of a hydrate or non-hydrate. These are encompassed in 6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide.
[0119] Compound (V), compound (VI), compound (VII), compound (IX) and compound (X) may be in the form of a salt, and examples thereof include those similar to the salts of 6-(7-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide.
[0120] 6-(7-Hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide or a salt thereof obtained according the production method of the present invention can be used as an agent for the prophylaxis or treatment of androgen-independent prostate cancer and the like, according the method described in WO 2009/057795 and the like.
EXAMPLES
[0121] The present invention is explained in detail in the following by referring to Reference Examples and Examples, which are not to be construed as limitative.
[0122] In Reference Examples and Examples, the room temperature means about 25° C.
Reference Example 1
[0123] To 4-formylimidazole (30.0 g, 0.30 mol) were added toluene (300 mL) and triethylamine (35.0 g, 0.34 mol), and then N,N-dimethylaminosulfonyl chloride (50.0 g, 0.34 mol) was added thereto at room temperature. The mixture was stirred at 70° C. for 20 hr, and the insoluble material was collected by filtration, and washed with toluene (300 mL) to give wet crystals. To the obtained wet crystals were added water (100 mL) and ethyl acetate (300 mL), and the crystals were dissolved with stirring at room temperature. The organic layer and the aqueous layer were separated. The obtained aqueous layer was extracted with ethyl acetate (200 mL), and the organic layer and the aqueous layer were separated. The obtained organic layer and the previously obtained organic layer were combined. These operations were repeated twice, and the organic layer was completely concentrated under reduced pressure to give crude crystals (32.0 g). To the crude crystals was added ethyl acetate (90 mL), and crystals were dissolved with heating to about 60° C. The solution was slowly cooled to 30° C. for recrystallization, hexane (180 mL) was added thereto, and the mixture was stirred at room temperature for 2 hr to give crystals. The obtained crystals were collected by filtration, and washed with a mixed solvent (45 mL) of ethyl acetate/hexane (1:2, volume ratio). The obtained wet crystals were dried under reduced pressure to give 1-N,N-dimethylaminosulfonyl-4-formyl-1H-imidazole (29.4 g, 0.14 mmol). yield 48%
[0124] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.93 (s, 6H), 7.90 (d, J=1.3 Hz, 1H), 7.96 (d, J=1.3 Hz, 1H), 9.95 (s, 1H)); HRMS (ESI) m/z Calcd for a C 6 H 10 N 3 O 3 S[m+H] + : 204.0365. Found: 204.0438.
Reference Example 2
[0125] 4-Formylimidazole (20.0 g, 208.14 mmol) and p-toluenesulfonyl chloride (43.7 g, 229.0 mmol) were suspended in N,N-dimethylacetamide (200 mL). To the obtained suspension was added dropwise triethylamine (23.2 g, 229.0 mmol) at 10° C. or below, and the mixture was stirred at 10° C. or below for 1 hr or more. To the reaction mixture was added n-heptane (60 mL) at 30° C. or below. To the obtained solution was added dropwise water (240 mL) at 30° C. or below for crystallization. The mixture was stirred at room temperature for 1 hr or more to give crystals. The obtained crystals were collected by filtration, and washed with water (300 mL) to give wet crystals. The obtained wet crystals were dried under reduced pressure at an outside temperature of 50° C. to give 1-tosyl-4-formyl-1H-imidazole (44.2 g, 176.6 mmol). yield 85%.
[0126] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.42 (s, 1H), 7.54-7.56 (m, 2H), 8.06-8.08 (m, 2H), 8.58 (s, 1H), 8.66 (s, 1H), 9.76 (s, 1H).
Reference Example 3
[0127] 4-Formylimidazole (11.7 g, 121.8 mmol) and acetonitrile (59 mL) were charged, and triethylamine (13.6 g, 133.9 mml) was added thereto at 30° C. or below. And then, a solution of benzenesulfonyl chloride (23.7 g, 133.9 mmol) in THF (35 mL) was added dropwise thereto at 30° C. or below, and the mixture was stirred at room temperature for 1 hr or more. After the reaction, water (94 mL) was added dropwise thereto at 30° C. or below for crystallization, and the mixture was stirred at room temperature for 1 hr or more, cooled to 10° C. or below, and stirred for 1 hr or more. The obtained crystals were collected by filtration, and washed with a mixed solvent (35 mL) of acetonitrile/water (1:2, volume ratio). The obtained wet crystals were dried under reduced pressure at an outside temperature of 50° C. to give 1-(phenylsulfonyl)-4-formyl-1H-imidazole (20.0 g, 84.7 mmol). yield 70%.
[0128] 1 H NMR (500 MHz, DMSO-d 6 ) δ7.74-7.77 (m, 2H), 7.88-7.89 (m, 1H), 8.19-8.21 (m, 2H), 8.62 (s, 1H), 8.70 (d, J=5.0 Hz, 1H), 9.76 (s, 1H); HRMS (ESI) m/z Calcd for a C 10 H 9 N 2 O 3 S[M+H] + : 237.0289. Found: 237.0330.
Reference Example 4
[0129] To a solution of 4-formylimidazole (10.0 g, 104.1 mmol) in tetrahydrofuran (100 mL) were added triethylamine (12.6 g, 124.9 mmol) and a catalytic amount of 4-dimethylaminopyridine (2.5 g, 20.8 mmol). A solution of di-t-butyl-dicarbonate (27.3 g, 124.9 mmol) in THF (50 mL) was added dropwise thereto at 30° C. or below, and the mixture was stirred at room temperature for 1 hr or more. After the reaction, water (100 mL) was added dropwise thereto at 30° C. or below to quench the reaction, and the ethyl acetate (200 mL) was added thereto. The organic layer was separated, and concentrated under reduced pressure to the volume of about 30 mL. To the residue was added diisopropyl ether (100 mL), and the mixture was concentrated to the volume of about 20 mL under reduced pressure. These operations were repeated twice to adjust the volume to about 20 mL. The crystals were collected by filtration, and washed with diisopropyl ether (20 mL), and then washed twice with water (50 mL). The obtained wet crystals were dried under reduced pressure at an outside temperature of 50° C. to give t-butyl 4-formyl-1H-imidazole-1-carboxylate (16.0 g, 81.5 mmol). yield 78%.
[0130] 1 H NMR (500 MHz, DMSO-d 6 ) δ1.60 (s, 9H), 8.37-8.39 (m, 2H), 9.81 (s, 1H).
Reference Example 5
[0131] 6-(7-Hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide (5.20 kg, 16.9 mol), ethanol (130 L) and activated carbon (260 g) were stirred at room temperature, and the insoluble material was filtered off, and washed with ethanol (15.6 L). The above-mentioned operations were repeated three times. The filtrates and washings were combined, and (2S,3S)-tartranilic acid (15.95 kg, 70.8 mol) and ethanol (20.8 L) were added thereto. The mixture was heated to about 50° C., allowed to cool to room temperature, stirred for about 4 hr, cooled to about 0° C., and stirred for about 1 hr. The precipitated crystals were collected by filtration, and washed with ethanol (31.2 L). The obtained wet crystals (about 23 kg) in ethanol (156 L) were stirred at room temperature for about 2 hr, and the mixture was cooled to about 0° C., and stirred for about 1 hr. The precipitated crystals were collected by filtration, and washed with ethanol (31.2 L). The obtained wet crystals (about 20 kg) were added to 1 mol/L aqueous sodium hydroxide solution (104 L), and the mixture was stirred at room temperature for about 1 hr. The precipitated crystals were collected by filtration, washed with water (93.6 L), and dried under reduced pressure to a constant amount to give 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide 1 hydrate (4.11 kg, 12.6 mol). yield 25%. containing 5.6 wt % water (by Karl-Fisher water measurement).
[0132] The powder X-ray diffraction pattern of 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide 1 hydrate is shown in FIG. 1 .
Reference Example 6
[0133] 6-((7S)-Hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide 1 hydrate (4.05 kg, 12.4 mol) was added to 60% aqueous methanol solution (118 L), and dissolved with heating to about 70° C. Activated carbon (203 g) was added thereto at the same temperature, and the insoluble material was filtered off, and washed with 60% aqueous methanol solution (11.6 L). The filtrate and washing were combined, and heated to about 73° C. to dissolve the precipitated crystals, the solution was cooled to about 55° C., and water (25.9 L) was added thereto. While cooling, the mixture was stirred at room temperature for about 1 hr, and then at about 0° C. for about 2 hr. The precipitated crystals were collected by filtration, washed with 50% aqueous methanol solution (12.2 L), and dried under reduced pressure to a constant amount to give 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide anhydride (3.13 kg, 10.2 mol). yield 82%.
[0134] The powder X-ray diffraction pattern of 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide anhydride is shown in FIG. 2 .
Reference Example 7
[0135] 6-Bromo-2-naphthoic acid (10.1 g, 40.1 mmol) and N,N-dimethylformamide (4.75 g, 65.0 mmol) were added to toluene (80 mL). To the reaction mixture was added dropwise thionyl chloride (5.7 g, 48.2 mmol) at 45 to 50° C., and the mixture was stirred for 1 hr, and allowed to cool to room temperature. The reaction mixture was added dropwise at 10 to 25° C. to a solution prepared by adding triethylamine (11.4 g, 112.4 mmol) and 40% methylamine methanol solution (8.1 g, 104.4 mmol) to toluene (80 mL), and the mixture was stirred at room temperature for 1 hr. To the reaction mixture was added dropwise water (50 mL), and the mixture was stirred at room temperature. The crystals were collected by filtration, and washed with a mixed solvent (25 mL) of methanol/water (2:8) to give wet crystals. The total amount of the wet crystals was added to N,N-dimethylacetamide (70 mL), and dissolved with heating to 60° C. The reaction mixture was allowed to cool to room temperature, and water (140 mL) was added dropwise thereto. The crystals were collected by filtration, and washed with water (80 mL) to give wet crystals. The total amount of the wet crystals was suspended in ethyl acetate (25 mL) with stirring at room temperature. The crystals were collected by filtration, and washed with ethyl acetate (5 mL). The obtained wet crystals were dried under reduced pressure to give 6-bromo-N-methyl-2-naphthamide (9.4 g, 35.6 mmol). yield 89%.
[0136] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.84 (d, J=4.4 Hz, 3H), 7.71 (dd, J=8.8, 2.2 Hz, 1H), 7.93-8.03 (m, 3H), 8.28 (d, J=1.9 Hz, 1H), 8.44 (s, 1H), 8.62 (d, J=4.1 Hz, 1H); HRMS (ESI) m/z Calcd for a C 12 H 11 NOBr [M+H] + : 264.0024. Found: 264.0019; Anal. Calcd for a C 12 H 10 NOBr: C, 54.57; H, 3.82; N, 5.30; Br, 30.25. Found: C, 54.56; H, 3.70; N, 5.34; Br, 30.23.
Reference Example 8
[0137] Under a nitrogen atmosphere, o-bromotrifluoromethylbenzene (1.35 kg, 6.00 mol) was added to tetrahydrofuran (7.9 L). The reaction mixture was cooled to −70° C., 1.6 mol/L n-butyllithium hexane solution (3.75 L, 6.00 mol) was added dropwise thereto, and the mixture was stirred at the same temperature for about 30 min. The reaction mixture was added dropwise at the same temperature to a solution prepared by adding 6-bromo-N-methyl-2-naphthamide (1.13 kg, 4.28 mol) to THF (62.2 L) at −70° C. under a nitrogen atmosphere, and the mixture was stirred for 1.5 hr. To the reaction mixture were added dropwise successively 1.6 mol/L n-butyllithium hexane solution (2.67 L, 4.27 mol) and a solution of 1-trityl-4-formyl-1H-imidazole (1.21 kg, 3.58 mol) in THF (7.9 L) at the same temperature, and the mixture was stirred for 2 hr. The reaction mixture was allowed to warm to −10° C., and 20 w/v % aqueous ammonium chloride solution (17.0 L) was added dropwise thereto at −10 to 0° C. The separated organic layer was concentrated under reduced pressure. To the residue was added ethyl acetate (11.3 L), and the mixture was stirred at room temperature. The crystals were collected by filtration, and washed with ethyl acetate (11.3 L). The obtained wet crystals were dried under reduced pressure to give 6-[hydroxy(1-trityl-1H-imidazol-4-yl)methyl]-N-methyl-2-naphthamide (1.31 kg, 2.50 mol). yield 58%.
Reference Example 9
[0138] To glucosamine hydrochloride (200 g, 0.928 mol) were added water (300 mL) and ammonium thiocyanate (212 g, 2.78 mol, 3.0 equivalents) at 25° C., and the mixture was stirred at 80 to 89° C. for 8 hr. The reaction mixture was allowed to cool to 60° C., water (300 mL) and seed crystals were added thereto, and the mixture was stirred at 25 to 40° C. for 15 hr. The crystals were collected by filtration, washed twice with water (100 mL), and vacuum-dried (50° C.) to a constant amount to give (1R,2S,3R)-1-(2-sulfanyl-1H-imidazol-4-yl)butane-1,2,3,4-tetraol (101.4 g). yield 50%.
Reference Example 10
[0139] Under nitrogen stream, to (1R,2S,3R)-1-(2-sulfanyl-1H-imidazol-4-yl)butane-1,2,3,4-tetraol (10 g, 45.4 mmol) was added water (40 mL), and to the obtained suspension was added dropwise an aqueous diluted solution of 30% aqueous hydrogen peroxide (15.4 g, 136 mmol, 3.0 equivalents) in water (40 mL) over 10 min at 17 to 43° C. (the compound was gradually dissolved to give an uniform pale-yellow solution). The reaction mixture was stirred at 24 to 36° C. for 4 hr, and barium carbonate (27 g, 136 mmol, 3.0 equivalents) was added over 5 min at 24 to 26° C. (neutralized to pH 7), and the mixture was stirred at 25 to 26° C. for 1 hr and 20 min. The insoluble material was filtered off, and washed with water (40 mL). To the filtrate and washing was added sodium sulfite (11.4 g, 90.8 mmol, 2.0 equivalents) over 5 min at 20 to 32° C. The obtained aqueous solution was stirred at 26 to 32° C. for 1 hr and 30 min to give an aqueous solution of (1R,2S,3R)-1-(1H-imidazol-4-yl)butane-1,2,3,4-tetraol. To this aqueous solution was added sodium periodate (29.1 g, 136 mmol, 3.0 equivalents) over 10 min at 12 to 30° C., and the mixture was stirred at 27 to 30° C. for 1 hr and 30 min. To the reaction mixture was added sodium periodate (2.91 g, 13.6 mmol, 0.3 equivalents) at 27 to 30° C., and the mixture was stirred at 27 to 30° C. for 2 hr. The insoluble material was filtered off, and washed four times with water (10 mL). To the filtrate and washing was added methanol (500 mL), and the inorganic salt was filtered off, and washed twice with methanol (50 mL). To the filtrate and washing was added activated carbon (3 g, SHIRASAGI A, trade name), and the mixture was stirred at room temperature for 1 hr. The insoluble material was filtered off, and washed with methanol. The filtrate and washing were concentrated under reduced pressure to give a crude compound (9.37 g). To the crude compound were added water (3 mL) and seed crystals for crystallization, and the mixture was stirred at room temperature for 24 hr, and then for 2 hr under ice-cooling. The crystals were collected by filtration, washed with cooled water (1 mL), and vacuum-dried (50° C.) to a constant amount to give 4(5)-formylimidazole (2.35 g). yield 54%.
Reference Example 11
[0140] To 4(5)-formylimidazole (2 g, 20.8 mmol) were added DMAc (30 mL) and triethylamine (3.5 mL, 25.0 mmol, 1.2 equivalents), and then trityl chloride (4.06 g, 14.6 mmol, 0.7 equivalents) was added thereto at room temperature. The mixture was stirred at room temperature for 24 hr, and to the reaction mixture was added water (60 mL) at room temperature, and the mixture was stirred at room temperature for 2 hr. The crystals were collected by filtration, washed with water, and vacuum-dried (50° C.) to a constant amount to give a crude compound (4.6 g). To the crude compound (0.2 g) was added methanol (1 mL), and the mixture was stirred at room temperature for 2 hr. The crystals were collected by filtration, was washed with methanol (0.2 mL), and vacuum-dried (50° C.) to a constant amount to give 1-trityl-4-formyl-1H-imidazole (0.14 g). yield 65%.
Example 1
[0141] Under a nitrogen atmosphere, 6-bromo-N-methyl-2-naphthamide (7.0 g, 26.5 mmol) was added to tetrahydrofuran (175 mL), and then 2.0 mol/L isopropylmagnesium chloride tetrahydrofuran solution (13.7 mL) was added dropwise thereto at room temperature. The reaction mixture was cooled to −30° C., 1.6 mol/L n-butyllithium hexane solution (26.6 mL) was added dropwise thereto, and the mixture was stirred at the same temperature for 2 hr. To the reaction mixture was added dropwise a solution of 1-trityl-4-formyl-1H-imidazole (13.5 g, 39.9 mmol) in tetrahydrofuran (140 mL) at −20° C., and the mixture was stirred at the same temperature for 2 hr. The reaction mixture was allowed to warm to 0° C., and stirred for 1 hr, and 20 w/v % aqueous ammonium chloride solution (105 mL) was added dropwise thereto. The organic layer was separated, and concentrated to the volume of about 90 mL under reduced pressure. To the residue was added tetrahydrofuran (140 mL), and the mixture was concentrated to the volume of about 90 mL under reduced pressure. To the residue was added acetone (140 mL), and the mixture was concentrated to the volume of about 140 mL under reduced pressure. These operations were repeated three times. To the residue was added acetone to adjust the volume to about 180 mL, and the mixture was stirred at room temperature. The crystals were collected by filtration, and washed with acetone (70 mL). The obtained wet crystals were dried under reduced pressure to give 6-[hydroxy(1-trityl-1H-imidazol-4-yl)methyl]-N-methyl-2-naphthamide (10.3 g, 19.7 mmol). yield 74%.
[0142] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.84 (d, J=4.7 Hz, 3H), 5.76 (d, J=5.0 Hz, 1H), 5.82 (d, J=4.7 Hz, 1H), 6.80 (s, 1H), 6.98-7.13 (m, 6H), 7.28 (d, J=1.6 Hz, 1H), 7.32-7.50 (m, 9H), 7.55 (dd, J=8.5, 1.6 Hz, 1H), 7.83-7.99 (m, 4H) 8.37 (s, 1H) 8.58 (d, J=4.4 Hz, 1H); HRMS (ESI) m/z Calcd for a C 35 H 30 N 3 O 2 [M+H] 524.2338. Found: 524.2325; Anal. Calcd for a C 35 H 29 N 3 O 2 : C, 80.28; H, 5.58; N, 8.02. Found: C, 80.17; H, 5.80; N, 7.81.
Example 2
[0143] Under a nitrogen atmosphere, 6-bromo-N-methyl-2-naphthamide (1.0 g, 3.79 mmol) was added to tetrahydrofuran (25 mL), and then 1.0 mol/L dibutylmagnesium heptane solution (2.0 mL) was added dropwise thereto at room temperature. The obtained solution was cooled to −13° C., 1.6 mol/L n-butyllithium hexane solution (2.6 mL) was added dropwise thereto, and the mixture was stirred at the same temperature for 1.5 hr. A solution of 1-trityl-4-formyl-1H-imidazole (1.4 g, 4.2 mmol) in tetrahydrofuran (15 mL) was added dropwise to the reaction mixture at −11° C., and the mixture was stirred at the same temperature for 5 hr. The reaction mixture was allowed to warm to 6° C. over 2.5 hr, and 20 w/v % aqueous ammonium chloride solution (30 mL) was added dropwise thereto. The organic layer was separated, and quantified to give 6-[hydroxy(1-trityl-1H-imidazol-4-yl)methyl]-N-methyl-2-naphthamide (1.2 g, 2.24 mmol). yield 71%.
Example 3
[0144] 6-[Hydroxy(1-trityl-1H-imidazol-4-yl)methyl]-N-methyl-2-naphthamide (10.0 g, 19.1 mmol) and manganese dioxide (10.0 g, 115.0 mmol) were added to a mixed solvent of N,N-dimethylacetamide (25 mL) and ethyl acetate (63 mL), and the mixture was stirred at 60° C. for 3 hr. The insoluble material was filtered off at the same temperature, and washed with ethyl acetate (60 mL). The filtrate and washing were combined and concentrated to the volume of 30 mL under reduced pressure. To the residue was added dropwise diisopropyl ether (100 mL), and the mixture was stirred at room temperature. The obtained crystals were collected by filtration, and washed with diisopropyl ether (30 mL) to give crude wet crystals (26.4 g). The crude wet crystals (10.8 g) were added to ethyl acetate (54 mL), and the mixture was warmed to 60° C., and stirred for 0.5 hr. The obtained mixture was allowed to cool to room temperature, and diisopropyl ether (108 mL) was added dropwise thereto. The mixture was stirred with cooling to 5° C. The obtained crystals were collected by filtration, and washed with a mixed solvent (27 mL) of diisopropyl ether/ethyl acetate (2:1, volume ratio). The obtained wet crystals were dried under reduced pressure to give N-methyl-6-[(1-trityl-1H-imidazol-4-yl)carbonyl]-2-naphthamide (8.2 g, 15.7 mmol). yield 82%.
[0145] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.85 (d, J=4.7 Hz, 3H), 7.17-7.22 (m, 6H), 7.40-7.50 (m, 9H), 7.69 (d, J=1.4 Hz, 1H), 7.77 (d, J=1.4 Hz, 1H), 7.99 (dd, J=8.5, 1.6 Hz, 1H), 8.13 (dd, J=18.4, 8.7 Hz, 2H), 8.21 (dd, J=8.5, 1.6 Hz, 1H), 8.48 (s, 1H), 8.68 (q, J=4.4 Hz, 1H), 9.01 (s, 1H); HRMS (ESI) m/z Calcd for a C 35 H 28 N 3 O 2 [M+H] 522.2182. Found: 522.2177; Anal. Calcd for a C 35 H 27 N 3 O 2 : C, 80.59; H, 5.22; N, 8.06. Found: C, 80.51; H, 5.17, N, 8.10.
Example 4
[0146] 6-[Hydroxy(1-trityl-1H-imidazol-4-yl)methyl]-N-methyl-2-naphthamide (10.0 g, 19.1 mmol) and manganese dioxide (6.6 g, 75.9 mmol) were added to N,N-dimethylacetamide (85 mL), and the mixture was stirred at 60° C. for 2 hr. The insoluble material was filtered off at the same temperature, and washed with N,N-dimethylacetamide (40 mL). The filtrate and washing were combined and cooled to 40° C., water (60 mL) was added dropwise thereto, and the mixture was stirred at room temperature. The obtained crystals were collected by filtration, and washed with water (50 mL). The wet crystals were dried under reduced pressure to give crude crystals (9.5 g). Ethyl acetate (100 mL) was warmed to 40° C., and the crude crystals (9.5 g) were added thereto. The obtained mixture was warmed to 50° C., and stirred for 0.5 hr. The solvent (20 mL) was evaporated under reduced pressure. The residue was allowed to cool to room temperature, and diisopropyl ether (80 mL) was added dropwise thereto, and the mixture was stirred at the same temperature. The obtained crystals were collected by filtration, and washed with a mixed solvent (30 mL) of diisopropyl ether/ethyl acetate (1:1, volume ratio). The obtained wet crystals were dried under reduced pressure to give N-methyl-6-[(1-trityl-1H-imidazol-4-yl)carbonyl]-2-naphthamide (8.9 g, 17.1 mmol). yield 89%.
Example 5
[0147] Under a nitrogen atmosphere, 6-[hydroxy(1-trityl-1H-imidazol-4-yl)methyl]-N-methyl-2-naphthamide (1.0 g, 1.91 mmol) was added to N,N-dimethylacetamide (50 mL), and then sodium hydride (oil, 0.15 g, 3.85 mmol) was added at room temperature, and the mixture was stirred at the same temperature for about 60 hr. To the reaction mixture were added dropwise water (50 mL) and 1 mol/L hydrochloric acid (5 mL) at room temperature, and the mixture was stirred at the same temperature for 45 min. Then, the reaction mixture was cooled to 0° C., and stirred for 2 hr. The crystals were collected by filtration, and washed with water (30 mL). The obtained wet crystals were dried under reduced pressure to give N-methyl-6-[(1-trityl-1H-imidazol-4-yl)carbonyl]-2-naphthamide (0.89 g, 1.71 mmol). yield 90%.
Example 6
[0148] Under a nitrogen atmosphere, zinc powder (15.0 g, 229.4 mmol) was suspended in tetrahydrofuran (57 mL), trimethylsilyl chloride (1.5 mL, 11.5 mmol) was added thereto at room temperature, and the mixture was stirred for 30 min. The reaction mixture was heated to 40° C., a solution of ethyl bromoacetate (12.7 mL, 114.5 mmol) in tetrahydrofuran (144 mL) was added dropwise thereto, and the mixture was stirred at the same temperature for 30 min. The reaction mixture was kept stand at room temperature, the excess amount of zinc was filtered off to give a reaction mixture containing (bromo(2-ethoxy-2-oxoethyl)zinc (hereinafter to be abbreviated as Reformatsky reagent). The prepared Reformatsky reagent (89.6 mL, corresponding to 2.5 eq.) was cooled to 0° C., cinchonine (7.1 g, 24.0 mmol), pyridine (6.2 mL, 76.8 mmol) and tetrahydrofuran (80 mL) were added thereto, and the mixture was stirred at the same temperature for 30 min. The reaction mixture was cooled to −25° C., N-methyl-6-[(1-trityl-1H-imidazol-4-yl)carbonyl]-2-naphthamide (10.0 g, 19.2 mmol) and tetrahydrofuran (20 mL) were added thereto, and the mixture was stirred at the same temperature for 1 hr and 45 min. The Reformatsky reagent (35.7 mL, corresponding to 1.0 eq.) was added thereto at the same temperature, and the mixture was stirred for 1 hr. To the reaction mixture were added ethyl acetate (140 mL) and 20 w/v % aqueous citric acid solution (140 mL) at 10° C. or below. The organic layer was separated, and washed with 10% sodium chloride-containing 20 w/v % aqueous citric acid solution (100 mL) at 5° C. (twice), 5 w/v % aqueous sodium bicarbonate (100 mL) (three times), and water (100 mL). The organic layer was concentrated to the volume of 60 mL under reduced pressure. To the residue was added methanol (100 mL), and the mixture was concentrated to the volume of 60 mL under reduced pressure. To the residue was added methanol to adjust the volume to 200 mL. Water (20 mL) was added thereto at room temperature, and the mixture was stirred for 1 hr. Then water (140 mL) was added dropwise thereto at the same temperature, and the mixture was stirred. The obtained crystals were collected by filtration, and washed with a mixed solvent (60 mL) of methanol/water (1:3, volume ratio). The obtained wet crystals were dried under reduced pressure to give ethyl (3S)-3-hydroxy-3-{6-[(methylamino)carbonyl]-2-naphthyl}-3-(1-trityl-1H-imidazol-4-yl)propanoate (11.3 g, 18.5 mmol). yield: 97%. enantiomeric excess: 96% ee.
[0149] 1 H NMR (500 MHz, DMSO-d 6 ) δ 0.93 (t, J=7.1 Hz, 3H), 2.84 (d, J=4.4 Hz, 3H), 3.20 (d, J=14.2 Hz, 1H), 3.29 (d, J=14.5 Hz, 1H), 3.86 (t, J=6.9 Hz, 2H), 5.86 (s, 1H), 6.79 (d, J=1.6 Hz, 1H), 7.06 (dd, J=7.9, 1.9 Hz, 6H), 7.31 (d, J=1.3 Hz, 1H), 7.33-7.45 (m, 9H), 7.73 (dd, J=8.7, 1.7 Hz, 1H), 7.82-7.95 (m, 3H), 8.02 (s, 1H), 8.36 (s, 1H), 8.58 (q, J=4.7 Hz, 1H); HRMS (ESI) m/z Calcd for a C 39 H 36 N 3 O 4 [M+H] + : 610.2706. Found: 610.2698; Anal. Calcd for a C 39 H 36 N 3 O 4 : C, 76.83; H, 5.79; N, 6.89. Found: C, 76.79; H, 5.95; N, 6.81.
Example 7
[0150] To a solution of anhydrous calcium chloride (4.55 g, 41.0 mmol) in ethanol (62.5 mL) was added sodium borohydride (3.11 g, 82.0 mmol) at −7° C., and the mixture was stirred at −7° C. for 30 min. To the reaction mixture were added dropwise a solution of ethyl (3S)-3-hydroxy-3-{6-[(methylamino)carbonyl]-2-naphthyl}-3-(1-trityl-1H-imidazol-4-yl)propanoate (10.0 g, 16.4 mmol) in tetrahydrofuran (80 mL), and tetrahydrofuran (20 mL) at −5° C. The reaction mixture was stirred at 5° C. for 8 hr, water (80 mL), 1 mol/L hydrochloric acid (82 mL) and ethyl acetate (200 mL) were added dropwise thereto at 5° C., and the mixture was stirred. To the separated organic layer was added 0.2 mol/L hydrochloric acid (82 mL) at 5° C., and the mixture was stirred, and adjusted to pH 7.5 with 0.5 mol/L aqueous sodium hydroxide solution at the same temperature. To the separated organic layer was added again 0.2 mol/L hydrochloric acid (82 mL) at 5° C., and the mixture was stirred, and adjusted to pH 7.5 with 0.5 mol/L aqueous sodium hydroxide solution at the same temperature. To the separated organic layer was added water (100 mL), and the mixture was adjusted to pH 9.5 with 0.5 mol/L aqueous sodium hydroxide solution. The separated organic layer was washed with 10 w/v % brine (100 mL). To the separated organic layer was added water (120 mL), and the mixture was stirred with heating to 60° C. for 4 hr. The separated organic layer was concentrated to the volume of about 38 mL at the same temperature under reduced pressure. To the residue was added ethyl acetate (80 mL), and the mixture was concentrated to the volume of about 38 mL under reduced pressure. These operations were repeated three times. To the residue was added ethyl acetate to adjust the volume to about 38 mL. Diisopropyl ether (75 mL) was added thereto, and the mixture was stirred with cooling to 5° C. The crystals were collected by filtration, and washed with a mixed solvent (30 mL) of diisopropyl ether/ethyl acetate (2:1, volume ratio). The obtained wet crystals were dried under reduced pressure to give 6-[(1S)-1,3-dihydroxy-1-(1-trityl-1H-imidazol-4-yl)propyl]-N-methyl-2-naphthamide (8.7 g, 15.3 mmol). yield 94%. enantiomeric excess: 94% ee.
[0151] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.19-2.35 (m, 1H), 2.40-2.49 (m, 1H), 2.83 (d, J=4.7 Hz, 3H), 3.38 (ddd, J=19.2, 8.8, 5.4 Hz, 2H), 4.47 (t, J=5.0 Hz, 1H), 5.7 (s, 1H), 6.9 (d, J=1.6 Hz, 1H), 7.00-7.12 (m, 6H), 7.32 (d, J=1.6 Hz, 1H), 7.34-7.45 (m, 9H) 7.75 (dd, J=8.7, 1.7 Hz, 1H), 7.82-7.97 (m, 3H), 8.00 (s, 1H), 8.36 (s, 1H), 8.6 (q, J=4.3 Hz, 1H); HRMS (ESI) m/z Calcd for a C 37 H 34 N 3 O 3 [M+H] 568.2600. Found: 568.2590.
Example 8
[0152] To THF (100 mL) and water (63 μg, 3.5 mmol) was added 6-[(1S)-1,3-dihydroxy-1-(1-trityl-1H-imidazol-4-yl)propyl]-N-methyl-2-naphthamide (10.0 g, 17.6 mmol). The reaction mixture was cooled to 10° C., and ethyldiisopropylamine (3.41 g, 26.4 mmol) and methanesulfonyl chloride (3.03 g, 26.4 mmol) were successively added thereto, and the mixture was stirred at room temperature for 1 hr. To the reaction mixture was added a solution of sodium carbonate (3.73 g, 35.2 mmol) in water (40 mL), and the mixture was warmed to 57° C., and stirred for 5 hr.
[0153] The mixture was concentrated under reduced pressure to adjust the volume of the residue to 45 mL. Ethyl acetate (50 mL) was added thereto at 45° C., and the mixture was stirred. The reaction mixture was stirred with cooling to room temperature and then cooling to 5° C. The crystals were collected by filtration, and washed with ethyl acetate (40 mL) cooled to 5° C. The obtained wet crystals were dried under reduced pressure to give crude 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide (5.3 g, 17.3 mmol). yield 98%.
Example 9
[0154] The crude 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide obtained in Example 8 (5.0 g, 16.3 mmol) was added to methanol (97.5 mL) and purified water (38 mL), and dissolved with heating to 70° C., and activated carbon (0.25 g) was added thereto. The reaction mixture was stirred at the same temperature for 20 min, and the activated carbon was filtered off, and washed with 72% methanol (5 mL). The filtrate and washing were combined, and purified water (35.5 mL) was added dropwise thereto at 55 to 60° C. The reaction mixture was stirred with cooling to 30° C., purified water (35.5 mL) was added thereto at the same temperature, and the mixture was stirred. The reaction mixture was stirred with cooling to 2° C., and the crystals were collected by filtration, and washed with 45% methanol (15 mL). The obtained wet crystals were dried under reduced pressure to give 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide (4.17 g, 13.6 mmol). yield 83%. enantiomeric excess: 99% ee.
[0155] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.84 (m, 1H), 2.88 (d, J=4.4 Hz, 3H), 2.93 (m, 1H), 4.19 (m, 1H), 4.25 (m, 1H), 6.26 (s, 1H), 6.69 (s, 1H), 7.65 (m, 1H), 7.66 (s, 1H), 7.95 (dd, J=8.5, 1.6 Hz, 1H), 8.00 (d, J=8.5 Hz, 2H), 8.09 (brs, 1H), 8.45 (brs, 1H), 8.65 (q, J=4.4 Hz, 1H); MS (EI) m/z 307 [M]+; Anal. Calcd for a C 18 H 17 N 3 O 2 : C, 70.34; H, 5.58; N, 13.67. Found: C, 70.31; H, 5.50; N, 13.66.
Example 10
[0156] To a mixture of toluene (100 mL), THF (20 mL) and 1 mol/L hydrochloric acid (100 mL) was added 6-[(1S)-1,3-dihydroxy-1-(1-trityl-1H-imidazol-4-yl)propyl]-N-methyl-2-naphthamide (10.0 g, 17.6 mmol). The reaction mixture was stirred vigorously at 60° C. for 2 hr. The reaction mixture was allowed to cool to room temperature. The aqueous layer was separated, and the obtained aqueous layer was washed twice with methyl tert-butyl ether (100 mL and 50 mL). To the obtained aqueous layer was added methanol (10 mL), and then carbonate (10.6 g) and water (10 mL) were added thereto. The obtained slurry was stirred overnight at room temperature. The obtained crystals were collected by filtration, and washed with 10% aqueous methanol. The obtained wet crystals were dried under reduced pressure to give crude crystals (5.56 g). To a mixture of methanol (30 mL) and water (3 mL) were added the crude crystals (4 g). After stirring at 50° C. for 1 hr, water (50 mL) was added to the slurry at 50° C. over 1 hr. The slurry was stirred at 50° C. for 1 hr, and then allowed to cool to room temperature. After stirring for 3 hr at room temperature, the crystals were collected by filtration and washed with water. The obtained wet crystals were dried under reduced pressure to give 6-[(1S)-1,3-dihydroxy-1-(1H-imidazol-4-yl)propyl]-N-methyl-2-naphthamide (3.69 g, 11.3 mmol). yield 89%.
[0157] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.33-2.39 (m, 1H), 2.47-2.52 (m, 1H), 2.83 and 2.79 (d, J=4.4 Hz, total 3H), 3.33 (br s, 1H), 3.47 (br s, 1H), 4.54 and 4.59 (br s, total 1H), 5.58 and 5.97 (s, total 1H), 6.83 and 6.94 (s, total 1H), 7.47 and 7.58 (s, total 1H), 7.53 and 7.75 (d, J=8.5 Hz, total 1H), 7.83-7.99 (m, 3H), 8.03 and 8.06 (s, 1H), 8.36 and 8.38 (s, 1H), 8.57 (d, J=4.1 Hz, 1H), 11.75 and 11.83 (s, total 1H); Anal. Calcd for C 18 H 19 N 3 O 3 : C, 66.45; H, 5.89; N, 12.91; O, 14.75. Found: C, 66.19; H, 5.99; N, 12.72.
Example 11
[0158] To a solution of 6-[(1S)-1,3-dihydroxy-1-(1H-imidazol-4-yl)propyl]-N-methyl-2-naphthamide (1.0 g, 3.1 mmol) in tetrahydrofuran (100 mL) were added N-ethyldiisopropylamine (2.39 g, 18.4 mmol) and methanesulfonyl chloride (2.11 g, 18.4 mmol) at room temperature. The mixture was stirred at the same temperature for 3 hr. To the reaction mixture was added a solution of sodium carbonate (1.31 g, 12.3 mmol) in water (3 mL). The mixture was heated to 60° C. and stirred for 5 hr. After the reaction mixture was allowed to cool to room temperature, ethyl acetate (25 mL) was added thereto. The organic layer was separated and concentrated under reduced pressure. Methanol (16.7 mL) and water (6.4 mL) were added to the residue. The mixture was heated to 65° C., and activated carbon (45 mg) was added thereto. After stirring at the same temperature for 30 min, the activated carbon was filtered off and washed with methanol (1.1 mL). Water (6.4 mL) was added to the filtrate at 55° C. The resulting mixture was allowed to cool to room temperature and stirred for 30 min. To the mixture was added water (6.4 mL) at the same temperature, and the mixture was stirred for 2 hr. The mixture was cooled to 0° C. and stirred for 2 hr. The obtained precipitated crystals were collected by filtration, washed with 45% aqueous methanol (3 mL), and dried under reduced pressure to give 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide (540 mg, 1.8 mmol). yield 57%.
Example 12
[0159] Under a nitrogen atmosphere, 6-bromo-N-methyl-2-naphthamide (10.0 g, 38 mmol) was added to tetrahydrofuran (250 mL), and then 2.0 mol/L isopropylmagnesium chloride tetrahydrofuran solution (19 mL) was added dropwise thereto at room temperature. The obtained reaction mixture was cooled to −20° C., 1.6 mol/L n-butyllithium hexane solution (40 mL) was added dropwise to the reaction mixture, and the mixture was stirred at the same temperature for 2 hr. To the obtained reaction mixture was added dropwise a solution of 1-N,N-dimethylaminosulfonyl-4-formyl-1H-imidazole (11.6 g, 57 mmol) in tetrahydrofuran (200 mL) at −20° C., and the mixture was stirred at the same temperature for 2 hr. The obtained reaction mixture was allowed to warm to 0° C., and stirred for 1 hr, and 20 w/v % aqueous ammonium chloride solution (150 mL) was added dropwise to the reaction mixture. The reaction mixture was separated to the organic layer and aqueous layer, and the obtained organic layer was concentrated to the volume of about 90 mL under reduced pressure. To the obtained residue was added tetrahydrofuran (140 mL), and the obtained reaction mixture was concentrated to the volume of about 80 mL under reduced pressure. To the obtained residue was added ethyl acetate (250 mL), and the mixture was concentrated to the volume of about 80 mL under reduced pressure. These operations were repeated three times. To the obtained residue was added ethyl acetate to adjust the volume to about 200 mL to give a ethyl acetate solution containing 6-[hydroxy(1-N,N-dimethylaminosulfonyl-1H-imidazol-4-yl)methyl]-N-methyl-2-naphthamide.
[0160] The NMR data of the obtained 6-[hydroxy(1-N,N-dimethylaminosulfonyl-1H-imidazol-4-yl)methyl]-N-methyl-2-naphthamide was shown below.
[0161] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.76-2.88 (m, 9H), 5.82 (s, 1H), 6.08 (s, 1H), 7.37-7.43 (m, 1H), 7.61 (dd, J=8.5, 1.58 Hz, 1H), 7.84-8.02 (m, 4H), 8.07 (d, J=1.3 Hz, 1H), 8.39 (s, 1H), 8.59 (d, J=4.1 Hz, 1H); HRMS (ESI) m/z Calcd for a C 18 H 21 N 4 O 4 S[m+H] + : 389.1205. Found: 389.1273.
Example 13
[0162] To the ethyl acetate solution containing 6-[hydroxy(1-N,N-dimethylaminosulfonyl-1H-imidazol-4-yl)methyl]-N-methyl-2-naphthamide, which is obtained in Example 10, were added manganese dioxide (20.6 g, 237.2 mmol) and ethyl acetate (200 mL), and the mixture was stirred at 60° C. for 10 hr. The insoluble material was filtered off from the reaction mixture at the same temperature, and washed with ethyl acetate (200 mL). The filtrate and washing were combined, and concentrated under reduced pressure to adjust the volume to about 300 mL. Water (150 mL) was added thereto, and the organic layer was separated. These operations were repeated twice. The organic layers were combined, and stirred at room temperature about for 1 hr. To the reaction mixture was added dropwise diisopropyl ether (150 mL), and the mixture was stirred at room temperature for 2 hr to give crystals. The obtained crystals were collected by filtration, and washed with a mixed solvent (90 mL) of diisopropyl ether/ethyl acetate (2:1, volume ratio) to give wet crystals. The obtained wet crystals were dried under reduced pressure to give N-methyl-6-[(1-N,N-dimethylaminosulfonyl-1H-imidazol-4-yl)carbonyl]-2-naphthamide (8.9 g, 22.9 mmol). total yield from 6-bromo-N-methyl-2-naphthamide: 60%.
[0163] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.84-2.91 (m, 3H), 2.93 (s, 6H), 8.02 (d, J=8.5 Hz, 1H), 8.14-8.23 (m, 3H), 8.43 (s, 1H), 8.47 (s, 1H), 8.51 (s, 1H), 8.71 (d, J=4.4 Hz, 1H), 8.94 (s, 1H); HRMS (ESI) m/z Calcd for a C 18 H 19 N 4 O 4 S[m+H] + : 387.1049. Found: 387.1118.
Example 14
[0164] Under a nitrogen atmosphere, zinc powder (15.0 g, 229.4 mmol) was suspended in tetrahydrofuran (57 mL), trimethylsilyl chloride (1.5 mL, 11.5 mmol) was added thereto at room temperature, and the mixture was stirred for 30 min. The reaction mixture was heated to 40° C., and to the reaction mixture was added dropwise a solution of ethyl bromoacetate (12.7 mL, 114.5 mmol) in tetrahydrofuran (144 mL). The obtained reaction mixture was stirred at 30 min for 40° C., and kept stand at room temperature, and the excess amount of zinc was filtered off to give a reaction mixture containing bromo(2-ethoxy-2-oxoethyl)zinc (hereinafter to be abbreviated as Reformatsky reagent). The obtained Reformatsky reagent (49.7 mL, corresponding to 2.5 eq.) was cooled to 0° C. or below, and to the Reformatsky reagent were added cinchonine (3.8 g, 12.9 mmol), pyridine (3.4 mL, 41.4 mmol) and tetrahydrofuran (32 mL). The obtained reaction mixture was stirred for 15 min, and cooled to −20° C., and to the reaction mixture were added N-methyl-6-[(1-N,N-dimethylaminosulfonyl-1H-imidazol-4-yl)carbonyl]-2-naphthamide (4.0 g, 10.4 mmol) and tetrahydrofuran (12 mL). The obtained reaction mixture was stirred at −20° C. for 1 hr. To the obtained reaction mixture was added the Reformatsky reagent (25.0 mL, corresponding to 1.25 eq.) at −20° C., the obtained reaction mixture was stirred for 30 min. To the obtained reaction mixture were added ethyl acetate (100 mL) and 20 w/v % aqueous citric acid solution (100 mL) at 10° C. or below. The separated organic layer was washed with 10% sodium chloride-containing 20 w/v % aqueous citric acid solution (100 mL) at 5° C. (twice), 5 w/v % aqueous sodium bicarbonate (100 mL) (three times), and the water (100 mL). The organic layer was concentrated to the volume of 20 mL under reduced pressure to give a residue. To the obtained residue was added methanol (50 mL), and the mixture was concentrated to the volume of 20 mL under reduced pressure to give a residue. These operations were repeated again. To the obtained residue was added water (8 mL), and the obtained solution was stirred for 1 hr. To the reaction mixture was added dropwise water (32 mL), and the mixture was stirred to give crystals. The obtained crystals were collected by filtration, and washed with a mixed solvent (30 mL) of methanol/water (1:3, volume ratio) to give wet crystals. The obtained wet crystals were dried under reduced pressure to give ethyl (3S)-3-hydroxy-3-{6-[(methylamino)carbonyl]-2-naphthyl}-3-(1-N,N-dimethylaminosulfonyl-1H-imidazol-4-yl)propanoate (4.29 g, 9.04 mmol). yield 87%. enantiomeric excess: 85% ee.
[0165] 1 H NMR (500 MHz, DMSO-d 6 ) δ 0.94 (t, J=7.1 Hz, 3H), 2.78 (s, 6H), 2.84 (d, J=4.7 Hz, 3H), 3.21-3.31 (m, 1H), 3.31-3.42 (m, 1H), 3.80-3.95 (m, 2H), 6.12 (s, 1H), 7.38 (d, J=1.6 Hz, 1H), 7.75 (dd, J=8.7, 1.73 Hz, 1H), 7.85-7.99 (m, 3H), 8.06-8.14 (m, 2H), 8.38 (s, 1H), 8.58 (d, J=4.4 Hz, 1H); HRMS (ESI) m/z Calcd for a C 22 H 27 N 4 O 6 S[m+H] + : 475.1573. Found: 475.1635.
Example 15
[0166] To a solution of anhydrous calcium chloride (2.05 g, 18.5 mmol) in ethanol (26.5 mL) was added sodium borohydride (1.40 g, 36.9 mmol) at −17° C., and the mixture was stirred at −16—
[0000] −7° C. for 30 min. To the obtained reaction mixture was added dropwise a solution of ethyl (3S)-3-hydroxy-3-{6-[(methylamino)carbonyl]-2-naphthyl}-3-(1-N,N-dimethylaminosulfonyl-1H-imidazol-4-yl)propanoate (3.5 g, 7.38 mmol) in tetrahydrofuran (36 mL) at −20° C. The obtained reaction mixture was stirred for 6 hr at 0° C., to the reaction mixture were added dropwise water (36 mL), 1 mol/L hydrochloric acid (37 mL) and ethyl acetate (90 mL) at 5° C., and the mixture was stirred. To the separated organic layer was added 0.2 mol/L hydrochloric acid (37 mL) at 5° C., and the mixture was stirred, and adjusted about pH 7.5 with 0.5 mol/L aqueous sodium hydroxide solution at 5° C. To the separated organic layer was added again 0.2 mol/L hydrochloric acid (37 mL) at 5° C., and the mixture was stirred, and adjusted to about pH 7.5 with 0.5 mol/L aqueous sodium hydroxide solution at the same temperature. To the separated organic layer was added water (45 mL), and the mixture was adjusted to about pH 9.5 with 0.5 mol/L aqueous sodium hydroxide solution. The separated organic layer was washed with 10 w/v % brine (45 mL). To the separated organic layer was added water (54 mL), and the mixture was heated to 60° C., and stirred for 4 hr. The separated organic layer was completely concentrated under reduced pressure to give 6-[(1S)-1,3-dihydroxy-1-(1-N,N-dimethylaminosulfonyl-1H-imidazol-4-yl)propyl]-N-methyl-2-naphthamide (2.1 g, 4.83 mmol). yield 66%. enantiomeric excess: 86% ee.
[0167] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.34-2.47 (m, 1H), 2.78 (s, 6H), 2.82-2.86 (m, 3H), 3.35-3.48 (m, 2H), 4.50 (t, J=4.9 Hz, 1H), 5.92 (s, 1H), 7.36 (d, J=1.3 Hz, 1H), 7.76 (dd, J=8.7, 1.73 Hz, 1H), 7.87-7.98 (m, 3H), 8.06-8.14 (m, 2H), 8.37 (s, 1 H), 8.57 (q, J=4.3 Hz, 1H); HRMS (ESI) m/z Calcd for a C 20 H 25 N 4 O 5 S[m+H] + : 433.1467. Found: 433.1535.
Example 16
[0168] Under a nitrogen atmosphere, 6-bromo-N-methyl-2-naphthamide (10.0 g, 37.9 mmol) was added to tetrahydrofuran (250 mL), and to the obtained solution was added dropwise 2.0 mol/L isopropylmagnesium chloride tetrahydrofuran solution (18.9 mL) at room temperature. The obtained reaction mixture was cooled to −30° C., 1.65 mol/L n-butyllithium hexane solution (37.9 mL) was added dropwise thereto, and the mixture was stirred at the same temperature for 1 hr or more. To the obtained reaction mixture was added dropwise a solution of 1-tosyl-4-formyl-1H-imidazole (14.2 g, 56.8 mmol) in tetrahydrofuran (200 mL) at −20° C., and the mixture was stirred at the same temperature for 2 hr. The obtained reaction mixture was warmed over 2 hr to 0° C., 20 w/v % aqueous ammonium chloride solution (150 mL) was added dropwise thereto. The separated organic layer was concentrated to the volume of about 130 mL under reduced pressure to give a residue. To the obtained residue was added tetrahydrofuran (200 mL), and the mixture was concentrated to the volume of about 130 mL under reduced pressure to give a residue. To the obtained residue was added acetone (200 mL), and the mixture was concentrated to the volume of about 200 mL under reduced pressure. These operations were repeated three times to give a residue. To the obtained residue was added acetone to adjust the volume to about 260 mL. The obtained solution was stirred at room temperature for 2 hr or more. The obtained crystals were collected by filtration, and washed with acetone (100 mL) to give wet crystals. The obtained wet crystals were dried under reduced pressure at an outside temperature of 50° C. to give 6-(hydroxy(1-tosyl-1H-imidazol-4-yl)methyl)-N-methyl-2-naphthamide (8.5 g, 19.5 mmol). yield 52%.
[0169] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.40 (s, 3H), 2.83 (d, J=5.0 Hz, 1H), 5.74 (d, J=5.0 Hz, 1H), 6.05 (d, J=5.0 Hz, 1H), 7.49-7.51 (m, 3H), 7.55-7.56 (m, 1H), 7.88-7.92 (m, 4H), 7.98-7.99 (m, 2H), 8.27 (s, 1H), 8.37 (s, 1H), 8.58-8.59 (q, J=5.0 Hz, 1H); HRMS (ESI) m/z Calcd for a C 23 H 22 N 3 O 4 S[m+H] 436.1286. Found: 436.1322.
Example 17
[0170] 6-(Hydroxy(1-tosyl-1H-imidazol-4-yl)methyl)-N-methyl-2-naphthamide (8.2 g, 18.8 mmol) and manganese dioxide (14.7 g, 169.1 mmol) were added to N,N-dimethylacetamide (70 mL), and the mixture was stirred at 60° C. for 7 hr. The insoluble material was filtered off from the obtained reaction mixture at 60° C., and washed with N,N-dimethylacetamide (33 mL). The filtrate and washing were combined, and cooled to 40° C., water (49 mL) was added dropwise thereto, and the mixture was stirred at the same temperature for 0.5 hr or more, and then at room temperature for 1 hr or more to give crystals. The obtained crystals were collected by filtration, and washed with water (51 mL) to give wet crystals. The obtained wet crystals were dried under reduced pressure at an outside temperature of 50° C. to give crude crystals (6.6 g). Ethyl acetate (66 mL) were warmed to 40° C., and the crude crystals (6.6 g) were added thereto. The obtained mixture was warmed to 50° C., and stirred for 0.5 hr or more, and 13 mL of the solvent was evaporated under reduced pressure. The obtained residue was allowed to cool to room temperature, diisopropyl ether (53 mL) was added dropwise thereto at the same temperature, and the mixture was stirred to give crystals. The obtained crystals were collected by filtration, and washed with a mixed solvent (20 mL) of diisopropyl ether/ethyl acetate (1:1, volume ratio) to give wet crystals. The obtained wet crystals were dried under reduced pressure at an outside temperature of 50° C. to give N-methyl-6-[(1-tosyl-1H-imidazol-4-yl)carbonyl]-2-naphthamide (6.5 g, 15.0 mmol). yield 79%.
[0171] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.42 (s, 3H), 2.85 (d, J=5.0 Hz, 3H), 7.55-7.56 (m, 2H), 8.01-8.02 (m, 1H), 8.12-8.17 (m, 5H), 8.49 (s, 1H), 8.61-8.64 (d, J=15.0 Hz, 2H), 8.69 (q, 1H), 8.86 (s, 1H); HRMS (ESI) m/z Calcd for a C 23 H 20 N 3 O 4 S[m+H] + : 434.1130. Found: 434.1168.
Example 18
[0172] The Reformatsky reagent was obtained according to the method described in Example 14. The obtained Reformatsky reagent (27.1 mL, corresponding to 2.5 eq.) was cooled to 0° C., cinchonine (2.1 g, 7.2 mmol) and pyridine (1.9 mL, 23.0 mmol) was added thereto, and the mixture was stirred at the same temperature for 30 min. The reaction mixture was cooled to −25° C., N-methyl-6-[(1-tosyl-1H-imidazol-4-yl)carbonyl]-2-naphthamide (2.5 g, 5.76 mmol) was added thereto, and the mixture was stirred at the same temperature for 1 hr. To the obtained reaction mixture was added the Reformatsky reagent (10.9 mL, corresponding to 1.0 eq.) at −25° C., and the mixture was stirred for 1 hr. The Reformatsky reagent (5.4 mL, corresponding to 0.5 eq.) was added again −25° C., and the mixture was stirred for 1 hr. To the obtained reaction mixture were added ethyl acetate (35 mL) and 20 w/v % aqueous citric acid solution (35 mL) at 10° C. or below. The separated organic layer was washed with 10% sodium chloride-containing 20 w/v % aqueous citric acid solution (35 mL) at 5° C. (twice), 5 w/v % aqueous sodium bicarbonate (35 mL) (three times), and water (35 mL). The separated organic layer was concentrated under reduced pressure to give ethyl (3S)-3-hydroxy-3-{6-[(methylamino)carbonyl]-2-naphthyl}-3-(1-tosyl-1H-imidazol-4-yl)propanoate (2.92 g, 5.6 mmol). yield: 97%.
[0173] 1 H NMR (500 MHz, DMSO-d 6 ) δ 0.79 (t, J=7.1 Hz, 3H), 2.39 (s, 3H), 2.83 (d, J=4.7 Hz, 3H), 3.19 (d, J=14.2 Hz, 1H), 3.30 (d, J=14.2 Hz, 1H), 3.76 (t, J=6.9 Hz, 2H), 6.13 (s, 1H), 7.44-7.52 (m, 3H), 7.68 (dd, J=8.7, 2.1 Hz, 1H), 7.85-7.94 (m, 3H), 7.97 (d, J=8.2 Hz, 2H), 8.00-8.03 (m, 1H), 8.26-8.41 (m, 2H), 8.57 (d, J=4.7 Hz, 1H).
Example 19
[0174] To a solution of anhydrous calcium chloride (1.86 g, 16.3 mmol) in ethanol (32 mL) were added sodium borohydride (1.27 g, 33.6 mmol) and ethanol (5 mL) at −10° C., and the mixture was stirred at −10° C. for 30 min. To the reaction mixture were added dropwise a solution of ethyl (3S)-3-hydroxy-3-{6-[(methylamino)carbonyl]-2-naphthyl}-3-(1-tosyl-1H-imidazol-4-yl)propanoate (2.5 g, 5.6 mmol) in tetrahydrofuran (73 mL)/ethanol (10 mL), and tetrahydrofuran (5 mL) at −10° C. The obtained reaction mixture was stirred at 5° C. for 6 hr, and to the obtained reaction mixture were added dropwise water (100 mL), 1 mol/L hydrochloric acid (40 mL) and ethyl acetate (200 mL) at 10° C. or below, and the mixture was stirred. To the separated organic layer was added 0.2 mol/L hydrochloric acid (14 mL) at 5° C., and the mixture was stirred. The reaction mixture was adjusted to pH 7.5 with 0.5 mol/L aqueous sodium hydroxide solution at 5° C. To the separated organic layer was added again 0.2 mol/L hydrochloric acid (14 mL) at 5° C., and the mixture was stirred. The reaction mixture was adjusted to pH 7.5 with 0.5 mol/L aqueous sodium hydroxide solution at 5° C. To the separated organic layer was added water (10 mL), and the mixture was adjusted to pH 9.5 with 0.5 mol/L aqueous sodium hydroxide solution. To the separated organic layer was added water (120 mL), and the mixture was heated to 60° C., and stirred for 3 hr. The separated organic layer was concentrated at 60° C. under reduced pressure to give 6-[(1S)-1,3-dihydroxy-1-(1-tosyl-1H-imidazol-4-yl)propyl]-N-methyl-2-naphthamide (2.9 g, 6.1 mmol).
[0175] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.36-2.47 (m, 1H), 2.38 (d, J=2.5 Hz, 3H), 2.59-2.71 (m, 1H), 2.83 (d, J=4.7 Hz, 3H), 3.61-3.68 (m, 1H), 3.68-3.76 (m, 1H), 4.45-4.47 (m, 1H), 5.91 (s, 1H), 7.42-7.45 (m, 1H), 7.45-7.51 (m, 2H), 7.68 (dt, J=8.7, 2.1 Hz, 1H), 7.72 (s, 1H), 7.84-7.93 (m, 2H), 7.93-8.03 (m, 4H), 8.27-8.40 (m, 2H), 8,48-8.65 (m, 1H).
Example 20
[0176] To a solution of anhydrous calcium chloride (1.86 g, 16.3 mmol) in ethanol (32 mL) were added sodium borohydride (1.27 g, 33.6 mmol) and ethanol (5 mL) at −10° C., and the mixture was stirred at −10° C. for 30 min. To the reaction mixture was added dropwise a solution of ethyl (3S)-3-hydroxy-3-{6-[(methylamino)carbonyl]-2-naphthyl}-3-(1-tosyl-1H-imidazol-4-yl)propanoate (2.5 g, 5.6 mmol) in tetrahydrofuran (73 mL)/ethanol (10 mL), and tetrahydrofuran (5 mL) at −10° C. The obtained reaction mixture was stirred at 7° C. for 21 hr, and to the obtained reaction mixture were added dropwise water (100 mL), 1 mol/L hydrochloric acid (40 mL) and ethyl acetate (200 mL) at 10° C. or below, and the mixture was stirred. To the separated organic layer was added 0.2 mol/L hydrochloric acid (14 mL) at 5° C., and the mixture was stirred. The reaction mixture was adjusted to pH 7.5 with 0.5 mol/L aqueous sodium hydroxide solution at 5° C. To the separated organic layer was added again 0.2 mol/L hydrochloric acid (14 mL) at 5° C., and the mixture was stirred. The reaction mixture was adjusted to pH 7.5 with 0.5 mol/L aqueous sodium hydroxide solution at 5° C. To the separated organic layer was added water (10 mL), and the mixture was adjusted to pH 9.5 with 0.5 mol/L aqueous sodium hydroxide solution. To the separated organic layer was added water (120 mL), and the mixture was heated to 60° C., and stirred for 3 hr. The separated organic layer was concentrated at 60° C. under reduced pressure to give 6-[(1S)-1,3-dihydroxy-1-(1H-imidazol-4-yl)propyl]-N-methyl-2-naphthamide (2.3 g, 7.0 mmol).
Example 21
[0177] To THF (4.8 mL) was added 6-[(1S)-1,3-dihydroxy-1-(1-tosyl-1H-imidazol-4-yl)propyl]-N-methyl-2-naphthamide (479.6 mg, 1.0 mmol). The reaction mixture was cooled to 10° C., and ethyldiisopropylamine (505.9 mg, 4.0 mmol) and methanesulfonyl chloride (458.8 mg, 4.0 mmol) were successively added thereto, and the mixture was stirred at room temperature for 2 hr. To the reaction mixture was added a solution of sodium carbonate (530.0 mg, 5.0 mmol) in water (2 mL), and the mixture was warmed to 57° C., and stirred for 5 hr. The separated organic layer was concentrated under reduced pressure. Methanol (4 mL) and activated carbon (40 mg) were added thereto. The reaction mixture was stirred at the same temperature for 20 min, and the activated carbon was filtered off, and washed with methanol (2 mL). The filtrate and washing were concentrated under reduced pressure. Methanol (1 mL), ethyl acetate (5 mL), and THF (10 mL) were added to the residue, and the mixture was washed twice with 10% sodium chloride-containing 5 w/v % aqueous sodium bicarbonate solution (15 mL). The separated organic layer was concentrated under reduced pressure to give 6-((7S)-hydroxy-6,7-dihydro-5H-pyrrolo[1,2-c]imidazol-7-yl)-N-methyl-2-naphthamide (135.4 mg, 0.44 mmol). yield 44%.
Example 22
[0178] Under a nitrogen atmosphere, 6-bromo-N-methyl-2-naphthamide (10.0 g, 37.9 mmol) was added to tetrahydrofuran (250 mL), and to the obtained solution was added dropwise 2.0 mol/L isopropylmagnesium chloride tetrahydrofuran solution (18.9 mL) at room temperature. The obtained reaction mixture was cooled to −30° C., 1.65 mol/L n-butyllithium hexane solution (37.9 mL) was added dropwise thereto, and the mixture was stirred at the same temperature for 1 hr or more. To the reaction mixture was added dropwise a solution of 1-(phenylsulfonyl)-4-formyl-1H-imidazole (13.4 g, 56.8 mmol) in tetrahydrofuran (100 mL) at −20° C., and the mixture was stirred at the same temperature for 2 hr. The reaction mixture was warmed over 2 hr to 0° C., and 20 w/v % aqueous ammonium chloride solution (150 mL) was added dropwise thereto. The separated organic layer was concentrated to the volume of about 130 mL under reduced pressure to give a residue. To the obtained residue was added tetrahydrofuran (200 mL), and the mixture was concentrated to the volume of about 130 mL under reduced pressure to give a residue. To the obtained residue was added ethyl acetate (200 mL), and the mixture was concentrated to the volume of about 200 mL under reduced pressure. These operations were repeated three times to give a residue. To the obtained residue was added ethyl acetate to adjust the volume to about 200 mL. The obtained reaction mixture was stirred at room temperature for 2 hr or more to give crystals. The crystals was collected by filtration, and washed with ethyl acetate (100 mL) to give wet crystals. The obtained wet crystals were dried under reduced pressure at an outside temperature of 50° C. to give 6-(hydroxy(1-(phenylsulfonyl)-1H-imidazol-4-yl)methyl)-N-methyl-2-naphthamide (9.2 g, 21.8 mmol). yield 58%.
[0179] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.83 (d, J=5.0 Hz, 3H), 5.74 (d, J=5.0 Hz, 1H), 6.06 (d, J=5.0 Hz, 1H), 7.69-7.72 (m, 2H), 7.81-7.84 (m, 1H), 7.90-7.94 (m, 4H), 8.11-8.13 (m, 2H), 8.30 (s, 1H), 8.37 (s, 1H), 8.57-8.59 (q, 1H).
Example 23
[0180] 6-(Hydroxy(1-(phenylsulfonyl)-1H-imidazol-4-yl)methyl)-N-methyl-2-naphthamide (8.8 g, 20.88 mmol) and manganese dioxide (16.4 g, 187.9 mmol) were added to N,N-dimethylacetamide (75 mL), and the mixture was stirred at 60° C. for 9.5 hr. The insoluble material was filtered off from the reaction mixture at 60° C., and washed with DMAc (35 mL). The filtrate and washing were combined, and cooled to 40° C., water (53 mL) was added dropwise thereto, and the mixture was stirred at the same temperature for 0.5 hr or more, and then at room temperature for 1 hr or more to give crystals. The obtained crystals were collected by filtration, and washed with water (44 mL) to give wet crystals. The obtained wet crystals were dried under reduced pressure at an outside temperature of 50° C. to give crude crystals (6.3 g). Ethyl acetate (63 mL) was warmed to 40° C., and the crude crystals (6.3 g) were added thereto. The obtained mixture was warmed to 50° C., and stirred for 0.5 hr or more. 13 mL of the solvent was evaporated under reduced pressure to give a residue. The obtained residue was allowed to cool to room temperature, diisopropyl ether (53 mL) was added dropwise thereto at the same temperature, and the mixture was stirred to give crystals. The obtained crystals were collected by filtration, and washed with a mixed solvent (20 mL) of diisopropyl ether/ethyl acetate (1:1, volume ratio) to give wet crystals. The obtained wet crystals were dried under reduced pressure at an outside temperature of 50° C. to give N-methyl-6-[(1-(phenylsulfonyl)-1H-imidazol-4-yl)carbonyl]-2-naphthamide (6.2 g, 14.9 mmol). yield 72%.
[0181] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.86 (d, J=5.0 Hz, 3H), 7.76 (t, J=10.0 Hz, 2H), 7.88 (t, J=10.0 Hz, 1H), 8.00 (d, J=10.0 Hz, 1H), 8.12 (q, J=5.0 Hz, 2H), 8.18 (d, J=10.0 Hz, 1H), 8.27 (d, J=10.0 Hz, 2H), 8.49 (s, 1H), 8.67 (d, J=10.0 Hz, 2H), 8.71 (q, J=5.0 Hz, 1H), 8.86 (s, 1H).
Example 24
[0182] The Reformatsky reagent was obtained according to the method described in Example 14. The obtained Reformatsky reagent (27.3 mL, corresponding to 2.5 eq.) was cooled to 0° C. or below, cinchonine (2.6 g, 8.9 mmol), pyridine (2.3 mL, 23.0 mmol) and THF (24 mL) were added thereto, and the mixture was stirred at the same temperature for 30 min. The reaction mixture was cooled to −25° C., N-methyl-6-((1-phenylsulfonyl-1H-imidazol-4-yl)carbonyl)-2-naphthamide (3.0 g, 7.2 mmol) was added thereto. The obtained reaction mixture was stirred at −20° C. for 1 hr. To the obtained reaction mixture was added the Reformatsky reagent (10.9 mL, corresponding to 1.0 eq.) at −25° C., and the mixture was stirred for 1.5 hr. The Reformatsky reagent (10.9 mL, corresponding to 1.0 eq.) was added again thereto −25° C., and the mixture was stirred for 1.5 hr. To the obtained reaction mixture were added ethyl acetate (42 mL) and 20 w/v % aqueous citric acid solution (42 mL) at 10° C. or below. The separated organic layer was washed successively with 10% sodium chloride-containing 20 w/v % aqueous citric acid solution (30 mL, twice) at 5° C., 5 w/v % aqueous sodium bicarbonate (30 mL, three times), and water (30 mL). The organic layer was concentrated to the volume of 18 mL under reduced pressure to give a residue. To the obtained residue was added methanol (30 mL), and the mixture was concentrated to the volume of 18 mL under reduced pressure to give a residue. To the residue was added methanol to adjust the volume to 30 mL. Water (3 mL) was added thereto at room temperature, and the mixture was stirred for 1 hr. Then water (21 mL) was added dropwise thereto at the same temperature, and the mixture was stirred. The obtained crystals were collected by filtration, and washed with a mixed solvent (9 mL) of methanol/water (1:3, volume ratio). The obtained wet crystals were dried under reduced pressure to give ethyl (3S)-3-hydroxy-3-{6-[(methylamino)carbonyl]-2-naphthyl}-3-(1-phenylsulfonyl-1H-imidazol-4-yl)propanoate (3.2 g, 6.3 mmol). yield 88%. enantiomeric excess: 61% ee.
[0183] 1 H NMR (500 MHz, DMSO-d 6 ) δ 0.78 (t, J=5.0 Hz, 3H), 2.82 (d, J=5.0 Hz, 3H), 3.19 (d, J=15.0 Hz, 1H), 3.30 (d, J=15.0 Hz, 1H), 3.76 (q, J=5.0 Hz, 2H), 6.15 (s, 1H), 7.50 (d, J=5.0 Hz, 1H), 7.69 (dd, J=15.0, 10.0 Hz, 3H), 7.79 (t, J=/010.0 Hz, 1H), 7.87-7.92 (m, 3H), 8.02 (s, 1H), 8.09-8.12 (m, 2H), 8.34 (s, 1H), 8.58 (q, J=5.0 Hz, 1H).
Example 25
[0184] To a solution of anhydrous calcium chloride (0.84 g, 7.4 mmol) in ethanol (9 mL) was added sodium borohydride (0.57 g, 14.8 mmol) at −15° C., and the mixture was stirred at −10° C. for 30 min. To the reaction mixture was added dropwise a solution of ethyl (3S)-3-hydroxy-3-{6-[(methylamino)carbonyl]-2-naphthyl}-3-(1-phenylsulfonyl-1H-imidazol-4-yl)propanoate (1.5 g, 3.0 mmol) in tetrahydrofuran (75 mL)/ethanol (15 mL) at −10° C. The obtained reaction mixture was stirred at 5° C. for 8 hr, and to the obtained reaction mixture were added dropwise water (12 mL), 1 mol/L hydrochloric acid (15 mL) and ethyl acetate (30 mL) at 10° C. or below, and the mixture was stirred. To the separated organic layer was added 0.2 mol/L hydrochloric acid (15 mL) at 5° C., and the mixture was stirred. The reaction mixture was adjusted to pH 7.5 with 0.5 mol/L aqueous sodium hydroxide solution at 5° C. To the separated organic layer was added again 0.2 mol/L hydrochloric acid (15 mL) at 5° C., and the mixture was stirred. The reaction mixture was adjusted to pH 7.5 with 0.5 mol/L aqueous sodium hydroxide solution at 5° C. To the separated organic layer was added water (15 mL), and the mixture was adjusted to pH 9.5 with 0.5 mol/L aqueous sodium hydroxide solution. The separated organic layer was washed with 10 w/v % brine (15 mL). To the separated organic layer was added water (18 mL), and the mixture was heated to 60° C., and stirred for 3 hr. The separated organic layer was concentrated under reduced pressure to give 6-[(1S)-1,3-dihydroxy-1-(1-phenylsulfonyl-1H-imidazol-4-yl)propyl]-N-methyl-2-naphthamide (1.2 g, 2.5 mmol). yield 83%. enantiomeric excess: 62% ee.
[0185] 1 H NMR (500 MHz, DMSO-d 6 ) δ 2.13-2.17 (m, 1H), 2.34-2.42 (m, 1H), 2.83 (d, J=5.0 Hz, 3H), 3.52-3.54 (m, 2H), 4.49 (t, J=5.0 Hz, 1H), 5.38 (s, 1H), 7.28-7.33 (m, 2H), 7.48 (d, J=5.0 Hz, 1H), 7.70 (dd, J=10.0, 5.0 Hz, 3H), 7.80 (t, J=10.0 Hz, 1H), 7.95-8.01 (m, 3H), 8.04-8.12 (m, 1H), 8.34 (s, 1H), 8.45 (s, 1H), 8.62 (q, J=5.0 Hz, 1H); HRMS (ESI) m/z calcd for C 24 H 24 N 3 O 5 S [m+H] + : 466.1392. Found: 466.1436.
Example 26
[0186] Under a nitrogen atmosphere, 6-bromo-N-methyl-2-naphthamide (5.0 g, 18.9 mmol) was added to tetrahydrofuran (125 mL), and to the obtained solution was added dropwise 2.0 mol/L isopropylmagnesium chloride tetrahydrofuran solution (9.5 mL) at room temperature. The obtained reaction mixture was cooled to −30° C., 1.65 mol/L n-butyllithium hexane solution (18.9 mL) was added dropwise thereto, and the mixture was stirred at the same temperature for 1 hr or more. To the reaction mixture was added dropwise a solution of t-butyl 4-formyl-1H-imidazole-1-carboxylate (6.7 g, 34.1 mmol) in tetrahydrofuran (50 mL) at −20° C., and the mixture was stirred at the same temperature for 2 hr. The obtained reaction mixture was warmed over 2 hr to 0° C., and 20 w/v % aqueous ammonium chloride solution (75 mL) was added dropwise thereto. The separated organic layer was concentrated to the volume of about 65 mL under reduced pressure to give a residue. To the obtained residue was added tetrahydrofuran (100 mL), and the mixture was concentrated to the volume of about 65 mL under reduced pressure to give a residue. To the obtained residue was added acetone (100 mL), and the mixture was concentrated to the volume of about 100 mL under reduced pressure. These operations were repeated three times to give a residue. The obtained residue was concentrated to dryness to give t-butyl 4-(hydroxy(6-methylcarbamoyl)naphthalen-2-yl)methyl)-1H-imidazole-1-carboxylate (10.5 g).
[0187] HRMS (ESI) m/z Calcd for a C 21 H 24 N 3 O 4 [m+H] + ; 382.1722. Found: 382.1759.
Example 27
[0188] t-Butyl 4-(hydroxy(6-methylcarbamoyl)naphthalen-2-yl)methyl)-1H-imidazole-1-carboxylate (10.2 g) and manganese dioxide (15.0 g, 172.5 mmol) were added to N,N-dimethylacetamide (35 mL), and the mixture was stirred at 60° C. for 14 hr. The insoluble material was filtered off from the obtained reaction mixture at 60° C., and washed with N,N-dimethylacetamide (25 mL). The filtrate and washing were combined, and concentrated under reduced pressure, and to the obtained residue were added ethyl acetate (100 mL) and water (50 mL). The separated organic layer was concentrated under reduced pressure to give t-butyl 4-(6-(methylcarbamoyl)-2-naphthoyl)-1H-imidazole-1-carboxylate (11.4 g).
[0189] HRMS (ESI) m/z calcd for a C 21 H 22 N 3 O 4 [M+H] + ; 380.1566. Found: 380.1607.
INDUSTRIAL APPLICABILITY
[0190] According to the production method of the present invention, imidazole derivatives useful for the prophylaxis or treatment of diseases, for which androgen or estrogen is an aggravating factor, can be produced efficiently and industrially under mild conditions.
[0191] This application is based on patent application No. 2011-133712 filed in Japan, the contents of which are encompassed in full herein.
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The present invention provides an advantageous production method of an imidazole derivative, which is suitable for industrial production.
Compound (VI) is produced by reacting compound (I) with a Grignard reagent or a magnesium reagent, and a lithium reagent, and then reacting the resulting compound with compound (V).
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Related Art
It is common knowledge that inorganic peroxides, particularly hydrogen peroxide and peroxide hydrates, such as perborate, percarbonate and perpyrophosphate, develop their full oxidation and bleaching action in aqueous solution only at temperatures in excess of 80° C. In order to obtain an adequate bleaching action even at lower temperatures, it has been proposed to add specific N-acyl compounds to the aqueous solutions of percompounds in order to activate the latter. According to German Published Application DAS No. 1,162,967, the compounds used for this purpose should contain at least two acyl groups attached to the same nitrogen atom, such as N,N,N'-triacetylmethylenediamine, N,N,N',N'-tetraacetylmethylenediamine and the like. According to German Published Application DAS No. 1,291,317, compounds of the general formula
RCO -- NR.sub.2 -- OCR.sub.1
serve this purpose, wherein R and R 1 signify C 1-3 alkyl residues, while R 2 may constitute an optional organic radical which may be combined with R 1 to form a ring, if desired substituted, such as caprolactam, N-acylated barbitone, phthalimide, anthranil, N-acylated hydantoin or saccharine rings. U.S. Pat. No. 3,715,184, described the use of acylated glycolurils of the general formula ##STR2## wherein at least two of the residues R 1 and R 4 constitute acyl residues having 2 to 8 carbon atoms, while the other residues signify hydrogen atoms and/or alkyl or aryl residues having 1 to 8 carbon atoms and/or acyl residues having 2 to 8 carbon atoms, as activators for percompounds. The acyl residues present in one molecule may be the same or different. Preferably, tetraacylglycolurils having similar C 2-4 acyl residues are used, particularly tetraacetylglycoluril.
It has also been proposed, in German Auslegeschrift (DAS) 2,360,340, to use oxamides of the formula
R -- NH -- CO -- CO -- NH -- R'
in which R and R' represent acyl radicals having 2 to 9 carbon atoms as bleaching activators. These oxamides are said to be distinguished by improved storage stability in the presence of peroxide. However, a substantial disadvantage of the described oxamides is their relatively very low activation value. Thus, in order to obtain adequate activation, very large quantities of bleaching activators have to be used, only a slight cold-bleaching action being obtainable when using quantities which meet practical requirements.
The acylated nitrogen compounds hydrolyze in the presence of aqueous hydrogen peroxiide to form peracids which develop a satisfactory bleaching and disinfecting action even in the range of temperature between 30° C and 60° C. However, owing to their nitrogen content, acylated imides can cause undesirable eutrophication of waters which are heavily loaded with waste water, so that it may be advantageous to use bleaching activators which are free from nitrogen. Nitrogen-free bleaching activators are also known, such as acid anhydrides in accordance with German Patent Specification 893,049 and German Published application (DAS) 1,038,693, or esters of phenols or polyvalent alcohols in accordance with German Pat. Specifications 1,246,658 and 1,227,179. However, it has transpired that the bleaching effects obtainable by means of these compounds are relatively slight.
Therefore, the task arose of providing new oxidation, bleaching and washing agents having a content of bleaching activators which do not have the aforesaid disadvantages.
OBJECTS OF THE INVENTION
An object of the present invention is to develop solid compositions with bleaches and bleach activators which do not contain nitrogen atoms.
Another object of the present invention is the development of solid oxidation compositions for washing and bleaching agents containing compounds releasing active oxygen in solution and at least one hexacyclic ester anhydride having the formula ##STR3## wherein R is a member selected from the group consisting of hydrogen, alkyl having 1 to 18 carbon atoms and --(CH 2 ) n --(CHOH) m --COOY, where n is an integer from 1 to 3, m is an integer from 0 to 1 and Y is a member selected from the group consisting of hydrogen, alkali metal, ammonium, lower alkanolammonium, and N-lower-alkyl-piperidinium.
A further object of the present invention is the development of a method of activating aqueous solutions of percompounds at temperatures below 70° C by utilization of said hexacyyclic ester - anhydride described above.
These and other objects of the present invention will become more apparent as the description thereof proceeds.
DESCRIPTION OF THE INVENTION
Accordingly, the present invention provides oxidation, bleaching and washing agents comprising inorganic percompounds and a 6-member cyclic ester - anhydride of an α-hydroxy-carboxylic acid or an α-hydroxydicarboxylic acid.
Suitable 6-member cyclic ester-anhydrides are those of Formula I: ##STR4## in which R represents H or an alkyl radical having 1 to 18 carbon atoms or a radical of the formula:
-- (CH.sub.2).sub.n -- (CHOH).sub.m -- COOY
in which Y = H, Na, K, NH 4 , or the cation of an organic ammonium base such as mono-, di-and triethanolamine, or N-methylpiperidine, n = 1, 2 or 3 and m = 0 or 1. Preferably, Y represents Na or K.
More particularly, the present invention relates to solid powdery-to-granular oxidation compositions for bleaching and washing agents consisting essentially of a water-soluble solid inorganic percompound in the form of its alkali metal salt and at least one hexacyclic ester-anhydride having the formula ##STR5## wherein R is a member selected from the group consisting of hydrogen, alkyl having 1 to 18 carbon atoms and
-- CH.sub.2).sub.n -- (CHOH).sub.m -- COOY,
where n is an integer from 1 to 3, m is an integer from 0 to 1, and Y is a member selected from the group consisting of hydrogen, alkali metal, ammonium, lower alkanolammonium, and N-lower-alkyl-piperidinium, as an activator, said activator being present in an amount sufficient that from 0.05 to 5 mols of said activator are present per mol of active oxygen atoms in said percompound.
Examples of suitable cyclic ester-anhydrides are: diglycolide (2,5-dioxo-1,4-dioxan) and dilactide (3,6-dioxo-2,5-dimethyl-1,4-dioxan), the dimeric lactones of α-hydroxybutyric acid, α-hydroxyvaleric acid, α-hydroxycaproic acid, α-hydroxylauric acid, α-hydroxymyristic acid, α-hydroxypalmitic acid, α-hydroxystearic acid, malic acid, α-hydroxyglutaric acid, α-hydroxyadipic acid and 2,5-dihydroxyadipic acid. Preferably, diglycolide and dilactide are used.
The fact that the said cyclic ester-anhydrides cause the bleaching activation of inorganic peroxides is highly unexpected, since they do not produce any measurable effect under the conditions in which the activation value is normally determined. It is common knowledge that the activation value is determined with hydrogen peroxide in the presence of an alkali reacting phosphate-borate buffer at α° C, wherein the peracid formed oxidized iodide to form free iodine which is back-titrated with sodium thiosulfate (see German Patent Specification 1,246,658). Hitherto, a positive reaction during the performing of this test was a prerequisite for the suitability of the relevant compound as a bleaching activator.
Although the cyclic ester-anhydrides, to be used in accordance with the invention, do not react positive during this test, they exhibit, in use, for example, when bleaching colored dirt on textiles, a marked improvement in the bleaching effect at low temperatures. Since the cyclic ester-anhydrides are free from aromatic radicals, they are also very readily and fully decomposable in waste water. Furthermore, cyclic ester-anhydrides, derived from α-hydroxy acids having 12 to 20 carbon atoms, have the advantage that they have washing-active properties after perhydrolysis and reconversion to the salts of α-hydroxy acids, and can improve the cleaning power of the agents.
The cyclic ester-anhydrides can be added to the oxidation, bleaching and cleaning agents or solutions immediatelly before use or, alternatively, they can be incorporated in the pulverulent or granular washing and bleaching agents and used together therewith. The present invention, therefore, relates to the use of the above-described ester-anhydrides as activators for H 2 O 2 or percompounds producing H 2 O 2 in water.
The percompounds to be activated in aqueous solution can be any type of inorganic or organic percompound which will release active oxygen in an aqueous solution. For economic reasons, the percompounds preferably utilized are inorganic peroxides, inorganic peracids, inorganic peroxyhydrates and products of the addition of hydrogen peroxide with inorganic and organic compounds.
Of the peroxides to be activated, hydrogen peroxide is of the greatest practical importance. It may be used as such, but may also be used in the form of its mostly solid peroxyhydrates or products of addition with inorganic and organic compounds. The latter include, for example, the products of addition of hydrogen peroxide to urea or melamine, and examples of the peroxyhydrates are the perborates, perortho-, perpyro-, and perpolyphosphates, percarbontes, and persilicates. These peroxyhydrates are preferably soluble in water and are ordinarily utilized in the form of their alkali metal salts, such as their sodium salts. The activators, according to the invention, however, may also be used together with true peracids, such as, for example, Caro's acid (peroxymonosulfuric acid, H 2 SO 5 ) or peroxydisulfuric acid (H 2 S 2 O 8 ) or their salts.
The activation, in accordance with the invention, of the oxygen is most clearly perceptible at temperatures in the range of 20° to 70° C, especially from 30° to 60° C. Nevertheless, it is possible to use higher temperatures up to 100° C, for example, particularly when using deficient quantities of activator, so that chemically activated oxygen is used at temperatures up to 70° C and thermally activated oxygen at higher temnperatures, particularly temperatures in excess of 80° C. Depending upon the problem to be solved, it is possible for the technician, when using the activators according to the invention, either to reduce the temperature of treatment and/or to shorten the time of treatment, the temperature remaining the same.
Finally, a low and a high temperature bleach can also be combined in one operation. In such cases, it may be advantageous to add less than the theoretical amounts of activator, then at low temperatues only a part of the active oxygen present is activated, and the remainder is available for the bleaching at elevated temperatures.
The conditions to be maintained during operation with the activators according to the invention, such as, for example, the concentration of the peroxide, temperature, pH value and time of treatment, depend substantially on the substance to be oxidized and/or bleached, and in some cases on the carrier material on or in which the substance to be bleached is present. The usually aqueoua oxidizing or bleaching liquids may contain from 20 to 500 mg, preferably from 50 to 250 mg, per liter of active oxygen and have a pH value of from 4 to 12, preferably from 7 to 11.5, and particularly from 8 to 11.
In addition to inorganic percompounds, such as sodium perborate in the form of mono or tetrahydrate, percarbonate, perpyrophosphate or urea perhydrate, such washing and bleaching agents can contain further conventional washing-active substances, such as surfactants, was alkalis, sequestering which bind calcium salts, and other builders as well as further additives conventionally contained in washing and cleaning agents.
Advantageously, the compounded agents contain the cyclic ester-anhydrides and the percompounds in the ratio of 0.2 to 20, preferably 0.5 to 10, mol of peroxygen to 1 mol of cyclic ester-anhydride.
Furthermore, the joint use of alkaline reacting compounds, such as compounds of alkali metal carbonates, bicarbonates, borates, silicates and phosphates or condensed alkli metal phosphates, is advisable in quantities such that the carboxylic acid, released during the bleaching process, is fully or at least partially neutralized.
Suitable surface-active compounds or tensides are those of the sulfonate or sulfate type, such as alkylbenzene sulfonates, particularly n-dodecylbenzene sulfonate, olefinsulfonates, alkylsulfonates and α-sulfo-fatty acid esters, primary and secondary alkyl sulfates, as well as the sulfates of ethoxylated or propoxylated fatty alcohols. The sulfated partial ethers and partial esters of polyhydric alcohols are also usable, such as the alkali salts of mono-higher-alkyl ether or of mono-higher-fatty acid ester of glycerol-monosulfuric acid ester or of 1,2-dioxypropane sulfonic acid. Sulfates of ethoxylated or propoxylated fatty acid amides and alkylphenols, as well as fatty acid taurides and fatty acid isothionates are also suitable.
Further suitable anionic surface-active compounds are alkali metal soaps of fatty acids of natural or synthetic origin, such as sodium soaps of coconut fatty acids, palm kernal fatty acids, or tallow fatty acids. Suitable zwitterionic surface-active compounds are the alkylbetaines and partichularly alkylsulfobetaines, such as 3-(N,N-dimethyl-N-higher-alkylammonium)-propane-1-sulfonate and 3-(N,N-dimethyl-N-higher-alkylammonium)-2-hydroxypropane-1-sulfonate.
The anionic surface-active compound may be present in the form of their alkali metal salts, such as sodium or potassium, and ammonium salts as well as salts of organic bases, such as mono-, di- or triethanolamine. Insofar as the said anionic and zwitterionic surface-active compounds have an aliphatic hydrocarbon radical, the latter should be preferably straight chain and have 8 to 22 carbon atoms. In the compounds having an araliphatic hydrocarbon radical, the preferably unbranched alkyl chains contain an average of 6 to 16 carbon atoms. The aryl hydrocarbon radical is cyclohexyl or preferably phenyl.
Suitable nonionic surface-active compounds or tensides are those of the class of the polyglycolether derivatives, such as those of alcohols having 10 to 24 carbon atoms from the group of alkanols, alkenols and alkanediols and/or alkylphenols having 6 to 15 carbon atoms in the alkyl chain and 3 to 30 alkoxy units. The alkoxy units are propoxy or preferably ethoxy and mixtures of propoxy and ethoxy units. Mixtures of such polyglycolether derivatives are particularly suitable in which at least one compound having 3 to 6 ethoxhy units and at least one compound having 7 to 20 ethoxy units are present in the weight ratio of 5:1 to 1:10. Preferably polyglycolether derivatives of straight chain, primary alkanols having 12 to 18 carbon atoms, and of alkylphenols having straight chain alkyl chains having 8 to 12 carbon atoms, are used.
Further suitable nonionic surface-active compounds are the glycolether derivatives of higher fatty acids, higher fatty acid amides, primary or secondary higher fatty amines, vicinal higher alkane diols, higher alkyl mercaptans and alkyl sulfamides which have 10 to 24 carbon atoms in the hydrocarbon radical and 3 to 30 glycolether groups, preferably ethoxy units. Nonionic surface-active compounds of the type of aminoxides and sulfoxides, which may be optionally ethoxylated, are also usable.
Suitable builders are the alkali metal carbonates and silicates, such as potassium and particularly of sodium, the latter having a ratio of SiO 2 to Na 2 O of 1:1 to 3.5:1. Suitable builders having a sequestering action are polymeric phosphates, particularly pentasodium tripolyphosphate which may be present mixed with its products of hydrolysis, the mono- and diphosphates, as well as higher condensed phosphates such as tetrapoluphosphates.
Alternatively, the polymeric phosphates can be entirely or partially replaced by phosphate-free sequestering agents. These include the alkali metal salts of aminopolycarboxylic acids, particularly nitrilotriacetic acid and ethylenediaminotetraacetic acid. Also suitable are the salts of diethylenetriaminopentaacetic acid as well as the higher homologues of the said aminopolycarboxylic acids. Further suitable aminopolycarboxylic acids are poly-(N-succinic acid)-ethylene imine, poly-(N-tricarballylic acid)-ethylene imine and poly-(N-butane-2,3,4-tricarboxylic acid)-ethylene imine.
The salts of aminopolycarboxylic acids can be replaced by, or mixed with, polyphopshonic acids having a sequestering action, such as alkali metal salts of aminopolyphosphonic acids, particularly amino-tri-(methylene phosphonic acid), 1-hydroxyethane-1,1-diphosphonic acid, methylene diphosphonic acid, ethylene diphosphonic acid as well as salts of the higher homologues of the said polyphosphobic acids.
Particular importance is attached to the nitrogen and phosphorus-free polycarboxylic acids forming complex salts with calcium ions, including polymers containing carboxyl groups. Citric acid, tartaric acid, benzenehexacarboxylic acid and tetrahydrofurantetracarboxylic acid are also suitable. Polycarboxylic acids contaning carboxy methyl ether groups are also usable, such as 2,2'-oxydisuccinic acid as well as polyvalent alcohols or hydrocarboxylic acids partially or fully etherified with glycolic acid, such as triscarboxymethyl glycerine, biscarboxymethyl glyceric acid and carboxymethylated or oxidized poly saccharides. Also suitable are the polymeric carboxylic acids having a molecular weight of at least 350 in the form of water-soluble sodium or potassium salts, such as polyacrylic acid, polymethacrylic acid, poly α-hydroxyacrylic acid, polymaleic acid, polyitaconic acid, polymesaconic acid, polybutenetricarboxylic acid, as well as the copolymers of the corresponding monomeric carboxylic acids one with another or with ethylenically-unsaturated compounds such as ethylene, propylene, isobutylene, vinylmethyl ether or furan.
Water-insoluble complex formers may also be used. These include phosphorylated cellulose and graft polymers of acrylic acid or methacrylic acid or cellulose, which can be present in the form of textile fabric, non-woven fabric or powder. Also suitable are spatially cross-linked and thus water-insoluble copolymers of acrylic acid, methacrylic acid, crotonic acid and maleic acid as other polymerizable polycarboxylic acids optionally with further ethylenically-unsaturated compounds in the form of sodium or potassium salts as sequestering agents. These insoluble copolymers can be in the form of fleeces, sponges, or alternatively, in the form of finely-ground foams having a low specific gravity and an open-cell structure.
Further suitable water-insoluble builders having a sequestering capability are alkali metal amuminosilicates which optionally contain bound water and in which the alkali metal can be exchanged for calcium or magnesium. These substances include, particularly, finely crystalline-to-amorphous aluminosilicates of the formula
(Na.sub.2 O ).sub.x . Al.sub.2 O.sub.3 . (SiO.sub.2).sub.y
wherein x represents a number of from 0.7 to 1.5, and y represents a number of from 1.3 to 4. The use of these aluminosilicates as builders is described in copending U.S. patent application Ser. No. 458,306, filed Apr. 5, 1974, now abandoned in favor of its continuation Ser. No. 800,308, filed May 25, 1977. Alternatively, mixtures of the aforesaid water-soluble and water-insoluble builder or complex formers can be used.
Magnesium silicate is particularly suitable as a stabilizer for the percompounds. Furthermore, enzymes from the class of the proteases, amylases and lipases may be present, particularly bacterial enzymes, such as those obtained from Bacillus subtilis.
Furthermore, the washing agents can contain optical brighteners, particularly derivatives of diaminostilbene disulfonic acids or their alkali metal salts. Salts of 4,4'-bis(2"-anilino-4"-morpholino-1,3,5-triazinyl-6"-amino)-stilbene-2,2'-disulfonic acid, for example, are suitable or similar compounds which contain, instead of the morpholino group, a diethanolamino group, a methylamino group, or a β-methoxyethylamino group. Furthermore, suitable optical brighteners for polyamide fibers are those of the diarylpyrazoline type, such as 1-(p-sulfonamidophenyl)-3-(p-chlorophenyl)-Δ 2 -pyrazoline, as well as similar compounds which contain a carboxymethyl or acetylamino group instead of the sulfonamido group. Furthermore, substitued aminocumarins are usable, such as 4-methyl-7-dimethylamino-cumarin or 4-methy-7-diethylamino-cumarin.
In addition, the compounds 1-(2-benzimidazolyl)-2-(1-hydroxyethyl-2-benzimidazolyl)-ethylene and 1-ethyl-3-phenyl-7-diethyolamino-carbostyril are usable as polyamide brighteners. Suitable optical brighteners for polyester and polyamide fibers are the compounds 2,5-di-(2-benzoxazolyl)-thiophene, 2-(2-benzoxazolyl)-naphtho-[2,3-b]-thiophene and 1,2-di-(5-methyl-2-benzoxazolyl)-ethylene. Furthermore, optical brighteners of the substituted diphenylstyril type may be present. Mixtures of the aforesaid optical brighteners may also be used.
Particularly suitable greying inhibitors or soil suspension agents are carboxymethylcellulose, methylcellulose, water-soluble polyesters and polyamides from polyvalent carboxylic acids and glycols or diamines which have free carboxyl groups, betaine groups or sulfobetaine groups capable of forming salts, as well as polymers or copolymers which are colloidally soluble in water, of vinyl alcohol, vinyl pyrrolicone, acrylamide and acrylonitrile.
Further suitable constituents are neutral salts, particularly sodium sulfate, as well as biocides or antimicrobials, such as halogenated diphenylmethanes, salicylanilides, carbanilides and phenols. Furthermore, liquid agents can contain hydrotropic substances and solvents, such as alkali metal salts of benzene sulfonic acid, toluene sulfonic acid or xylene sulfonic acid, urea, glycerine, polyglycerine, deithyleneglycol, or triethyleneglycol, polyethyleneglycol, ethanol, i-propanol, and other ether alcohols.
If required, known foam stabilizers, such as fatty acid alkanolamides, may also be present, such as laurylmonoethanolamide or diethanolamide or coconut fatty acid mono- or diisopropanolamides.
The cyclic ester-anhydrides to be used in accordance with the invention may be mixed with the pulverulent bleaching and washing agents, containing inorganic percompounds, without special precautions, since, even without a protective coating, they have adequate storage stability when stored under normal conditions. It is only in those cases in which it is impossible to avoid longer storage times at temperatures in excess of 25° to 30° C and high relative atmospheric humidity that it may be advisable to store the bleaching activators separately from the washing and bleaching agents containing persalt or to provide them with a protective coating of water-repellent materials or to embed them therein.
Examples of such cases of application are tablets which contain, in addition to the bleaching activator, conventional tabletting agents, such as starch, starch ether, microcrystalline or depolymerized cellulose, cellulose ether or swellable magnesium aluminum silicates ("Veegum", registered trademark), and alkali earth metal soaps, particularly magnesium stearate, as well as finely powdered mineral parting agents, particularly colloidal SiO 2 ("Aerosil", registered trademark) and, if required, surface-active wetting agents which promote the wetting and dissolving capacity. It will be appreciated that, alternatively, tablets of this type may be composed such that they contain the bleaching activator as well as the inorganic percompound (both of them preferably in a pregranulated form) and, optionally, further constituents of washing agents. In this case, the tabletting agent at the same time acts as a parting agent between the reactants.
A further embodiment suitable for particularly unfavorable storage conditions is the embedding of the bleaching activators in so-called "prills", i.e., loose powders which are producible by spraying a molten mass with simultaneous cooling of the material sprayed and which substantially comprise spherical individual particles having a diameter of approximately 0.1 to 2.5 mm. Embedding materials which have proved to be successful are, in particular, mixtures of insoluble fat-like compounds, particularly fatty acid mixtures and/or fatty alcohols melting between 35° and 60° C, as well as water-soluble, plasticizable compounds such as polyethyleneglycols and/or polyethyleneglycol ethers of fatty alcohols, alkylphenols, fatty acids, fatty acid amides, diols and other water-soluble polyglycol ether derivatives. By way of example, the weight ratio of water-insoluble to water-soluble embedding components can be 5:1 to 1:1. In addition, it is also possible to incorporate cellulose or starch ethers or "disintegrating agents" having a similar action and which are swellable in water and promote the dissolving capacity. The prills can be directly incorporated in the pulverulent oxidation, bleaching and washing agents. Such embedding processes are described in U.S. Pat. No. 4,003,841.
The cyclic ester-anhydrides can also be used to advantage in polishing and scouring agents. In addition to the inorganic peroxides and, if required, tensides and builders, these polishing and scouring agents can also contain abrasives such as pumice powder, marble powder, feldspar or quartz powder, corundum, synthetic resin granulates, steel cuttings or mixtures of such abrasives. The polishing and scouring agents may be present in the form of powder, rods or cubes or, alternatively, in a liquid form or in polishing pads based on steel wool or plastic wool which are impregnated with effective cleaning and bleaching substances.
Further fields of application for the cyclic and mixtures thereof with organic peroxides are washing agents for agents for automatic dishwashers, disinfectants and deodorizing preparations for the santiary and clinical field where they may be used in, for example, toilet and and drain cleaners, for disinfecting swimming pools and for the sterilizing or medical instruments and infected articles, as well as the food and beverage industry, for example, as an additive to alkaline cleaners for bottles and milk cans and in so-called beer coils, for sterilizing the water used for washing beer glasses in restaurants. They are also suitable for disinfecting the body and for the bleaching of human hair or, alternatively, for brightening chemical compounds. Basically, it is possible to use them in all fields in which agents containing active chlorine are customarily used and in which the aggressive properties and the unpleasant odor of chlorine are troublesome.
The oxidation, bleaching and washing agents generally contain the cyclic ester-anhydrides in quantities of from 0.5% to 50%, preferably from 1% to 30%, by weight. Some basic formulations for bleaching, washing and cleaning agents, in which the cyclic ester-anhydrides have proved to be successful, are given hereinafter. However, the range of application is not confined to these formulations.
FORMULATIONS
A. Washing Agent
5% to 40%, preferably 12% to 30%, by weight of tensides or combinations of tensides, comprising:
0 to 100%, preferably 25% to 65%, by weight of anionic tensides of the sulfonate and/or sulfate type,
1% to 100%, preferably 5% to 40%, by weight of nonionic tensides,
0 to 100%, preferably 10% to 50%, by weight of soap,
0 to 6%, preferably 0.5% to 3%, by weight of foam stabilizer,
0 to 8%, preferably 0.5% to 5%, by weight of foam inhibitor,
10% to 82%, preferably 35% to 75%, by weight of builders wherein at least a portion of these builders react alkaline, and wherein the amount of the alkaline to neutral reacting builders amounts preferably to 0.5-fold to 7-fold, and particularly 1-fold to 5-fold the total tenside component,
10% to 50%, preferably 15% to 35%, by weight of a combination of percompound, particularly perborate and cyclic ester-anhydrides and, if required, stabilizers for the percompound, the quantity of this combination preferably being such that the active oxygen content of the total bleaching and washing agent amounts to 1% to 4%, preferably 1.5% to 3.5% by weight.
0 to 15%, preferably 1% to 12%, by weight of other washing agent constituents, such as oil suspension agents, optical brighteners, enzymes, perfume, dyes, and water.
B. Scouring Agent
60% to 95%, preferably 80% to 90%, by weight of water-insoluble constituents having a scouring action.
40% to 5%, preferably 20% to 10%, by weight of an essentially water-soluble mixture comprising:
5% to 100%, preferably 10% to 50%, by weight of a combination of percompound and cyclic ester-anhydrides, the quantity ratio of percompound to activator lying in the range given above,
0 to 95%, preferably 10% to 60%, by weight of anionic, nonionic and/or zwitterionic tensides,
0 to 95%, preferably 10% to 50%, by weight of particularly alkaline reacting inorganic builders and organic complex formers,
0 to 20%, preferably 1 to 10%, by weight of other conventional constituents of scouring agents.
C. Agent for Dishwashing Machines
0 to 5%, preferably 0.1% to 3%, by weight of a low-foaming tenside, particularly a nonionic surface-active compound from the class of the block polymers of ethylene oxide and propylene oxide,
30% to 98%, preferably 40% to 95%, by weight of builders, wherein at least a portion of these builders reacts alkaline and is preferably composed of the following:
20% to 100% by weight of Na or K tripolyphosphate,
0 to 90% by weight of a water-insoluble, cation-exchanging sodium aluminosilicate,
0 to 50%, preferably 5% to 50%, by weight of sodium silicate (Na 2 O : SiO 2 = 1:1 to 1:3.5),
0.1% to 50%, preferably 0.5% to 10%, by weight of a combination comprising an inorganic percompound, particularly perborate and cyclic ester-anhydrides and, if required, stabilizers for the percompound, the quantity ratio of activator to percompound corresponding to the range given above.
D. Alkaline Cleaner
50% to 99% by weight of at least one alkaline-reacting compound from the class of the sodium or potassium hydroxides, carbonates, phosphates, polymeric phosphates, borates and silicates (Na 2 O : SiO 2 = 2:1 to 1:3),
0 to 20%, preferably 0.1% to 10%, by weight of at least one sequestering agent from the class of the aminopolyphosphonates and hydroxyalkanepolyphosphonates,
0 to 5%, preferably 0.1% to 3%, by weight of at least one nonionic and/or anionic surfactant,
0.1% to 20%, preferably 0.2% to 10% by weight of a combination of inorganic percompound, particularly perborate, and cyclic ester-anhydrides and, if required, stabilizers for the percompound, the quantity ratio of activator to percompound corresponding to the range given above.
E. Bleaching Agent
10% to 100%, preferably 50% to 95%, by weight of a combination of inorganic percompound, particularly perborate and cyclic lactones and, if required, stabilizers for the percompound, the quantity ratio of activator to percompound corresponding to the range given above,
0 to 50%, preferably 2% to 25%, by weight of at least one alkaline-reacting compound from the class of the sodium or potassium hydroxides, carbonates, phosphates, polymeric phosphates, borates and silicates (Na 2 O : SiO 2 = 2:1 to 1:3),
0 to 20%, preferably 0.1% to 10%, by weight of at least one sequestering agent from the class of the aminopolycarboxylates, aminopolyphosphonates and hydroxyalkanepolyphosphonates,
0 to 20%, preferably 0.1% to 10%, by weight of other constituents, such as corrosion inhibitors, optical brighteners and neutral salts.
Sodium perborate tetrahydrate (NaBO2 . H 2 O 2 . 3H 2 O) has particular practical important among the preferably inorganic percompounds yielding H 2 O 2 in aqueous solution. Partially or completely dehydrated perborates, i.e., perborates dehydrated up to NaBO 2 . H 2 O 2 , may be used instead of sodium perborate tetrahydrate. Alternatively, the borates NaBO 2 . H 2 O 2 (as described in German Patent No. 901,287 or in U.S. Pat. No. 2,491,789) may be used in which the ratio Na 2 O : B 2 O 3 is less than 0.5:1 and preferably from 0.4 to 0.15:1, while the ratio H 2 O 2 : Na is from 0.5 to 4:1. All these perborates may be replaced entirely or partially by other inorganic percompounds, particularly by peroxyhydrates, for example, the peroxyhydrates of the ortho-, pyro- or polyphosphates, particularly tripolyphosphates, and of the carbonates. These peroxyhydrates are preferably soluble in water and are ordinarily utilized in the form of their alkali metal salts, such as the sodium salts.
It is advisable to incorporate quantities of from 0.25% to 10% by weight or conventional water-soluble and/or water-insoluble stabilizers for stabilizing the percompounds in the products of the invention. The magnesium silicates of a ratio of MgO:SiO 2 = 4:1 to 1:4, preferably 2:1 to 1:2, and particularly 1:1, generally obtained by precipitation from aqueous solutions, are suitable as water-insoluble stabilizers for percompounds. These compounds, for example, amount to from 1% to 8%, preferably 2% to 7%, of the weight of the entire preparation. Other alkaline earth metal silicates, cadmium silicates or tin silicates of corresponding composition may be used instead of the magnesium silicates. Water-containing oxides of tin are also suitable as stabilizers. Stabilizers soluble in water, which may be present together with stabilizers insoluble in water, are the organic complex formers whose quantity can amount to 0.25% to 5%, preferably 0.5% to 2.5%, of the weight of the entire preparation.
The following examples are illustrative of the practice of the invention without being limitative in any respect.
EXAMPLES
Cotton textile samples were uniformly impregnated with a tea decoction, red wine and blackcurrent juice, and were then dried. The samples were washed in a laboratory washing machine (launderometer) with the use of the following spray-dried washing agent (data given in parts by weight).
8.5 n-dodecylbenzene sulfonate (Na salt)
3.5 sodium soap (coconut and tallow fatty acids 1:1)
4.0 fatty alcohol 10-fold ethoxylated (C 16-18 mixture, iodine number = 50)
40.0 pentasodiumtripolyphosphate
5.0 sodium silicate (Na 2 O : SiO 2 = 1:3.3)
2.0 Mg silicate
1.5 carboxymethylcellulose
0.5 Na ethylenediaminetetraacetate
0.3 optical brightener
7.5 sodium sulfate
7.2 water
The proportions of washing agent, percompound and activator are given in rhe following Table I. The treatment temperatures were 30° and 60° C, the liquor ratio (weight of textile to washing liquor in liters) 1:10, and the treatment lasted 15 minutes, whereupon the samples were rinsed three times with water and dried. The samples were evaluated photometrically (wavelength of the light 465 nm). The results are given in the following Table I.
TABLE I__________________________________________________________________________ BlackcurrentWashing Sodium Digly- Tea Red Wine JuiceExampleAgent Perborate colide 30° C 60° C 30° C 60° C 30° C 60° CInitialgm/l gm/l gm/l % Remissionvalue-- -- -- 30.9 35.7 22.3__________________________________________________________________________-- 4.5 -- -- 46.2 57.5 52.9 55.4 55.2 60.6-- 4.5 0.5 -- 50.2 61.8 53.6 58.5 55.9 62.41 4.5 0.5 0.75 52.1 62.1 60.9 69.2 57.4 65.22 4.5 0.5 1.0 54.2 62.4 62.6 69.9 60.2 66.63 4.5 0.5 1.25 57.6 63.2 64.0 70.6 60.9 67.14 4.5 0.5 1.50 59.0 63.2 66.1 71.0 61.9 67.45 4.5 0.5 1.75 59.2 63.6 66.9 72.5 61.4 67.76 4.5 0.5 2.00 59.4 64.1 68.2 72.5 63.5 67.2__________________________________________________________________________
The preceding specific embodiments are illustrative of the invention. It is to be understood, however, that other expedients disclosed herein or known to those skilled in the art, may be employed without departing from the spirit of the invention or the scope of the appended claims.
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The method of activating aqueous solutions of percompounds utilizing hexacyclic ester-anhydrides of α-hydroxycarboxylic acids of the formula ##STR1## as activators, solid activated compositions comprising solid percompounds and said cyclic ester-anhydrides of α-hydroxycarboxylic acids, as activators.
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“This is a [X] division of application Ser. No. 08/729,463, filed Oct. 11, 1996 now U.S. Pat. No. 6,044,174.”
FIELD OF THE INVENTION
This invention relates to the processing of human handwriting for purposes of information storage, automatic character recognition, and the like. More particularly, this invention relates to the processing of spatiotemporally sampled symbols, including the representation of such symbols in parametric form.
ART BACKGROUND
The automatic analysis of human handwriting begins with sampling and digitization of the image or signal produced directly by human manipulation of a writing instrument, referred to herein, in a general sense, as a stylus. Purely graphical analysis can be performed on data sampled from a static image. However, for dynamic analysis, and more generally for analyzing data with reference to a temporal sequence, it is advantageous for the human subject to produce by manipulating an instrumented stylus or tablet that permits spatiotemporal sampling.
One exemplary instrumented tablet is described in U.S. Pat. No. 5,463,388, issued on Oct. 31, 1995 to R. A. Boie et al. This tablet includes a rectangular array of capacitance-sensing electrodes. The position of a hand-held stylus is determined, e.g., from the centroid of the respective capacitance values, as calculated in a microcontroller.
Parameter methods have been used for a number of years in connection, for example, with automatic signature verification. According to these methods, the signature (or other handwritten symbol) is represented in an abstract parameter space. The parametric representation consists of a set of numerical values of functions that are evaluated on the sampled data, and that relate to some combination of graphical and dynamic properties of the sampled data. Generally, a parametric representation is a condensed representation, in the sense that it occupies fewer bits of data-storage capacity than do the raw, sampled data.
Parametric representations of signatures have been used with some success for signature verification. In signature verification, the parameters are evaluated on a newly entered signature (or group of signatures), and the results are compared with a stored set of reference values. Such a procedure does not require the reconstruction, from parameters, of either the reference signature or the newly entered signature. Therefore, there is no need to choose parameters that preserve enough graphical information to reconstruct these signatures. Instead, parameters for signature verification are selected on the basis, e.g., of a tradeoff between selectivity and computational efficiency.
SUMMARY OF THE INVENTION
I have invented a parametric representation of handwritten symbols that not only permits efficient data storage, but also permits the symbols to be reconstructed, with a high degree of legibility, from the stored parameters.
Thus, in one broad aspect, my invention involves a method for representing a handwritten symbol in parametric form. This method comprises obtaining a temporally sequenced record of data points. Each of these data points describes the x and y coordinates of a sampled point on the handwritten symbol, and also includes a pen-condition flag that describes whether the pen was in the pen-up or pen-down position when that data point was recorded. (Instrumented tablets are available that will indicate not only whether the pen was up, but also what the pen pressure was on the tablet. In cases when such a tablet is used, it will often be useful to apply a threshold to the pen-pressure data, and set the pen-condition flag to “pen up” whenever the pressure falls below the threshold).
The method further comprises segmenting the handwritten symbol into elementary strokes. As will be seen below, this segmentation is typically achieved by identifying natural breakpoints between strokes. Breakpoints are identified by such criteria as abruptness of direction changes, as well as by pen lifts.
The method further comprises recording, for each stroke, a so-called standard parameter set that comprises the x and y coordinates of the stroke's endpoints, the arc length s of the stroke, the net turning angle φ and the relative initial tangent angle θ. The net turning angle is defined with reference to the tangent to the stroke (treating the stroke as a geometrical curve). If the tangent is envisaged as a directed, rigid rod lying against the stroke, then φ is the net angle through which the rod rotates as the point of tangency moves along the curve from the initial to the final endpoint. The relative initial tangent angle φ is defined with reference to the endpoint vector; i.e., the vector from the initial to the final endpoint. More specifically, θ is the angle from the endpoint vector to the tangent at the initial endpoint.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the standard parameter set for stroke representations, according to the invention in one embodiment.
FIG. 2A is a representation of an illustrative curve in the Cartesian plane.
FIG. 2B is a representation of the curve of FIG. 2A in the s, φ plane.
FIG. 3A is a representation, in the Cartesian plane, of a pair of pen strokes having an intervening pen-lift segment.
FIG. 3B is a representation, in the s, φ plane, of the pen strokes of FIG. 3A. A dotted line appearing in the figure is an artificial representation of the pen-lift segment.
FIG. 4 illustrates a smoothing procedure useful for the practice of the invention in some embodiments.
FIG. 5A is a representation, in the Cartesian plane, of a handwritten letter “A.”
FIG. 5B is a representation, in the s, φ plane, of the handwritten “A” of FIG. 5 A.
FIG. 6 illustrates certain auxiliary parameters useful for stroke representations.
FIG. 7 illustrates a machine for producing stroke-parameter data.
DETAILED DESCRIPTION
The standard parameter set for an exemplary curve is illustrated in FIG. 1 . As noted above, the parameters include the Cartesian coordinates x 1 , y 1 and x 2 , y 2 of the endpoints the angle θ of the initial tangent measured from the endpoint vector, the angle φ through which the tangent turns as the point of tangency traverses Ithe curve, and the curve's arc length s.
As illustrated in FIGS. 2A and 2B, any continuous curve in the Cartesian plane (FIG. 2A) is readily represented by a single-valued function φ(s) (FIG. 2 B), where φ(s) is the tangent angle at distance s from the starting point as measured along the curve. Because φ(s) is derived incrementally from the Cartesian curve by taking the polar coordinates Δs, φ(s) of each Cartesian increment Δx, Δy, I will call φ(s) the “polar curve” associated with the given Cartesian curve.
The polar curve has certain properties that make is convenient for analyzing handwritten symbols. As notes φ(s) is a single-valued function. Moreover, φ(s) is invariant to a translation of the Cartesian curve. A rotation of the Cartesian figure shifts φ(s) up or down without changing its shape. A magnification of the Cartesian figure stretches φ(s) in the s-direction. Any straight line segment in the Cartesian plane maps into a horizontal line segment in the polar plane. Any circular arc in the Cartesian plane maps into a diagonal line segment in the polar plane. (The slope of the line segment is proportional to the curvature of the arc). An inflection point in the Cartesian plane (i.e., a point where the curvature changes sign) maps into a maximum or minimum of the corresponding polar curve.
Curves produced by human handwriting are often interrupted by pen lifts. The sampling process can generally provide the coordinates of the point where the pen left the tablet, and the coordinates of the point where the pen returned to the tablet. However, the actual trajectory of the pen between these points is not available, in general. Therefore, in general, there is no way to attribute values of the arc-length variable s to this trajectory. Because of this, the polar cure φ(s) loses track of the relative locations of the respective curve segments before the pen lift and after the return of the pen to the tablet.
A convenient artifice is advantageously used to fill in this missing information. As illustrated in FIGS. 3A and 3B, a straight line segment is added to the Cartesian plane, connecting the pen-up and pen-down points. As explained above, this line segment maps into a horizontal line segment in the polar plane.
When this artifice is included, the polar curve contains enough information to permit reconstruction of the Cartesian curve according to the formulas: x ( s ) = ∫ 0 s cos ( φ ( s ′ ) ) s ′ y ( s ) = ∫ 0 s sin ( φ ( s ′ ) ) s ′
As will be seen below, the standard parameter set (which contains far less data than the complete polar representation of a stroke) will alone generally provide sufficient information for a highly legible reconstruction of the stroke.
Thus, the practice of the invention will typically include representing a handwritten symbol as a polar curve, segmenting the polar curve into strokes, and evaluating the standard parameter set as a condensed record of each stroke.
Smoothing . Before segmentation per se is undertaken, it is desirable to smooth the polar curve to remove, inter alia, quantization noise that comes from forcing the sampled data points to occupy points on a finite rectangular grid. According to a currently preferred smoothing algorithm, multiple points are collapsed; that is, any grid points sampled more than once is recorded as a single point, but the associated redundancy is also recorded as a weight in the statistical sense. Then, straight lines are collapsed; that is, any straight run of collinear points has only its first and last points recorded. The weights of the deleted points are reallocated to the first and last points in such a way as to leave the centroid of the weights unchanged. Then, midpoints are assigned; that is, each adjacent pair of points is replaced by a weighted midpoint at the centroid of the corresponding weights. This procedure is illustrated in FIG. 4 .
One exception is made to this procedure in order to prevent the corner at the meeting of two long intervals from being bypassed by a diagonal. Given two such long intervals, the midpoints of the first interval is assigned to the corner joint. The length of an interval to be treated in this manner, and the sharpness that defines a corner, are determined by appropriate threshold tests.
Segmentation . Our preferred segmentation procedure inserts breakpoints at corners and cusps, where direction changes abruptly. These features appear as discontinuities in the polar curve. For example, FIGS. 5A and 5B show data from a handwritten Roman letter A. The polar curve of FIG. 5B shows each of the natural strokes of the letter as a horizontal line segment set off by discontinuities. It is also significant, as will become apparent below, that the stylus moves more slowly near the discontinuities than it does elsewhere, as evidenced by the fact that the s coordinates of the sampled points lie closer together near the discontinuities.
A filter function is readily defined that assumes relatively high values at discontinuities and pen slowdowns, and still higher values when both of these features occur together. An adjustable threshold is readily applied to the output of this function for discriminating actual corners and cusps from background noise. The threshold level should be chosen carefully. If it is too low, natural strokes will be subdivided into an excessive number of smaller strokes. If it is too high, a pair of strokes separated by, e.g., a slightly rounded corner will be interpreted as a single stroke. In some cases, it may be advantageous to discriminate through the use of multiple threshold levels.
The thresholded filter partitions the list of data points into a sequence of alternating subsets referred to herein, respectively, as strokes and transitions. If the filter output is below threshold at a given point, that point lies in a stroke. Otherwise, the point lies in a transition. A separate thresholding operation eliminates apparent strokes that are shorter than a preset lower bound and lie within transitions.
Points that belong to transitions are discarded; points that belong to strokes are retained.
It should be noted that the results of the thresholded filter function are dependent upon curvature and pen speed. Therefore, these results will vary with changes in the temporal and spatial scales, unless an appropriate normalization procedure is used. For applications to discrete symbol recognizers, the natural unit for normalization is the complete symbol. Therefore, we currently prefer to normalize by scaling each symbol to a standard height, and then scaling time such that the maximum pen speed is defined as having a standard value such as unit value.
In addition to finding cusps and corners, it is advantageous to search for significant pen lifts and pen landings that might have failed to generate an above-threshold response from the filter function, and to place breakpoints at such locations. However, this task is complicated by the tendency of some writers to execute abrupt direction changes by lifting the pen too late, or landing the pen too soon, relative to a reorientation of the pen that was meant to take place entirely in the pen-up state. I refer to the graphical results of these direction changes as hooks. Hooks can be recognized as short, straight pendown strokes that are roughly aligned with adjacent (artificial) pen-up strokes.
Furthermore, it is advantageous to place breakpoints at major inflection points and at certain closely spaced pairs of inflection points. As noted above, an inflection point is represented as a maximum or minimum of the polar curve.
According to our current procedure, we seek the overall maximum and minimum of the locally smoothed curve φ(s) within each individual segment (as defined by the steps described thus far). The maximum point s M and the minimum point s m are collectively referred to as extremal points. We count an extremal point as an inflection point if it is sufficiently separated from both endpoints of the segment (in the polar plane) and from the other extremal point.
That is, a threshold Σ and a threshold Φ, are preset. Then an extremal point (s e , φ e ) is counted if: (i) s e differs by at least Σ from the s-coordinates of both endpoints and the other extremal point, and (ii) φ e differs by at least Φ from the corresponding φ-coordinates.
This procedure finds only major inflection points, and is insensitive to those produced by minor waviness of the pen stroke. Consequently, the procedure as thus far described may overlook significant features such as the cusp of a numeral 3 or of a Roman letter B that has been perfunctorily formed as a rounded dent. To mitigate this problem, we have included a special procedure for seeking closely spaced pairs of inflection points. This additional procedure seeks pairs consisting of a local maximum and a local minimum of the polar cure that: (i) are sufficiently close together in the s dimension (as determined by a further threshold test); and (ii) are sufficiently separated in both the s and φ dimensions from the endpoints of the stroke.
If a given pair of extrema satisfies these three conditions, a break is inserted at the midpoint between the extrema (in the s dimension), and the endpoint tangent angles are assigned the respective values of φ at the two inflection points. This has the effect of substituting a sharp corner for the perfunctory dent.
Calculation of Stroke Parameters . The output of the segmentation procedure is a list of point coordinates for each stroke. Each lists is reduced to the standard parameters for the corresponding stroke as explained below.
The Cartesian endpoints are set equal, respectively, to the first coordinate pair and the last coordinate pair on the list. The arc length s is obtained by summing the lengths of the interpoint increments (i.e., by evaluating a discretized approximation to the path-length integral).
Further smoothing is desirable for obtaining the angles θ and φ. The angle θ is obtained by taking a linear regression over the angles of the first several increments, and then evaluating the linear regression function at the initial endpoint. At the final endpoint, a similar regression yields the angle θ+φ.
For some applications, certain auxiliary parameters may be a useful supplement to the set of standard parameters. Exemplary such auxiliary parameters, illustrated in FIG. 6, are: the length s 0 of the endpoint vector, which extends from the initial to the final endpoint of the stroke; the Cartesian coordinates of the point P where the initial and final tangents intersect; and the path length s p from the initial to the final endpoint via P (i.e., along two legs of the triangle having a vertex at P and having the endpoint vector as a base). In addition, it will be useful in at least some cases to record a binary indicator f which assumes one binary value where the pen is up, and the other binary value when the pen is down. Such a binary pen-up indicator is useful for distinguishing artificial strokes (representing, pen-up displacements of the stylus) from strokes that were actually drawn.
Alternative Format of Stroke-Parameter Data . It will be recalled that the angel θ is the angle of the initial tangent, relative to the endpoint vector, and that the angle φ is the net turning angle of the tangent as the point of tangency traverses the stroke. It will be appreciated that this is not a unique way to represent the tangency directions of the stroke. For example, let the tangent of angle ρ be the slope of the endpoint vector, i.e., let ρ be defined by ρ= arctan ( y 2 - y 1 ) ( x 2 - x 1 ) .
Then the initial and final tangent angles, relative to the x-axis, are given by
ψ 1 =ρ+θ, ψ 2 =ρ+θ+φ.
For at least some applications, we have found it convenient to use the following format for recording stroke-parameter data for m 2
strokes: s 1 ψ 1 x 1 y 1 s 2 ψ 2 x 2 y 2 s 3 ψ 3 x 3 y 3 s 4 ψ 4 x 4 y 4 ⋯ ⋯ ⋯ ⋯ s m ψ m x m y m
Here, each line corresponds to an endpoint; thus each pair of sequential lines corresponds to a stroke if the first line of the pair is odd-numbered, and each pair corresponds to a joint between strokes if the first line is even-numbered. Each of the angles ψ i is a tangent angle, relative to the x-axis. The arc length s and the pen-up indicator f each only need to be recorded once per stroke (i.e., once per pair of lines). Therefore, we represent s and f alternately in the column denoted s i . That is, s i is the arc length if i is odd, and is the pen-up indicator if i is even.
Utilization of Stroke-Parameter Data . The standard parameters can be readily used as input for machine recognition of symbols. In such cases, it is unnecessary to reconstruct legible graphical symbols from these abstract data if, e.g., a machine-recognition system is provided that classifies input patterns by comparing stroke parameters directly with the stroke parameters of stored library symbols.
On the other hand, appropriate reconstruction is needed if the original writing is to be reconstructed for ordinary reading by a human user. In such cases, a curve must be provided for representing each stroke. Each of these curves must satisfy the endpoint conditions of the stroke. These conditions are satisfied, by definition, if: (i) the initial and final endpoints of the provided curve coincide with the initial and final stroke endpoints (x 1 , y 1 ) and (x 2 , y 2 ), respectively; (ii) the arc length of the provided curve is equal to s; and (iii) the angles of the initial and final tangents of the provided curve are those angles specified by θ and φ.
In general, there are infinitely many curves that will satisfy a given set of endpoint conditions. One exemplary approach to selecting a unique curve that satisfies these conditions is based on the spring wire model. A piece of spring wire constrained to satisfy conditions (i), (ii), (iii) above will assume the unique shape that minimizes stored elastic energy. Mathematically, stored elastic energy is proportional to the integral, over s, of the squared curvature. Minimizing this integral, then, subject to conditions (i), (ii), (iii) yields a unique reconstruction curve.
According to another exemplary approach, each reconstructed curve is composed of smoothly joined straight lines and circular arcs. If the arcs are constrained to have equal radii and the number of segments (lines and arcs) is minimized, then for a given set of stroke parameter values the curve is unique. Moreover, the number of segments in this unique curve is always less than or equal to three. A simple algorithm finds the segments. This approach is described in detail in my U.S. Pat. Ser. No. 6,208,757, “Method And Apparatus For Reconstructing Handwritten Symbols From Parametric Representations Thereof,” assigned to the assignee hereof, which is hereby incorporated by reference.
A Machine for Producing Stroke-Parameter Data . The illustrative machine 100 schematically depicted in FIG. 7 receives raw data from an input device such as tablet 110 . Optionally, the raw data are first stored in a storage device 120 such as a magnetic disk or computer memory, and later read into a memory 130 of machine 100 . The various operations performed in machine 100 , after fetching the raw data from memory 130 , may readily be carried out by special-purpose circuits designed to carry out such operations. However, in many cases it will be most convenient to carry out these operations in a digital signal processor or general-purpose digital computer under the control of the respective portions of an appropriate computer program. In either case, the operative entity for carrying out each of the respective operations is discussed individually in the following discussion, and referred to a respective block of the accompanying FIG. 7 .
Smoother 140 processes the raw data from memory 130 , thereby to produce a reduced set of smoothed data points. Typically, the output of the smoother will include polar as well as Cartesian coordinates, and will include a binarized pen-up indicator. Although pen pressure data may be useful in at least some smoothing procedures, these data will not typically be included, explicitly, in the output of the smoother. As noted above, the time coordinate will typically be useful for segmentation.
Segmenter 150 assigns sets of contiguous data points to discrete segments, according, e.g., to the segmentation procedure described above. In accordance with that procedure, segmenter 150 includes scaler 151 for normalizing height and time in order to make the segmentation procedure invariant to changes in spatiotemporal scale. The segmenter further includes detector 152 for corners and cusps, detector 153 for pen lifts and pen landings, and detector 154 for inflection points. The utilization of the resulting output data in the exemplary segmentation procedure is described above.
The stroke-by-stroke output of segmenter 150 is processed by parameter extractor 160 to produce, e.g., the standard parameter set and whatever auxiliary parameters are desired.
The output parameter data are then stored in a suitable medium 170 , such as a computer memory or other data-storage device.
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A method for encoding handwritten symbols operates upon penstroke data received from a device capable of sampling a stylus position at discrete intervals. Each handwritten symbol is segmented into an ordered sequence of discrete strokes. An are length and initial and final tangent angles are evaluated for each of these strokes. Each stroke is encoded in the form of a parameter set comprising position coordinates of the initial and final endpoints of the stroke, the arc length, and the initial and final tangent angles. In specific embodiments of the invention, the segmentation is based, in part, on properties of the handwritten symbol when it is expressed as a curve φ(s), wherein s represents arc length and φ represents the net turning angle.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to U.S. application Ser. No. 13/850,854 filed on Mar. 26, 2013, now U.S. Pat. No. 8,803,790, which is in turn a divisional of and claims priority to U.S. application Ser. No. 13/722,537 filed on Dec. 20, 2012, now U.S. Pat. No. 8,704,752, which is in turn a divisional of and claimed priority to U.S. application Ser. No. 12/793,474 filed on Jun. 3, 2010, now U.S. Pat. No. 8,350,799, which is a non-provisional application of U.S. Provisional Application No. 61/183,592 filed Jun. 3, 2009, each of which are herein incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] Disclosed embodiments relate generally to an LED backlight having individually controlled subsections and an associated liquid crystal display.
BACKGROUND OF THE ART
[0003] Liquid Crystal Displays (LCDs) contain several layers which work in combination to create a viewable image. A backlight is used to generate the rays of light that pass through what is commonly referred to as the LCD stack, which typically contains several layers that perform either basic or enhanced functions. The most fundamental layer within the LCD stack is the liquid crystal material, which may be actively configured in response to an applied voltage in order to pass or block a certain amount of light which is originating from the backlight. The layer of liquid crystal material is divided into many small regions which are typically referred to as pixels. For full-color displays these pixels are typically further divided into independently-controllable regions of red, green and blue subpixels, where the red subpixel has a red color filter, blue subpixel has a blue color filter, and green subpixel has a green color filter. These three colors are typically called the primary colors. Of course, some displays may use additional color filters (such as adding a yellow filter) and these could also be used with the embodiments herein.
[0004] The light which is passing through each subpixel originates as “white” (or broadband) light from the backlight, although in general this light is far from being uniform across the visible spectrum. The subpixel color filters allow each subpixel to transmit a certain amount of each color (red, green or blue). When viewed from a distance, the three subpixels appear as one composite pixel and by electrically controlling the amount of light which passes for each subpixel color the composite pixel can produce a very wide range of different colors due to the effective mixing of light from the red, green, and blue subpixels.
[0005] Currently, the common illumination source for LCD backlight assemblies is fluorescent tubes, but the industry is moving toward light emitting diodes (LEDs). Environmental concerns, small space requirements, lower energy consumption, and long lifetime are some of the reasons that the LCD industry is beginning the widespread usage of LEDs for backlights.
[0006] LCDs are becoming popular for not only home entertainment purposes, but are now being used as informational/advertising displays in both indoor and outdoor locations. When used for information/advertising purposes, the displays may remain ‘on’ for extended periods of time and thus would see much more use than a traditional home theatre use. Further, when displays are used in areas where the ambient light level is fairly high (especially outdoors) the displays must be very bright in order to maintain adequate picture brightness. When used for extended periods of time and/or outdoors, overall energy consumption can become an issue. Thus, it is desirable to limit the power consumption of these displays as much as possible while maintaining image fidelity.
SUMMARY
[0007] Exemplary embodiments provide a backlight with individually controlled subsections. The luminance for each subsection can be controlled based on the image data being sent to the LCD. The incoming image data may be analyzed to determine the requirements for each subsection, and some may be selectively ‘dimmed’ if they correspond to portions of the image which do not require the full luminance output of the backlight. Selectively dimming portions of the backlight allows for several benefits, including but not limited to reduced power consumption, longer product lifetime, and higher contrast ratios.
[0008] These and other objects are achieved by a device as described in the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A better understanding will be obtained from a reading of the following detailed description and the accompanying drawings wherein identical reference characters refer to identical parts and in which:
[0010] FIG. 1 is a front view of a backlight with individually controlled subsections;
[0011] FIG. 2 is a front view of LCD image data where the image is divided into several subimages;
[0012] FIG. 3 is a histogram of a subimage;
[0013] FIG. 4 is a flow chart for one embodiment for analyzing the subimage histogram data;
[0014] FIG. 5 is a front view of the backlight where each subsection is being driven at the appropriate luminance level based off the histogram data for the corresponding subimage;
[0015] FIG. 6 is a front view of the re-scaled LCD image data;
[0016] FIG. 7 is a front view of the backlight from FIG. 4 after diffusion;
[0017] FIG. 8 is the image resulting from combining the diffuse backlight of FIG. 7 with the rescaled LCD image of FIG. 6 ;
[0018] FIG. 9 a surface plot of a fully illuminated subsection of the backlight that has been convolved with a Gaussian filter;
[0019] FIG. 10 is a plot of relative luminance versus physical position on a pair of adjacent subsections when using the virtual subsection method;
[0020] FIG. 11 is a perspective view of one embodiment for controlling the ‘bleeding’ of light between adjacent subsections of the backlight;
[0021] FIG. 12 is a plot of relative luminance versus physical position on subsections when using pre-determined brightness profiles; and
[0022] FIG. 13 is a schematic view of one embodiment for the physical architecture of controlling the dynamic backlight.
DETAILED DESCRIPTION
[0023] FIG. 1 shows a backlight 10 which has been divided into several individually-controllable subsections 15 . The backlight 10 produces light through a plurality of LEDs (not shown) which are mounted to the front face of the backlight 10 . In this example, an 8×8 array of subsections 15 is shown. However, any number, shape, and size of subsections may be used with the various embodiments. The number of actual subsections may depend upon: the size of the display, cost, complexity of controlling circuitry desired, and desire for maximum power savings. Ideally, the greater number of subsections will provide a higher level of control and performance by the system. It should be noted that lines 16 are only used to represent the divisions regarding control of the subsections 15 and are not required as actual lines or physical divisions of the backlight 10 .
[0024] FIG. 2 provides the LCD image data 20 , where this image is divided into subimages 22 which correspond with the subsections 15 of the backlight 10 (shown in FIG. 1 ). Again, the lines 26 are only used to represent the divisions of the subimages and are not physical divisions of the LCD and should not be visible through the LCD assembly.
[0025] FIG. 3 shows a plot of histogram data for one of the subimages 22 shown in FIG. 2 . The brightness index value is shown along the x-axis and the number of pixels within the subimage which have the corresponding brightness index value is shown along the y-axis. Here, the brightness index values range from 0 (no saturation) to 255 (fully saturated). Three separate plots are shown in FIG. 3 : red subpixels 37 , blue subpixels 30 , and green subpixels 35 . It can be observed from this plot that the red subpixels will control the brightness requirements for the subsection of the backlight as the red subpixel histogram data is skewed to the right of the green 35 and blue 30 data. Further, it can also be observed that the blue data 30 is bimodal, meaning that there are two peaks in the data, a first one 31 near zero and a second one 32 near 60. This bimodal characteristic will be discussed further below.
[0026] The histogram data for each subimage is analyzed to determine the proper luminance level for the backlight subsection corresponding to each subimage. FIG. 4 shows one embodiment for analyzing the histogram data for each channel (in this example: red, green, and blue) to determine the proper luminance setting for the backlight subsection.
[0027] Once the histogram data has been created 40 , a first average μ 1 and standard deviation σ 1 are calculated 41 . The following is one method for calculating these values and analyzing them:
[0028] Let N=the total number of pixels (red, green, or blue) in the subimage.
[0029] Denote the histogram as H(i) where i ranges from 0 to 255
[0000]
Calculate
the
average
from
:
μ
1
=
1
N
∑
i
=
0
255
i
·
H
(
i
)
Calculate
Standard
Deviation
σ
1
=
1
N
(
∑
i
=
0
255
H
(
i
)
·
i
2
)
-
μ
1
2
[0030] The initial luminance value for this subsection of the backlight may then be calculated 42 as the average value plus one and a half standard deviations. Y=μ 1 +1.5·σ 1 . It should be noted that one and a half standard deviations was chosen as effective for one embodiment. Depending on several factors, some systems may require more or less than 1.5 standard deviations for adequate system performance. This variable could be adjusted for each display.
[0031] The backlight luminance can range from ‘off’ to ‘full on’ and these points, along with all of the settings in between, should be calibrated with the brightness index values from the histogram which can also vary from 0 (off) to 255 (full on). Thus, once the initial luminance value is calculated it may be compared with the maximum value of 255 (see step 43 ). If the initial luminance value is greater than 255, then the backlight luminance for this subsection is simply set to full on (255) and is stored for this channel (go directly from step 43 to step 47 ). The use of ‘channel’ herein denotes one of the primary colors that are used to create the image within the LCD. As discussed above, a typical LCD contains three channels (Red, Green, and Blue) but other LCD designs may use additional colors (such as Yellow) and thus may contain 4 or more channels.
[0032] Next, the histogram data for this channel may be tested for a bimodal distribution 44 . This step may be performed because if the distribution contains multiple peaks, simply averaging and adding some amount of standard deviations may completely miss a peak which would require a higher backlight level. For example, in reference to FIG. 3 , as mentioned above, the blue curve 30 may be considered bimodal. The initial luminance Y 1 for the blue curve 30 may fall somewhere in between peaks 31 and 32 , thus missing the peak 32 which requires the highest amount of backlight (i.e. if the blue curve were driving the backlight level, the minimum luminance level would have to be closer to 70, to ensure that peak 32 achieves its necessary illumination). In this particular case however, it would not affect the outcome of the analysis because the highest luminance value between the three channels is the value which will be finally used for the subsection (see step 48 in FIG. 4 ). However, the test for bimodal distribution may still be performed to ensure that the driving color (in this particular case the red channel is actually the driving color) does not contain several peaks such that one would not be adequately illuminated.
[0033] The following is one method for determining if a histogram is bimodal 44 . Using Otsu's algorithm, find the optimal separation point between distributions in the histogram:
[0000] C=nB ( T ) nO ( T )[μ B ( T )−μ O ( t )] (Otsu's algorithm)
where: T is the threshold value and ranges from 0 to 255 nB(T) is the number of pixels that fall below the threshold value nO(T) is the number of pixels that fall above the threshold value μB(T) is the average value of the pixels below the threshold value μO(T) is the average value of the pixels above the threshold value Perform Otsu's algorithm for each for each value of T in the histogram and determine the T which corresponds to the maximum value of C (this will be referred to as T max also known as the Otsu Threshold). Compare T max to the first average value μ 1 . If, |T max −μ 1 |≦Δ, then the histogram data is not bimodal and the luminance value for the subsection is equal to the initial luminance value.
[0000]
Y
f
=Y
i
Note, Δ may be selected for each display setup and may need to be adjusted depending on the type of display and what is being shown on the display. Acceptable results have been found for some displays with a Δ value near 10.
If, |T max −μ 1 |>Δ, then the histogram data is bimodal and the following steps should be performed:
Calculate a second average and a second standard deviation based on the histogram data to the right of the Otsu Threshold T max . (see step 45 in FIG. 4 )
[0000]
Set
j
=
T
max
.
N
=
∑
i
=
j
+
1
255
H
(
i
)
//
Set
N
to
new
sample
size
Calculate
the
Second
average
from
:
μ
2
=
1
N
∑
i
=
j
+
1
255
i
·
H
(
i
)
Calculate the Second Standard Deviation from:
[0000]
σ
2
=
1
N
(
∑
i
=
j
+
1
255
H
(
i
)
·
i
2
)
-
μ
2
2
[0047] The final luminance value (Y f ) for this channel can then be calculated 46 as the average plus one standard deviation. Y f =μ 2 +1.0·σ 2 Again, acceptable results have been found by using one standard deviation, but different display setups may require a different number of standard deviations. This final luminance value should be compared to the maximum luminance value possible (255) and if it is larger than this value, the luminance value will simply be stored as the maximum luminance of 255. (If Y f >255 then Y f =255) The final luminance value for this channel is then stored 47 and steps 40 - 47 are repeated for the remaining two channels. Finally, when the final luminance value for all three channels (R, G, and B) has been determined, they are compared with one another and the largest final luminance value Y f is stored 48 as the proper luminance value for the backlight subsection.
[0048] FIG. 5 shows what the backlight 10 may look like once each of the luminance values has been stored and the corresponding subsections are driven at their proper luminance values (after Gamma correction has been performed, if necessary—see below for more information on Gamma correction). This may involve a conversion of the luminance values to current/voltage levels and can easily be accomplished by one skilled in the art by creating a linear relationship where luminance level 0 corresponds with 0 amps (or volts) and luminance level 255 corresponds to x amps (or volts), where x represents the power level that generates the maximum luminance from the LEDs). It can be easily observed from FIG. 5 that some subsections are completely on (white) while others are slightly gray to dark grey. The capability of dimming these sections of the backlight will save power as well as provide a deeper black/dark color since the backlight is not shining through the liquid crystal material at full luminance.
[0049] However, LCD subpixel voltages are typically determined based on a ‘full on’ backlight and when sections of the backlight are dimmed, the subpixel voltages may need rescaled (‘adjusted’) to ensure that the picture fidelity remains high and the proper colors are produced by the display. One method for rescaling the LCD subpixel voltages is to divide the subpixel voltage by the ratio of proper luminance level to maximum luminance. FIG. 6 shows the resulting LCD image data (without the adjusted backlight levels) once it has been rescaled based on the calculated backlight luminance levels.
[0050] For example, subsection 50 shown in FIG. 5 may have a luminance level of 128. This would be 128 out of a possible 255 (maximum luminance), resulting in 128/255=approximately ½. As an illustration, assume that one of the subpixel voltages for subsection 50 was originally 1 mV. To rescale this subpixel voltage, divide 1 mV by ½. Now, the subpixel voltage should be 2 mV. Assuming that we are dealing with a normally black LCD stack (voltage is required to orient the crystals to pass light) this increase in subpixel voltages is required because we have decreased the backlight level. Thus, from FIG. 5 we know that the backlight will decrease approx. 50% at subsection 50 , so in order to create the original colors in the image, the subpixel voltage must be increased in order to allow more light through the liquid crystals. The seemingly brighter resulting LCD image for subsection 50 can be observed in FIG. 6 . Note, that FIG. 6 only shows the image data and does not take into account the actual backlight levels that are illuminating the LCD, so although subsection 50 appears lighter, this will be accounted for once the new backlight levels are applied.
[0051] As a second example, subsection 55 shown in FIG. 5 may have a luminance level of 255 (maximum luminance). This would be 255/255, or 1. Thus, assuming any original subpixel voltage for subsection 55 , say V, the resulting scaled subpixel voltage would be identical because the backlight subsection remains at full on. V/1=V. This can be observed in FIG. 5 as the subsection 55 appears white. Also notice that subsection 55 in FIG. 6 , appears identical to the original image in FIG. 2 because the backlight remains at ‘full on’ so the subpixel voltages have not been altered from their original settings.
[0052] It is common in LCD assemblies to place a light diffusing/scattering element (herein ‘diffuser’) in between the backlight and the liquid crystal material in order to provide a more uniform appearance of light through the display. Without the diffuser, the LED point-sources of light may be visible through the final display. Thus, when the backlight from FIG. 5 is placed behind a diffuser, the resulting luminance pattern can be seen in FIG. 7 . Further, when the diffused backlight from FIG. 7 is placed behind the rescaled LCD image data from FIG. 6 , the resulting image from the LCD is shown in FIG. 8 .
[0053] As can be easily observed, the diffusing properties alter the actual luminance levels of the backlight, especially near the edges of the subsections. Looking at subsection 50 for example, the luminance in the center 51 is acceptable, while the luminance near the edges 52 has been increased due to ‘bleed over’ from brighter adjacent subsections 60 .
[0054] One method discovered to account for this phenomenon is the creation of a ‘virtual backlight’ or ‘VB’ where the ‘bleed over’ behavior of adjacent subsections can be mathematically modeled and accounted for during the rescaling of the LCD subpixel voltages. There are many methods for mathematically modeling a given backlight in order to create a VB.
[0055] One method for creating the VB may be referred to as ‘virtual subsections’ and is based on the use of a stored matrix of data that represents the appearance of a single, fully illuminated subsection in the backlight assembly as seen through the diffuser. FIG. 9 provides a surface plot of a fully illuminated subsection 90 that has been convolved with a Gaussian filter. The subsection 90 has a width (W) 93 , height (H) 92 , and a tail (T) 95 , where W, H, and T are each measured in pixels. The tail 95 represents the subpixels which may be impacted by the luminance from adjacent subsections of the backlight. In other words, illumination of the subsection that extends beyond the physical edge of the subsection 90 . Thus, the dimensions of the stored matrix for the subsection would be (2T+W)×(2T+H). Because the virtual subsection is larger than the actual subsection, the adjacent subsections may be overlapped and the principle of additive light may be used to blend the edges of the subsections.
[0056] FIG. 10 illustrates the relative luminance versus physical position on a pair of adjacent subsections. The x-axis of this figure represents the pixel location while the y-axis represents the relative luminance of the backlight subsections. Relative luminance refers to the percentage of the backlight luminance Y, which was determined for the subsection (subsection) in FIG. 4 . Thus, 0.5 would represent one-half of the luminance, 0.25 would represent one-quarter of the luminance, etc. The plot for a first subsection 100 and an adjacent second subsection 101 are shown. The line 105 represents the physical dividing line between the subsections. Looking at the first subsection 100 , at pixel zero the full luminance level is recorded. The relative luminance decreases as the pixel location increases (as we approach the division between the subsections 105 ). At pixel 90 , only half of the full luminance level is recorded. As the pixel location continues to increase (as we move away from the division between the subsections 105 ) the relative luminance continues to decrease until it reaches zero at pixel 180 . Thus, for this example the tail T, of each subsection may be 90 pixels long. A symmetrically-opposite trend can be seen with the plot for the adjacent subsection 101 .
[0057] It should be noted that because the plot for the adjacent subsections 100 and 101 are symmetrical about line 105 and about the relative luminance of 0.5, if the subsections were driven to the same backlight luminance level they would blend to create 100% luminance across the line 105 between the subsections. Obviously, at line 105 the VB data for each subsection is at 0.5 or 50% of the backlight luminance for that subsection, so if each subsection were driven to the same backlight luminance, these would add together to create the same luminance level across the line 105 . If the subsections were driven to different luminance levels, as the VB data is entered, this will blend between the different luminance levels. For example, at pixel location 38 within subsection 100 , the VB data should be 90% of the luminance for subsection 100 plus 10% of the luminance for subsection 101 .
[0058] Obviously, the relationship shown in FIG. 10 is only applied to adjacent subsection edges and to subpixels which are within the ‘tail’ portion of the adjacent subsections. Thus, subsection edges which are not adjacent to any other subsections (i.e. along the perimeter of the overall display) may not show this relationship and may simply use 100% of the luminance level as the VB data for that subsection.
[0059] By using the luminance values for each backlight subsection along with the model for backlight luminance along the subsection edges, an array of VB data for each subsection can be stored and then combined to create a larger array which contains VB data for each pixel in the display. As discussed above, the original subpixel voltages may then be divided by the ratio of VB data over the maximum backlight value in order to properly rescale the original LCD image data.
[0060] It should be noted that although a Gaussian curve has been used in FIG. 10 to represent the relationship between adjacent subsections, this is not required. For some embodiments a linear relationship or exponential function may provide a more appropriate mathematical representation of what is actually occurring with the diffused backlight. Other mathematical models are discussed below. This brings up an interesting point to keep in mind when designing this type of system. Either a mathematical system can be derived to model the existing physical backlight or the physical backlight may be designed so that it performs similar to a selected mathematical model.
[0061] If using the gaussian relationship shown in FIG. 10 , it may be advantageous to design the physical system such that this type of relationship actually exists. For example, the backlight and diffuser should be designed such that only 50% luminance exists at the overlapping edge of each subsection. FIG. 11 shows one method for accomplishing this specific embodiment, where an array of dividing walls 120 has been used between the backlight LEDs 125 and the diffusing element (not shown). FIG. 11 shows a simplified figure as only a 3×3 array is shown and the figure does not show LEDs in every subsection. However, as discussed above, the number of backlight subsections can vary depending on many different factors, and one skilled in the art can easily modify the simplified FIG. 11 into an 8×8 array (or any other arrangement) with LEDs in every subsection.
[0062] Preferably, there would be a gap between the end of the dividing walls 120 and the diffuser. This would prevent any of the dividing walls 120 from being visible through the final display. The precise geometry of the dividing walls 120 and their relationship to the diffuser may require fine tuning for each display. Acceptable results have been found for 70 inch LCD displays where the dividing walls 120 are about two to three inches high with a gap between the dividing wall 120 and diffuser of 30-40 mm.
[0063] As mentioned above, other mathematical models may be used to simulate the backlight through the diffuser. One other method is to use a point spread function (PSF). If the diffuser is treated like an optical low pass filter, then a 2D filter operation can be performed on the virtual backlight. One could also modify the PSF by observing that a diffused backlight only requires a blurring operation along the boundaries between subsections.
[0064] An examination of the edges between a fully illuminated subsection and an adjacent dimmer subsection constructed via the Gaussian Point Spread Function reveals a series of common curves. FIG. 12 shows the change in relative illumination from 1 to 0.5 (curve 130 ), 1 to 0.25 (curve 132 ), and 1 to 0 (curve 134 ). If we denote Z(x) as the curve that goes from 1 to zero, then it is possible to recreate any change in brightness between adjoining subsections with the equation: f(x)=y 1 +Z(x)·(y 0 −y 1 ) where y 0 is the brightness of the starting subsection and y 1 is the brightness of the ending subsection.
[0065] Thus, a two-step process for this method could include: (1) Create a series of changing brightness lines that run vertically down the middle of each subsection using the above formula. If the subsections are rectangular, then a “longer” brightness function will be required for this operation and (2) Starting at the top of the VB, create a series of horizontal brightness curves using the data from step 1 as the endpoints for each curve.
[0066] A final technique to produce a virtual backlight would be through the use of Bezier Curves. In this approach, cubic splines could be used to interpolate between the subsection centers and thus simulate diffusion. For each point in the Virtual Backlight, the following equation would be calculated:
[0000] B ( t )=(1− t ) 3 P 0 +3 t (1− t ) 2 P 1 +3 t 2 (1− t ) P 2 +t 3 P 3 , tε[ 0,1].
[0067] As discussed above, once the data for the VB has been generated, it may be divided into the corresponding subpixel voltages in order to properly rescale the LCD video image. This can be accomplished in many ways. Because division is typically a time-consuming operation, one exemplary embodiment may use a 256 byte lookup table of 8-bit scaling factors. These would be multiplied by each pixel and then followed by an 8-bit shift. The 8-bit shift can be skipped if only the upper byte of the product is used. If an overflow occurs, the resulting pixel value would be 255.
[0068] Before driving the backlight subsections with the appropriate luminance values, gamma correction may be applied. This step may help correct the contrast and may also provide additional power savings. Assuming backlight intensities from 0 to 255, one method of gamma correction may be: I=255·(Y/255) γ where γ is typically equal to 2.2 (but this may be varied depending on the application). For example, assume that the luminance value (Y) for the subsection was calculated to be 128. When this value is used in the gamma equation above, the actual intensity of the backlight (I) is calculated to be 56. This backlight intensity (I) can now be converted to actual voltage/current and sent to the appropriate backlight subsection. Also, the re-scaled image data can now be sent to the LCD as the backlight is updated.
[0069] An example for the physical architecture which could perform the operations as discussed above is now presented. It should be pointed out that this architecture is only an example and those skilled in the art could modify this example or create other types of physical architecture which are capable of performing the operations discussed herein.
[0070] FIG. 13 shows a schematic representation of one example for the physical architecture. This specific example assumes the following: the input is RGB data on a 24-bit wide data bus, an 8×8 backlight array is used, the output is RGB data on a 24-bit wide data bus, an external pixel clock is available, the maximum LCD resolution is 1080 by 1920 for a total of 2,073,600 pixels, the Samsung LTI700HD01 is the assumed LCD, the design should support a pixel clock of 148.5 Mhz.
[0071] Two frame buffers 200 may be used to store the incoming frame and process and output the outgoing frame. Each frame buffer should store 2,073,600 RGB values and the width of the frame buffer should be at least 24 bits. Eight, three channel histogram accumulators 210 may be used for statistical processing. Each accumulator 210 should consist of 256 15-bit counters. There may be accumulators for each of the three color channels (if using an RGB-type LCD). The output of each counter should be double buffered. Two virtual backlight buffers 215 may be used to store newly created backlight based on incoming image data and rescale the gain of outgoing LCD data.
[0072] The embodiment for the architecture described here would implement the steps above using a “Pitch and Catch” approach. While one block is ‘catching’ and analyzing the incoming video data, the other block is scaling and ‘pitching’ video data to the output. As shown in FIG. 13 , the upper half of the system is in “catch” mode. During this phase, incoming RGB data is sampled by the histogram accumulators 210 while being stored in the frame buffer 200 . After 135 lines have been buffered, the contents of the twenty-four histogram accumulators 210 are made available to the digital signal processor 220 (DSP). The DSP 220 then calculates the brightness of each of the corresponding subsections and updates the virtual backlight buffer 215 . This process is repeated seven more times for the remaining video data. Note that the last eight subsections placed into the virtual backlight may have to be calculated during the “vertical retrace” period.
[0073] The lower half of the system is operating in “pitch” mode. During this phase, each pixel from the input buffer 200 is divided by the corresponding pixel in the virtual backlight buffer 215 and sent to the video out MUX. To speed execution and avoid the use of a hardware divider, a lookup table may be used to determine a scaling factor. This factor can then be used to rescale the RGB data with three 8×8 multipliers. Concurrent with the rescaling operation, the individual subsections of the backlight matrix will be updated synchronously using the values calculated during the “catch” phase.
[0074] It should be noted that the system and method described herein has been described with reference to each ‘frame’ and in an exemplary embodiment the backlight subsections would be updated for each ‘frame.’ However, there are many different frame rates of video which exist as well as different refresh rates of LCD displays (ex. 60 Hz, 120 Hz, 240 Hz, etc.). As used herein, the term ‘frame’ represents each time that the pixel voltages are updated for the LCD display. Thus, the backlight subsections should preferably be updated (and the LCD subpixel voltages re-scaled) each time that a new set of subpixel data is sent to the LCD display.
[0075] Having shown and described preferred embodiments, those skilled in the art will realize that many variations and modifications may be made to affect the described embodiments and still be within the scope of the claims. Thus, many of the elements indicated above may be altered or replaced by different elements which will provide the same result and fall within the spirit of the claimed embodiments. It is the intention, therefore, to limit the invention only as indicated by the scope of the claims.
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Disclosed herein is a system for controlling the interactions of light between adjacent subsections of a dynamic LED backlight. Preferred embodiments contain a dividing wall positioned between each adjacent subsection of the LED backlight. The dividing wall may be in contact with the LED backlight and extend away from the LED backlight. The dividing wall may prohibit light from a first subsection from entering an adjacent second subsection at its full luminance. The luminance for each adjacent subsection may be approximately half of the full luminance of each subsection, when measured at the location of the dividing wall.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present Application is based on Indian Provisional Application No. 1700/CHE/2011 filed on May 18, 2011, which in turn corresponds to Indian Application No. 848/CHE/2011 filed on Mar. 18, 2011, and priority is hereby claimed under 35 USC §119 based on these applications. Each of these applications are hereby incorporated by reference in their entirety into the present application.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to the field of mechanical equipment used in hospitals for transferring patients from one location to another location. More particularly the present invention relates to the transfer belt mechanism used in trolleys, gurneys and stretchers used for transferring patients from one bed to another bed, a bed to operation theatre, a bed to x-ray table and a bed to a stretcher etc.
BACKGROUND OF THE INVENTION
[0003] A wide variety of patient transfer trolley products have been designed to move patients from one location to another and, in particular, to transfer mobility-impaired individuals. In a hospital, patients are often transferred from their beds to pre-surgery room to operation theatre to recovery room to ICU and back.
[0004] Typically, different patient transfer gurneys are used for transferring the patient from one location within the hospital to another. Therefore, when a patient is to be taken from one location to another location within the hospital, the patient must be moved from hospital ward bed to transfer gurney and transferred to the other location. In many cases 4 to 5 hospital staff physically lift the patient off the hospital ward bed and put the patient on the transfer gurney. This could be risky and uncomfortable to both the patient and the hospital staff. The process of moving the patient from the ward bed to the transfer gurney should be smooth, safe and efficient without causing injury or further damage to the patient and at the same time safe and convenient to the hospital staff transferring the patients.
[0005] Patients often have trouble moving themselves from one bed to another and from one location in a hospital/care facility to another. Further, in a hospital the nurses and the hospital staff involved in patient transfer are prone to the occupational hazard of lower back ache, which is associated with physical stress experienced while transferring patients. Invalid patients, especially those with fractures due to accidents should be handled with extreme care while being transferred. The patient should be kept as still as possible without relative movement of the limbs, neck, chest and other parts of the body, during the transfer process.
[0006] There are several Patents related to Patient Transfer Gurney systems. U.S. Pat. No. 4,631,761 issued to Ganmill limited has some drawbacks. It has one significant drawback wherein the endless transfer Belt causes a disadvantage during operation. The disadvantage is that when the top of the belt is moving in one direction, the bottom of the belt moves in the opposite direction. Therefore, while the top of the belt is trying to load the patient on to itself, the bottom of the belt will push the mattress (or sheets) on which the patient is lying on, along with the patient, away from the belt and the patient transfer trolley. This makes it difficult for loading the patient onto the patient transfer trolley.
[0007] U.S. Pat. No. 3,493,979 issued to Advanced Products Corporation of America discloses a device for transferring an object from one location to another comprises a pair of superposed endless belts mounted in a frame and adapted to be inserted between the object and its supporting surface. The device has gears, rollers and chains in the mechanisms to drive the belts. These require grease, lubrication and constant maintenance to work smoothly. Further the stretcher appears to be heavy and bulky to be handled or to be pushed or moved by the hospital staff.
[0008] U.S. Pat. No. 3,418,670 issued to Morgan et al discloses a roller stretcher with a pair of endless belt which are wound over respective upper and lower guides. A driving mechanism rotates one of the rollers so that one of the belts is moved. The belts are in frictional contact with each other whereby the non driven belt is moved by frictional contact with the driven belt. Replacement of belts is difficult and time consuming. Further, the leading edge (portion which goes under the patient) will be too thick due to the fact that there are 2 rollers on the leading edge. This thickness of the leading edge of the stretcher makes the transfer uncomfortable to patients and sometimes even painful. In case of spinal injury this transfer mechanism can further damage the patient and can even lead to fatal consequences.
[0009] U.S. Pat. No. 5,185,894 issued to Stierlen-Maquet AG discloses a patient shifting apparatus having a mobile frame supported on rollers, a cantilevered platform arranged on the frame. A transport band movable in both directions by a drive mechanism, which proceeding from a first winding roll supported by the frame, extends over the upper side of the platform, over the free longitudinal edge of the platform and along the bottom side of the platform to a second winding roll supported by the frame and onto which it is windable. Here the belt goes in zig-zag manner and bends multiple times before it goes from one roller to other roller. Therefore the torque required to move the belt is more. In this mechanism replacement of the belt, either for maintenance or for sterilization, is tedious. Further the mechanism has gears, chains, sprockets which are prone to breakdowns and have maintenance issues. The gears and chains in the mechanism may require lubrication for smooth operation and therefore not conducive to sterilization.
[0010] Hence there is a need to provide an improved mechanism for patient transfer gurney system which overcomes the problems such as, expensive to manufacture, prone to breakdowns, heavier to push, where belt replacement is time consuming and not conducive to sterilization and sanitization and at the same time can load the patient on to itself smoothly, safely and efficiently without causing injury or further damage to the patient and at the same time; safe and convenient to the hospital staff transferring the patients.
SUMMARY OF THE INVENTION
[0011] One of the objectives of the present invention is to provide a mechanism involved in patient transfer apparatus used for transferring invalid patients lying in supine position, from one horizontal surface to another horizontal surface, for e.g.—transferring patients from one bed to another bed, a bed to a stretcher, a bed to an operation theatre table, a bed to an x-ray unit and vice versa in a smooth and stress free manner without lifting the patient.
[0012] One of the objectives of the present invention is to provide a belt that can be easily removed and sterilized before another patient is put on especially for patients with infections.
[0013] One of the objectives of the present invention is to make the transfer less painful and cause less discomfort to the patient back and spine while the patient is loaded or unloaded.
[0014] One of the objectives of the present invention is to provide lighter yet having all advantages of the horizontal patient transfer system, so that the hospital staff can manually push it with less strain or less number of office staff are required to push the patient transfer gurney from one location to another location.
[0015] One of the objectives of the present invention is to provide a patient transfer gurney wherein the belts used can be quickly and easily replaced.
[0016] Another objective of the present invention is to provide the mechanism involved in patient transfer gurney more robust and less prone to breakdown and easier for maintenance.
[0017] Another objective of the present invention is to bring down the cost of manufacturing of the patient transfer gurney.
[0018] Another objective of the present invention is to ensure that the patient transfer gurney can easily be sterilized and sanitized and that the system includes least number of parts, joints, slits and gaps which are difficult to clean and having scope for bacteria can grow.
[0019] Another objective of the present invention is to provide a patient transfer gurney mechanism which does not have gears, chains, or components that require grease and lubrication and mechanisms which are not conducive to sanitization and sterilization process.
[0020] Advantages and features of the invention include but are not necessarily limited to that the mechanized system that moves, so that the patient remains stationary during loading, and that the system is easy and safe for the operator(s) and the patient. The system does not require lifting, or rolling the injured person onto the device for transferring
[0021] According to one aspect of the present invention the mechanism used in patient transfer gurney system has a cantilevered stretcher design, mounted on a frame with four caster wheels and two pillars, wherein said cantilevered stretcher can go under the patient lying in supine position, and can position itself between the patient and the mattress without causing significant movement of the limbs, neck, chest and other parts of the body of the patient, thereby transferring the patient on to itself safety. There are two pillars mounted vertically on the frame with four caster wheels. The cantilevered stretcher is mounted on two pillars and it can travel vertically up and down on two linear bearings sliding on the two pillars. This up and down vertical motion is affected through two electric actuators. The stretcher up and down movement motion can be controlled by electric switches controlling the two electric actuators which work in tandem. After the stretcher positions the patient on to itself in a supine position, it can lift the patient clearly off the bed by moving vertically upwards. The entire patient transfer gurney can then be wheeled off to another location on the caster wheels.
[0022] Further, the cantilever stretcher includes a transfer belt mechanism, which has two flexible non endless belts (whose width is slightly less than the length of the stretcher and whose length is slightly longer than thrice the width of the stretcher) and two rollers on the side of the stretcher where it is mounted on two pillars. The ends of these two belts are attached on to the first roller. One belt (the upper belt) goes around the stretcher, the second belt (the lower belt) goes around the plate below the stretcher and the other ends of both these belts are attached on to second roller. When the first roller is rotated, both the belts wind around that roller and unwind from the second roller and vice versa. The lower portion of upper belt and the upper portion of the lower belt are in contact with each other and always move in the same direction and same speed. The upper portion of the upper belt moves over the stretcher in the direction of the two pillars taking the patient on to it without causing significant movement to the patient. The lower portion of the lower belt pulls itself towards the mattress (or the mattress towards itself). Both the belts working tandem in this manner makes the patient transfer efficient.
[0023] As described above, the non endless belt mechanism (arrangement of flexible non endless belts moving between the stretcher and plate in same directions, with upper flexible non endless belt going around the stretcher and lower belt going around the plate) can be implemented in three and four roller arrangement.
[0024] Additional features of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of an illustrated embodiment exemplifying the best mode of carrying out the invention as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like part numbers.
[0026] FIG. 1 is a side view of the two roller version of the embodiment of the present invention. In other words it is the two roller version of the Transfer Belt mechanism. This is the preferred embodiment of the present invention.
[0027] FIG. 1A depicts the direction of the two belts while loading the patient and FIG. 1B depicts the direction of the belt while unloading the patient.
[0028] FIG. 2 is a side view of the three roller version of the embodiment of the present invention. In other words it is the three roller version of the Transfer Belt mechanism.
[0029] FIG. 2A depicts the direction of the two belts while loading the patient and FIG. 2B depicts the direction of the belt while unloading the patient.
[0030] FIG. 3 is a side view of the four roller version of the embodiment of the present invention. In other words it is the four roller version of the Transfer Belt mechanism.
[0031] FIG. 3A depicts the direction of the two belts while loading the patient and FIG. 3B depicts the direction of the belt while unloading the patient.
[0032] FIG. 4 is the side view of the patient transfer gurney system with the two roller version of the Transfer Belt Mechanism which is the preferred embodiment of the present invention.
[0033] FIG. 5 is perspective view of the patient transfer gurney system with the two roller version of the Transfer Belt Mechanism which is the preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within the FIG. 1
DETAILED DESCRIPTION OF THE INVENTION
[0035] As shown in FIG. 1 , the mechanism includes two flexible non endless belts attached to two rollers, according to the preferred embodiment. In the illustrated embodiment, two flexible non endless belts ( 101 , 102 ) whose width is slightly less than the length of the stretcher and whose length is slightly longer than thrice the width of the stretcher, wherein said stretcher has two rollers ( 103 a, 103 b ) on the side where it is mounted on two pillars (not shown in the FIG. 1 ). One end of first non endless belt 101 also referred as upper belt and one end of second non endless belt 102 referred as lower belt are attached on to roller 103 a. The belt 101 or also referred as upper belt goes around the stretcher 104 , the belt 102 or also referred as lower belt goes around the Plate 105 below the stretcher and the other ends of both these belts are attached on to roller 103 b. Further, the mechanism comprises a friction reduction shield structure ( 103 a 1 ) to avoid friction between the belt 101 and roller 103 a. When the roller 103 a is rotated, both the belts wind around that roller and unwind from the roller 103 b and vice versa. The lower portion of the upper belt 101 and the upper portion of lower belt 102 are in contact with each other and always move in the same direction and same speed. The upper portion of the upper belt 101 which is above the stretcher moves in the direction of the two pillars taking the patient on to it without causing jerks or any significant relative movement to the patient. The lower portion of the lower belt 102 pulls itself towards the mattress (or the mattress toward itself). The direction of the two belts 101 , 102 while loading and unloading of the patient is as depicted in FIGS. 1A and 1B . Both the belts working tandem in this manner makes the transfer more efficient. The belts are preferably constructed of a material which can be sterilized. The above described mechanism can be easily mounted by means of linear bearings on to the two pillars which are mounted on the frame with caster wheels, thereby forming the patient transfer gurney system for easy and more effective patient transfer.
[0036] FIG. 2 is three roller version of the present invention. As shown in FIG. 2 , the mechanism includes two flexible non endless belts attached to three rollers. In the illustrated embodiment as shown in FIG. 2 , two flexible non endless belts ( 106 , 107 ) whose width is slightly less than the length of the stretcher and whose length is slightly longer than thrice the width of the stretcher, wherein said stretcher has three rollers ( 108 a, 108 b, 108 c ) on the side where it is mounted on two pillars (not shown in the FIG. 2 ). One end of first non endless belt 106 and one end of second non endless belt 107 are attached to the first roller 108 a. The first non endless belt 106 or also referred as upper belt goes around the stretcher 104 , the second non endless belt 107 or also referred as lower belt goes around the Stainless steel tray 105 and the other end of the first non endless belt 106 is attached to second roller 108 b and the second non endless belt 107 other end is attached to the third roller 108 c. Further, the mechanism comprises a friction reduction shield structure ( 108 a 1 ) attached to first roller 108 a to avoid friction between the second non endless belt 107 and first roller 108 a as shown in FIG. 2 . The lower surface of one belt and the upper surface of other belt are in contact with each other and always move in the same direction and same speed. The direction of the two belts 106 , 107 while loading and unloading of the patient is as depicted in FIGS. 2A and 2B . The above described mechanism can be easily mounted by means of linear bearings on to the two pillars which are mounted on the frame with caster wheels, thereby forming the patient transfer gurney system for easy and more effective patient transfer.
[0037] FIG. 3 is the four roller version of the invention. As shown in FIG. 3 , the mechanism includes two flexible non endless belts attached to four rollers. In the illustrated embodiment as shown in FIG. 3 , two flexible non endless belts ( 109 , 110 ) whose width is slightly less than the length of the stretcher and whose length is slightly longer than thrice the width of the stretcher, wherein said stretcher has four rollers ( 111 a, 111 b, 111 c, 111 d ) on the side where it is mounted on two pillars (not shown in FIG. 3 ). One end of first non endless belt 109 is attached to the first roller 111 a and the other end of the first non endless belt 109 is attached to third roller 111 c, One end of the second non endless belt 110 is attached to the second roller 111 b and the other end is attached to the fourth roller 111 d. The first non endless belt 109 or also referred as upper belt goes around the stretcher 104 , the second non endless belt 107 or also referred as lower belt goes around the Stainless steel tray 105 . The lower surface of one belt and the upper surface of other belt are in contact with each other and always move in the same direction and same speed. The direction of the two belts 109 , 110 while loading and unloading of the patient is as depicted in FIGS. 3A and 3B . Further, the mechanism comprises a first friction reduction shield structure 111 a 1 attached to first roller 111 a to avoid friction between the first non endless belt 109 and the belt wound around other rollers and a second friction reduction shield structure 111 b 1 attached to second roller 111 b to avoid friction between the second non endless belt 110 and the belt wound around other rollers. The direction of the two belts 109 , 110 while loading and unloading of the patient is as depicted in FIGS. 3A and 3B . The above described mechanism can be easily mounted by means of linear bearings on to the two pillars which are mounted on the frame with caster wheels, thereby forming the patient transfer gurney system for easy and more effective patient transfer.
[0038] As shown in FIG. 4 , the Patient Transfer Gurney has a cantilever stretcher with the transfer belt mechanism. Using linear bearings the cantilever stretcher with the transfer belt mechanism is mounted on the two pillars 115 which is fixed on the frame with four caster wheels 119 . The electric actuators 116 shown in FIG. 4 can lift or lower the entire stretcher along with transfer belt mechanism. The stretcher up and down movement motion can be controlled by electric switches (not shown in FIG. 4 ) controlling the two electric actuators which work in tandem. After the stretcher loads the patient on to itself in a supine position, it can lift the patient clearly off the bed by moving vertically upwards. The entire patient transfer gurney arrangement can then be wheeled off to another location on the caster wheels. The arrangement includes a support 117 for the pillars, friction reduction shield 103 a 1 , further the system includes a steel strip 113 for clamping and attaching the belt on to the rollers and a linear bearing case 114 and a side railing 112 for safety of the patient. The cantilevered stretcher with transfer belt mechanism has two flexible non endless belts ( 101 , 102 ) and the two rollers 103 a & 103 b. the details of this transfer mechanism is explained in FIG. 1 and its description in para [0034]. The stretcher with transfer belt mechanism on the frame mounted the frame with caster wheels 119 and two pillars 115 via linear bearings with case 114 .
[0039] FIG. 5 is the three dimensional perspective view of the patient transfer system of FIG. 4 .
[0040] A power drive (not shown) may optionally be provided for caster wheels, including speed control. The motor(s), linkages and power supply (rechargeable battery) may be stored within the lower interior portion of base, with controls mounted near handlebars.
[0041] Although the mechanism shown and described above is configured as a stretcher, it is within the purview of the invention that the device could be configured as a gurney, for example with legs. Additionally, although the mechanism shown and described for use with respect to an injured human being, they can be used for non-injured humans, injured or non-injured animals other than humans such as in a veterinary medical setting, and non-animal objects such as in a materials handling setting. The mechanism can also be used in to transfer the patients in different postures other than the supine position.
[0042] Thus, the mechanism of the present invention provides an effective way of transfer of patients. The present invention provides for the safe, fast and easy transfer of patients with many types of restrictions and helps reduce or eliminate the lifting of patients by hospital workers.
[0043] While the above description contains much specificity, these are not to be construed as limitations on the scope of the invention, but rather as one preferred embodiment thereof. Many variations are possible. For example, the present invention will be available in different sizes. In addition, the present invention could include a special footrest that can carry the legs of taller or heavier patients.
[0044] Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result.
[0045] It is believed that the system and method of the present invention and many of its advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.
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The cantilevered stretcher has a transfer belt mechanism which includes two rollers mounted on the side having two flexible non endless belts, where ends of these two flexible non-endless belts attached to one roller and the other ends of these two flexible non-endless belts attached to second roller. Further one belt goes around the stretcher and the other belt goes around the plate below the stretcher. The arrangement of flexible non endless belts moving between the stretcher and plate in same directions, with upper flexible non endless belt going around the stretcher and lower belt going around the plate can be implemented in three and four roller systems. This mechanism can load the patient onto itself in a way that is efficient and easy to operate, thereby making the patient transfer process easier. Further this mechanism is conducive to sterilization, easier to maintain.
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FIELD OF THE INVENTION
This invention relates to the refinishing of the surfaces of bodies of acrylo-butadiene-styrene (ABS) polymer. In a preferred embodiment the invention relates to a process for refinishing the surfaces of ABS telephone sets.
DESCRIPTION OF PRIOR ART
The refinishing of used and scratched articles of thermoplastic resin is well known. It has been known for some time that a solvent treatment of the surface can remove scratches by dissolving the surface layer and then redistributing the dissolved plastic. In particular, surfaces of bodies made from acrylo-butadiene-styrene polymer have been treated in this way. The solvents used vary widely but typical solvents include organic solvent, for example, dichloroethane and trichlorotrifluoroethane. A mixture of these two solvents has also been used. Other solvents that have been used include ketones, particularly acetone and methyl ethyl ketone, chlorinated hydrocarbons, xylene, perchloroethylene and trichloroe-thylene. These solvents may be diluted with certain inert materials, for example toluene.
In addition to the above ABS resins, it is also known to refinish surfaces of acrylic resins, acetates, butyrates, polycarbonates and polystyrene by solvent treatment. Generally speaking these resins may all be treated with the same solvents. That is the solvents useful for the refinishing of the surface of a body of one resin may also be used to refinish the surface of a body of another resin.
A body of a thermoplastic resin that needs to be refinished is usually stressed in two ways. First, there are internal stresses produced in the molding of the body. These stresses are particularly pronounced, first at that part of the body that was originally close to the gate to an injection mold when the body was produced and, secondly, at those parts surrounding points in the die where the plastic material changed direction during molding or where two fronts or different columns of resin meet. In a thin-walled body the above internal stresses may stretch right through the article.
The second sort of stress is that induced by marring the surface of the body.
During the refinishing of the surface of the body by solvents, the internal stresses can cause problems. In particular, internal stresses can be released and produce undulations in the surface of the body during the solvent process.
It is also known that bodies of thermoplastic resin can be refinished by coating them, usually by spraying with a paint or lacquer. This coating method has been widely used but has a number of disadvantages. First, the paint or lacquer can chip off the refinished body. Secondly, once refinished in this way, subsequent refinishing becomes difficult and economically unattractive. It is usual to throw away a body that has been refinished by painting or lacquering once the article requires further refinishing.
Commonly assigned, copending U.S. application Ser. No. 817,204 filed July 20th, 1977, now U.S. Pat. No. 4,133,912 (Canadian application Ser. No. 257,509 filed July 21st, 1976)describes and claims a process in which the solvent refinishing of thermoplastic articles is carried out by a process that includes a cooling step prior to solvent vapor treatment. That process has achieved excellent results in most instances but is of limited use where an article is badly flawed, for example by deep scratches or indentations. For a badly flawed article the time of contact with the solvents that is required can be such that the benefits of the cooling are lost. Further, it can be that the body does not have enough wall thickness to allow material to flow to fill the flaw.
SUMMARY OF THE INVENTION
The present invention seeks to provide a method of refinishing the surface of a body of ABS polymer that does not have the above disadvantages. The invention includes a coating step in which the article is coated with ABS polymer, cooled then subjected to a solvent vapor treatment.
Accordingly the present invention is a process for refinishing the surface of a body made from acrylo-butadiene-styrene (ABS) polymer, the process comprising coating the body with a layer of ABS, cooling at least the surface of the coated body to a temperature in the range 32° F. to 40° F., that is below the temperature at which a predetermined solvent for ABS will readily dissolve or soften the surface of the ABS, then contacting the surface of the body with a solvent for a time sufficient to flow the surface but not to warm appreciably the inner layer of the body.
Desirably the whole body to be refinished is cooled.
The ABS that is coated is preferably as close as possible to the original composition of the body. It has been found that with telephone hand sets ground-up sets are ideal as a source of ABS. It is useful to use hand sets that are cracked or similarly damaged as a source of ABS, thus preventing both waste and the necessity of disposing of the sets.
The defined temperature range is not too far below a typical ambient temperature. Particularly in a moist temperature, low temperatures can cause condensation of moisture onto the surface with consequent imperfections in the refinished surface. Generally the more active the solvent in dissolving the resin the lower the temperature used.
DESCRIPTION OF THE DRAWINGS
The invention is illustrated, by way of example, in the accompanying drawing which is a schematic, block diagram illustrating a process according to the present invention.
DESCRIPTION OF PREFERRED EMBODIMENT
Upon receipt of ABS articles to be refinished in a reconditioning plant, the bodies are sorted by type, colour and condition. Only those in bad condition will generally require the treatment by the process of the present invention. Those in better condition may be treated using the process described and claimed in my above patent application, that is the coating step is not needed. As indicated above others may be beyond repair. For example cracked bodies cannot satisfactorily be repaired using the process of the present invention or the process of the above patent application.
As shown in the drawing, when a body of ABS polymer that is relatively badly damaged is to be refinished the body is first subjected to a cleaning process. Typically this can be carried out by immersing and scrubbing the body in a surface-active material, for example a synthetic detergent. After this first cleaning, which can also be used to remove pieces of paper and the like adhering to the surface, the body may be abraded to remove relatively deep scratches and imperfections in the surface. The surface abrasion may be carried out by buffing the surface, by tumbling the articles with abrasive granules, by grinding or any similar, known process.
After the surface abrasion, the articles are dried. The articles may be dried by passing through an oven or by leaving them in a warm atmosphere. After the drying they are coated. The articles are passed through a conventional coating apparatus in which a solution or dispersion of ABS is preferably sprayed on them. The ABS polymer should be as close as possible in composition to the article to be refinished. As indicated above ground hand sets have been used but, in addition, medium density ABS resin has been used. The solvents used are any that will dissolve the ABS coating material and are sufficiently volatile that their presence does not become a hindrance to the subsequent steps in the process. The solvent systems that have been used include (a) acetone with methyl ethyl ketone in equal proportions and (b) toluene. Furthermore, a mixture of acetone: methyl ethyl ketone: toluene in the proportions by volume of 1:1:2 has proved useful.
The coating composition should desirably include pigment, for example the well known commercially available inorganic pigments, that match the colour of the body to be refinished. However, in this regard, it may be pointed out that the method of the present invention is also appropriate for applying an entirely different colour with excellent results. The colours that have been used include beige, yellow, ivory, white, gray, green, red and off white. The combination of solvent, ABS and pigment is typically blended in a mechanical blender using a dispersing agent. The dispersing agent available under the trademark Araldite 507 has proved useful.
After the coating the bodies are placed in a tray, for example in the case of telephone hand sets, a tray that can hold up to twelve sets. On the tray the articles are passed into a refrigerated unit where they are chilled. Simple refrigeration systems, for example those using the halogenated hydrocarbons available under the trade mark FREON, can be used. In a typical embodiment, a tray containing twelve telephone sets was maintained in the chilling chamber for eight minutes. The temperature of the chilling chamber was 40° F. The tray was moved through the chilling chamber. The dwell time will vary with the thickness of the article. The thicker the article, the longer the dwell. However, the dwell time should be adjusted so that at least the surface of the article and the underlying layer leave the chilling chamber at the desired temperature.
After the cooling treatment the bodies are passed into a solvent vapour. A simple heated coil can be positioned in the base of a bath that also contains a relatively volatile solvent. By heating of the coil the solvent is evaporated. Desirably the trays containing the articles may be lowered into the chamber and thus the vapour of the solvent. The walls of the solvent vapour chamber should be sufficiently high so that condensation of the solvent vapours can take place and, desirably, cooling coils are positioned in the vapour to assist condensation. Furthermore, to avoid any possible pollution hazards, extraction fans and condensors should be positioned over the solvent vapour baths.
A typical dwell time for the body in the vapor is in the range 5 to 30 seconds. The time will vary with, for example, color and the percentage of ABS in the coating. Routine experiments will easily determine the appropriate time however it has been found that a white coating may need only 5 seconds but a black coating may require 20 to 30 seconds in the vapor.
With the treatment of ABS articles methylene chloride or mixtures of halogenated hydrocarbons have proved useful as the solvent vapour, however, the solvents listed above as solvents for the ABS coating composition are all relatively volatile and can be used as the solvent vapour.
The process according to the present invention and, in particular, incorporating a coating step and a chilling step into a solvent refinishing process, has provided excellent results. One passage of the article through the illustrated process has proved adequate. Surface deformation after the process has not been observed.
The process is applicable to any ABS article. Of particular significance is the fact that the coated ABS, after the process of the present invention, is indistinguishable from the ABS of the refinished body. The combination of coating the body with ABS, cooling the surface and then solvent treatment of the coated surface is an extremely effective method of producing an extra layer on the body to be refinished but the limits of the extra layer cannot be determined by, for example, cutting the refinished body apart and observing the cut surface. Even with a microscope the observation of a boundary is difficult. The refinished body, produced in the process of the present invention, is as new in that there is no apparent coating. There is merely a uniform structure throughout the cross section of the refinished body, even when the applied ABS does not correspond precisely in composition to the ABS of the body refinished. This has the great advantage that a body can be refinished any number of times using the process of the present invention.
Also of interest, particularly to telephone set manufacturers, is that the color of a set can be changed. In telephones certain colors are fashionable for a time then demand falls. As a result a manufacturer can be left with large stocks of telephones of an apparently unpopular color. These telephones can be recolored using the process of the invention.
Using the invention it is also possible to produce telephones in unpigmented ABS resin. The resin is translucent. According to demand these telephones can be colored, by the process of the present invention a fairly short time before installation. This greatly reduces stock-keeping needs.
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A process for refinishing the surface of a body of acrylo-butadiene-styrene (ABS) polymer by applying to the surface a coating material and treating the body with a solvent. The surface is cooled, together with at least the material underlying the surface, to a temperature in the range about 32° F. to 40° F. The surface of the body is then contacted with a solvent vapor for a time sufficient to reflow the surface but not to warm appreciably the inner layer of the body. The process avoids distortion in the refinished surface.
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BACKGROUND
1. Field of Invention
This invention relates to a device for remotely injecting an animal with a liquid.
2. Description of the Related Art
Most large animals both wild and domestic are wary of human contact and are, therefore, difficult to capture when capture is necessary for medical treatment or other purposes. For example, in ranch or feedlot operations cattle often must be injected with a drug or treated for disease or injury. When allowed free range cattle become wary and difficult to catch. Capturing a single animal for injection entails many risks including possible injury to the cow, possible injury to the cowboy, and disruption of the herd which may lead to weight loss or injury to other cattle.
In cases where the intent of capture is injection of a drug or other fluid a method of remote injection is preferable to actual physical capture of the animal. In many instances the animal may be approached to a distance sufficient for remote injection without the disruption and risk of injury caused by physical capture.
Several systems for remote injection of animals have been conceived. Generally such systems involve a missile which may be projected toward the animal from a distance by apparatuses such as crossbows, blowguns, and compressed gas guns. Typically these systems include a barrel with a needle assembly at the forward end. The barrel typically contains a primary chamber at the forward end which holds the fluid to be injected. The primary chamber is typically separated from a secondary chamber at the rearward end of the barrel by a plunger or piston which forms a seal. When the primary chamber is charged or loaded the plunger or piston is pushed rearward and held in place by a trigger mechanism. The secondary chamber ordinarily includes some form of potential energy source such as a compressed spring tending to push the plunger or piston forward. Upon impact of the missile with the target animal the trigger mechanism is tripped allowing the piston or plunger to move forward. The potential energy source in the secondary chamber forces the piston or plunger forward and pushes the fluid through the needle assembly and into the animal.
Several inventions embrace the above describe system to some extent and include a variety of trigger mechanisms and sources of potential energy. Some of the inventions include a method of remote retrieval of the missile and some include a barb on the needle assembly which serves to hold the missile in place during the injection process.
U.S. Pat. No. 3,042,406; Gregory (1962) discloses a missile which generally conforms to the system described above. The trigger mechanism is a spring which holds the plunger in a rearward position when the missile is charged. Potential energy is supplied by elastic bands tending to pull the plunger forward. Upon impact the spring is released which allows the elastic bands to pull the plunger forward. The patent also teaches a compressible collar at the front of the missile. Upon impact the collar compresses and after the injection process is complete the collar regains its uncompressed shape and ejects the needle from the animal.
The patent teaches no method of remote retrieval of the missile and no method of holding the missile in place during the injection process.
U.S. Pat. No. 4,106,770; Gray (1978) discloses a projectile which operates in a manner similar to that described above. The trigger mechanism includes clips or "fingers" which hold the plunger in a rearward position when the projectile is charged and a slideable weight. Potential energy is provided in the form of a spring compressed when the missile is charged. Upon impact the slideable weight moves forward releasing the plunger from the clips and allowing the spring to force the plunger forward.
The patent teaches no method of remote retrieval of the missile and no method of holding the missile in place during the injection process.
U.S. Pat. No. 4,121,586; Lawrence et al. (1978) discloses a dart operating in a manner similar to that described above. The trigger mechanism includes a breakable retaining pin which holds the plunger in a rearward position when the dart is charged. Potential energy is supplied in the form of stretched elastic bands which tend to push the plunger forward. Upon impact the retaining pin breaks allowing the elastic bands to push the plunger forward.
The patent teaches no method of remote retrieval of the missile and no method of holding the missile in place during the injection process.
U.S. Pat. No. 4,182,327; Haley (1980) discloses an apparatus which operates in a manner similar to that described above. The trigger mechanism involves a hollow needle assembly. The rearward end of the needle assembly includes a conical surface which forms a seal with a similar conical surface at the front of the barrel when the needle assembly is in a forward position. Upon impact the needle assembly is forced rearward and held in a rearward position by a clip. With the needle assembly in a rearward position ports in the needle assembly are exposed allowing fluid to flow from the primary chamber through the ports into the needle assembly. Potential energy is supplied in the form of a spring which is compressed when the plunger is pushed rearward.
The patent teaches a barb which serves to hold the apparatus in place in the animal during the injection process and also includes a method of remotely retrieving the apparatus.
U.S. Pat. No. 4,863,428; Chevalier (1989) discloses a dart which operates in a manner similar to that describe above. The trigger mechanism includes a cap which is pushed onto the end of the needle assembly after the dart is charged. The cap prevents fluid from flowing through the needle assembly. Upon impact the needle assembly is pushed through the cap exposing the end of the hollow needle. Potential energy is supplied by a spring in the secondary chamber which is compressed when the dart is charged and the plunger forced rearward.
The patent teaches a barb which serves to hold the apparatus in place in the animal during the injection process, but includes no method of remotely retrieving the apparatus.
U.S. Pat. No. 5,202,533; Vandersteen (1993) discloses an apparatus which operates in a manner similar to that described above. The trigger mechanism involves two O-rings. The first O-ring encircles the perimeter of a release member connected to the plunger by a shaft. A second O-ring is seated inside the perimeter of the barrel. The outside diameter of the first O-ring is greater than the inside diameter of the second. When the plunger is pushed rearward the O-ring on the release member is forced passed the second O-ring, but is held in place and prevented from moving forward by the difference in diameters of the O-rings. Upon impact the O-ring on the release member is pushed passed the second O-ring allowing the plunger to move forward. Potential energy is supplied by a spring in the secondary chamber which is compressed when the apparatus is charged and the plunger is forced rearward.
The patent teaches a remote retrieval method and also includes a ferrule on the needle which acts to hold the apparatus in place during the injection process.
Each of the prior art devices is unsatisfactory for many reasons. Each of the devices includes one or more such unsatisfactory aspects which make them unsatisfactory for field use. Other disadvantages may be apparent to persons reasonably knowledgeable in the art.
Those devices lacking a system for remote retrieval largely defeat the purpose of remote injection. If a target animal is missed or more than one animal is to be injected non-remote retrieval is likely to cause disruption and possibly to cause injury to the device, the animals, or the rancher.
Those devices lacking a barb or ferrule to hold the device in place are likely to be ejected from the animal prior to completion of the injection process.
Those devices having a barb or ferrule to hold the device in place during the injection process are likely to cause skin or tissue damage with concurrent possibilities of infection or disease upon impact or ejection of the device.
The trigger mechanisms of the prior art devices are either complicated and difficult and costly to manufacture or subject to failure on a relatively consistent basis.
The source of potential energy in many of the prior art devices are unnecessarily complicated, must be replaced prior to each injection, or include parts subject to wear and failure.
In may cases loading or charging of prior art devices is unnecessarily complicated and time consuming and often involves at least partial dismantling and reassembly of the device.
SUMMARY OF INVENTION
1. Summary:
The present invention comprises a device for remote injection of liquid into an animal. The device has a hollow body with a forward section and a tail section. The forward section of the body includes a needle assembly having a hollow needle in operative contact with the hollow body.
Within the hollow body there is a slideable piston the front face of which defines a primary chamber suitable for containing the liquid to be injected. The rear face of the piston defines a secondary chamber. Resilient means within the secondary chamber urges the piston toward the primary chamber when the needle enters the animal so as to force the liquid through the needle into the animal.
In the preferred embodiment the device is loaded by pulling back the plunger and drawing fluid through the needle assembly into the primary chamber in much the same manner as with a conventional syringe. A check valve is interposed between the needle assembly and the primary chamber. The check valve comprises an O-ring valve seat in the forward end of the forward section of the hollow body and a ball which fits against the valve seat and prevents the flow of liquid from the primary chamber to the needle assembly when the needle assembly is in the forward or charged position. The ball is held in place against the valve seat by resilient means and by the pressure of the fluid contained within the primary chamber. Upon impact with the target animal the needle assembly is pushed back to a rearward or discharge position. Upon moving rearward the needle assembly pushes the ball rearward away from the valve seat. The needle assembly is locked in discharge position and the hollow needle is then in operational contact with the primary chamber. The unseated ball allows fluid to flow from the primary chamber through the needle assembly into the target animal. Pulling back the plunger to charge the device compresses the resilient means in the secondary chamber.
Another aspect of the invention is a nose cone attached to the front surface of the forward section by a fastening means. The opening of the nose cone faces rearward. There is a hole in the middle of the forwardmost surface of the nose cone. The needle passes through and fits within the hole in the nose cone.
A tag fashioned from a flexible material is connected to the forwardmost surface of the nose cone by a fastening means. The needle passes through a hole in the tag. The forwardmost surface of the tag is coated with adhesive means. Upon impact the adhesive holds the device in place with the needle piercing the animal's skin for the duration of the injection process. The adhesive means is strong relative to the strength of the fastening means connecting the tag to the nose cone. After the injection process is complete the relatively weak fastening means is broken and the device retrieved leaving the tag attached to the animal. The tag remaining on the target animal indicates which animals have been injected and may be color coded to accomplish multiple marking purposes including, but not limited to, the date or type of injection.
The device may be projected toward the target animal by any of several conventional apparatuses including a crossbow, a compressed gas gun, a blowgun, or a long rod. The invention further includes a remote retrieval system consisting of a line connecting the device to the projecting apparatus.
2. Advantages of the Invention:
There are several advantages to the instant invention which will be apparent to a person reasonably knowledgeable in the art. Many, but not all, of those advantages are indicated below.
The invention includes a system for remote injection of animals.
The invention includes a system for retrieval of the remote injection device by remote means in the event that the target animal is missed or more than one animal is to be injected.
The invention includes a ball and valve seat check valve as a part of the trigger mechanism which is very simple, inexpensive and easy to manufacture, reliable, and durable. The check valve operates in a simple and straightforward manner and involves a minimum of complicated or moving parts.
The invention is simple and easy to load or charge. Charging is accomplished quickly with no tools and does not involve disassembly or removal of any parts.
The nose cone is formed in a shape promoting the aerodynamics of the device. The shape of the nose cone further serves to cushion the impact of the device upon contact with the target animal. The shape prevents the needle assembly rearward from the shaft of the needle from piercing the hide of the animal and causing hide and tissue damage. The rearward movement of the nose cone provides some further cushioning of the impact between the target animal and the injection device. The hole in the nose cone provides support to the needle.
The tag accomplishes the object of holding the device in place during the injection process. The tag is disposable, separates from the rest of the device after the injection process is complete, and remains attached to the skin of the animal. After the injection process is complete the tag accomplishes the object of marking which animals have been injected. The tag may also be color coded to indicate data including type or date of injection. Use of the tag to hold the device in place during the injection process eliminates the possibility of damage to the skin or tissue of the animal intrinsic to the use of a barb or ferrule.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further described in connection with the accompanying drawings, in which:
FIG. 1 is a perspective sectional view of the entire invention;
FIG. 2 is an enlarged, rearward, partial, perspective sectional view showing the secondary chamber and enclosed details; and
FIG. 3 is an enlarged, exploded, perspective view of the trigger mechanism and the fluid delivery system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The general layout and configuration of the invention is depicted in FIG. 1. The injection apparatus comprises a cylindrical hollow body I with a hollow needle 3 at the forward end and a tail cover 5 at the rearward end. Inside the hollow body 1 near the forward end is a cylindrical primary chamber 7. Inside the hollow body 1 at the rearward end is a cylindrical secondary chamber 9. The rearward end of the primary chamber 7 is formed by a movable piston 11. A forward face 13 of piston 11 defines the primary chamber 7. A rearward face 15 of piston 11 defines the secondary chamber 9. The piston 11 has a cylindrical outer surface 17 carrying an O-ring 19 to provide a seal. The rear end of the hollow body 1 is internally threaded as indicated at 21. The rear end of the hollow body 1 is closed by the tail cover 5 which is threadably engaged with the end of the hollow body 1 at 21. Inside the secondary chamber 9 is a piston spring 25 which has one end abutting rearward face 15 and a second end abutting the tail cover 5.
As depicted in FIG. 2 a plurality of prongs 27 at the forward end of a piston rod 29 are insertable through an opening 33 in the tail cover 5. The prongs 27 are further insertable through a piston opening 35 and slots 36 equal in number to the number of prongs 27. The piston rod 29 may be rotated causing the prongs 27 to contact a piston surface 37 inside a piston core 38 and engage the piston rod 29 with the piston 11.
Referring now to FIG. 3 an opening comprising a series of cylindrical apertures of various diameters connects the forwardmost face of the hollow body 1 with the primary chamber 7. The forwardmost of the apertures is indicated at 41, the next forwardmost at 43, the next forwardmost at 45, the next forwardmost at 47, and the most rearward at 49. Aperture 43 is screw threaded. A valve seat 51 is exteriorly screw threaded and screws into aperture 43. An O-ring groove 53 inside valve seat 51 carries an O-ring 55 providing a seal. Another O-ring groove 57 at the rearward end of the valve seat 51 carries an O-ring 58 providing a seal. Inside aperture 47 is a ball 59. The ball 59 is moveable from a forward position against O-ring 58 to a rearward position against a shoulder 61 inside aperture 47. A ball spring 63 abuts the ball 59 at one end and a shoulder 65 at the other end. The ball spring 63 tends to force the ball 59 against O-ring 58 and forms a sealed barrier between the primary chamber 7 and the apertures forward of the valve seat 51. A sliding cartridge 67 fits inside aperture 41. A cartridge tube 68 passes through the center of the cartridge 67 for its entire length. The rear end of the cartridge is a hollow shaft 69. The shaft 69 slides inside the valve seat 51 forming a seal with O-ring 55. A plurality of screws 71 pass through an equal number of counter bored holes 73 and are screwed into an equal number of holes 75 in the forward face of hollow body 1. The length of the screw 71 is sufficient to allow the sliding cartridge to move forward until surfaces 77 contact the heads of the screws 71. The rearward end of the hollow needle 3 is flanged at 79 and the flange screws into threads 81 on the inside of a cylindrical needle adapter 83. The needle adapter 83 is also threaded at its rearward end at 85 and is screwed into threads 87 on the inside of the sliding cartridge 67. The forward end of the needle 3 is cut at a slant to provide a sharp needle point 88
Continuing to refer to FIG. 3 a nose cone 89 of generally cylindrical shape fits over a neck 91 around the forwardmost end of the hollow body 1. A needle shaft 93 passes through an opening 95 in the center of the forwardmost surface of the nose cone 89. The nose cone, therefore, supports the needle and prevents bending or breaking. Threads 97 on the forward end of the sliding cartridge 67 engage with threads 99 on the inside of the nose cone 89. A plurality of swing arms 101 pivot on an equal number of pins 103 attached to the forward end of hollow body 1. An equal number of arm springs 105 also on the pins 103 engage surface 107 on hollow body 1 and surface 109 on the swing arms 101 and tend to force the rearward ends of the swing arms 101 outward and through slots 111 in the nose cone 89. Notches 113 engage surfaces 114 at the rear of slots 111 and prevent the nose cone 89 from moving forward.
Continuing to refer to FIG. 3 a tag 115 fits over the hollow needle 3. The tag is shaped to conform with the forward surface of the nose cone 89. The needle shaft 93 passes through a hole 117 in the center of the tag. The tag 115 is affixed to the forwardmost surface of the nose cone 89. In the preferred embodiment the tag is affixed to the nose cone with glue, but any fastening means including a hook-and-loop fastener may be used providing the bond between the tag and the nose cone may be broken without causing damage to either the nose cone or the tag. The forwardmost surface of the tag is coated with a strong adhesive. In the preferred embodiment tag glue, a glue widely used by ranchers and cowboys to affix various items to the hides of cattle, is used to coat the forwardmost face of the tag. The hollow needle 3, cartridge 67, nose cone 89, and tag 115 are connected and move forward and rearward as a unit. In a rearward position all of these elements are held in the rearward position by the swing arms 101 and their notches 113 contacting with surface 114 at the rearward end of nose cone slots 111.
In operation of the preferred embodiment the prongs 27 on the piston rod 29 are inserted through piston opening 33 into the piston core 38 in the piston 11 and piston rod 29 is rotated which causes the prongs 27 to contact the piston surface 37 and engages the piston rod 29 with the piston 11. The needle point 88 is inserted into the fluid to be injected and the piston rod 29 is pulled back which also pulls the piston 11 rearward and compresses piston spring 25. The fluid is drawn through the hollow needle 3, through cartridge tube 68, and into the primary chamber 7.
Referring again to FIG. 2 a plurality of marks 121 on piston rod 29 indicate the amount of fluid drawn into the primary chamber.
Referring again to FIG. 3 when the appropriate amount of fluid has been drawn into the primary chamber 7 and the piston rod 29 has been released spring 63 and the pressure of the fluid in primary chamber 7 press ball 59 against O-ring 58 which prevents fluid from flowing from the primary chamber. After the primary chamber is loaded, rotating the piston rod 29 in a reverse direction disengages the prongs 27 and allows the piston rod to be removed.
The loaded apparatus can be fired by a wide variety of guns, including compressed gas (e.g., CO 2 ) or air guns and chemical explosion guns. For example, a standard Palmer gun could be used. In addition, with relatively minor adaptation the device could be fired by a bow or cross-bow. The device may also be hand held and used for simple injection of preloaded fluids or operated on the end of a stick or rod.
Referring again to FIG. 3 upon impact with the target animal the hollow needle 3, the nose cone 89, the tag 115, and the sliding cartridge 67, are forced rearward. Surfaces 123 at the rearward end of nose cone 89 contact surfaces 125 on swing arms 101 which forces the rearward end of the swing arms toward the center of the hollow body 1 and compresses arm springs 105. Surfaces 109 move rearward passed notches 113 and the arm springs 105 force the swing arms 101 outward into slots 111 engaging notches 113 with surfaces 114 and holding the hollow needle 3, nose cone 89, and sliding cartridge 67 in a rearward position. O-ring 55 prevents fluid from leaking around the outside of the cartridge 67. The rearward end of cartridge tube 68 unseats ball 59 pushing it rearward from O-ring 58 and places primary chamber 7 in operational contact with hollow needle 3. Piston spring 25 and fluid pressure force piston 11 forward forcing the fluid in the primary chamber 7 through channels 127 in aperture 47 and slots 129 and through the cartridge tube 68 and the hollow needle 3 into the target animal. The adhesive on the forward face of the tag 115 holds the injection apparatus in place against the target animal during the time required for the injection to be completed.
Referring again to FIG. 2 a line 131 is attached at one end to a ring 132 on the tail cover 5. The line 131 may be used to retrieve the injection apparatus.
After the injection process is complete the injection apparatus is pulled from the target animal by reeling in the line or pulling the line by hand. The bond created by the adhesive between the tag 115 and the target animal is stronger than the bond between the tag and the nose cone 89. When the injection device is pulled from the animal, the tag breaks free of the injection apparatus and remains affixed to the target animal. In the preferred embodiment tags are provided in a plurality of colors and serve to mark the target animal for various purposes. For example, one color could be used to indicate one injection fluid and another color used to indicate a different injection fluid.
The injection apparatus is prepared for subsequent injections by manually depressing the swing arms 101, disengaging notches 113 and pulling the nose cone 89 forward. The distance between the heads of the screws 71 and the surfaces 77 on the sliding cartridge 67 is sufficient to allow the swing arms 101 and the nose cone 89 to be reset while preventing the nose cone 89 from being pulled completely away from the hollow body 1. A new tag 115 is affixed to the front of the nose cone. The piston rod 29 is reinserted into piston 11. A new dose of fluid is drawn into the primary chamber 7 by pulling back on the piston rod and the piston rod is removed.
In the preferred embodiment the hollow body 1 is injection molded plastic approximately five inches long and an inch and a quarter in diameter. The size of the hollow body is calculated to keep the injection apparatus as small and light as possible while maintaining a primary chamber 7 sufficiently large to accommodate relatively large doses necessary for medical treatment of large animals. The injection apparatus could be constructed in various sizes to accommodate either smaller or larger doses. While plastics such as cellulose-acetate-butyrate, polyester, polypropylene, and polyethylene could be used, the preferred material is polycarbonate. Other parts including the nose cone 89, cartridge 67, piston 11, valve seat 51, and tail cover 5, are also injection molded and of the same material as the hollow body. The needle 3 is preferably made from stainless steel. The tag 115 is preferably made of paper or other biodegradable material and shaped to conform with the front face of the nose cone 89, but could also be made of plastic or the like. The ball 59 is preferably made of a resilient material such as rubber or the like. The piston rod 29 is preferably made of steel or the like.
The shape of the nose cone 89 and the cushioning effected by its rearward movement upon impact act to prevent tissue and hide damage and trauma to the target animal.
The present invention is not limited to any particular components, materials, or configurations, and modifications of the invention will be apparent to those skilled in the art in light of the foregoing description. This description is intended to provide specific examples of individual embodiments which clearly disclose the present invention. Accordingly, the invention is not limited to these embodiments or to the use of elements having the specific configurations and shapes as presented herein. All alternative modifications and variations of the present invention which fall within the spirit and broad scope of the appended claims are included.
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A device for humane injection of fluid into animals from a distance is disclosed. The device comprises a hollow body with a primary chamber suitable for holding the fluid to be injected, a hollow needle at the forward end of the hollow body, a disposable tag attached to the forwardmost surface of the hollow body, and a remote retrieval means. The device may be projected toward the target animal by any of several conventional methods including compressed gas or chemical explosion gun. Upon impact with the target animal a trigger mechanism which comprises a ball and valve seat check valve is tripped allowing a resilient means to force the fluid through the needle and into the animal. The device is held in place during the injection process by an adhesive means on the forwardmost surface of the tag. After injection the device is pulled form the animal using the retrieval means. The tag separates from the device and remains attached to the skin marking the animal.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/302,526, filed Jul. 2, 2001
BACKGROUND OF INVENTION
1. Field of the Invention
The invention relates to extraction cleaning machines incorporating agitation brushes. In one of its aspects, the invention relates to an extraction cleaning machine incorporating a multi-row agitation brush. In another of its aspects, the invention relates to extraction cleaning machines incorporating a twist-wire agitation brush. In yet another of its aspects, the invention relates to extraction cleaning machines incorporating an agitation brush dampening mechanism. In yet another of its aspects, the invention relates to an extraction cleaning machines incorporating an agitation brush that applies a predetermined force to a carpet.
2. Description of Related Art
Extraction cleaning machines are used for removing dirt from surfaces such as carpeting, upholstery, drapes and the like. Known extraction cleaning machines can be in the form of a canister-type unit as disclosed in U.S. Pat. No. 5,237,720 to Blase et al.; an upright unit as disclosed in U.S. Pat. No. 6,134,744 to Kasen et al. and U.S. Pat. No. 6,167,587 to Kasper et al.; and a hand-held unit as disclosed in U.S. Pat. No. 5,367,740 to McCray.
Vacuum cleaning machines are also used for removing dirt from surfaces. Vacuum cleaning machines have rotating brushes to agitate the surface, thus enhancing cleaning effectiveness. Brushes can be in the form of multiple rows of bristles as disclosed in U.S. Pat. No. 2,659,921 to Osborn, and twist-wire type bristles in U.S. Pat. No. 1,205,162 to Clements.
SUMMARY OF INVENTION
An extraction cleaning machine has a housing with a solution dispensing system and a solution recovery system mounted thereto for applying a cleaning solution to a surface being cleaned and recovering the solution from the surface, and an agitation brush for agitation of the surface being cleaned. A drive motor is mounted in the housing and is connected to the agitation brush for rotation of the elongated agitation brush about the longitudinal axis.
In one embodiment, the elongated agitation brush is selected from a multi-row, helically arranged bristle brush and a helically arranged twisted wire brush. The helically arranged bristle brush has at least four rows of bristles. The helically arranged twist wire brush comprises a continuous helical array of radially extending bristles bound by a pair of twisted wires forming a spindle.
In another embodiment, the elongated agitation brush is mounted to the housing through a pair of arms which are pivotally attached at one end to the housing and rotatably support the elongated brush roll at another end thereof. A spring is mounted between the arms and the housing to bias the elongated brush roll with respect to the housing into contact with the surface to be cleaned. In a preferred embodiment, at least one of the arms has a resiliently mounted projection which against a surface of the housing to resist transient vibrations of the elongated agitation brush with respect to the housing. The resiliently mounted projection is mounted on an integrally formed flexible tab on the at least one arm.
In another embodiment, a torsional spring provides a rotational bias about pivot pins located on brush arms to force the agitation brush toward the surface to be cleaned. In alternate embodiments, downward force of the brush can also be accomplished with a compression spring or cantilever beam spring mounted between the brush arm and the base housing.
In another embodiment, a cover encircles the elongated agitation brush and is removably mounted thereto for contacting the surface to be cleaned. Desirably, the elongated cover is a fabric and is secured onto the elongated agitation brush with a hook and pile fastener.
In one embodiment, the housing is a hand held deep cleaner housing. In another embodiment, the housing comprises a base including a pair of wheels for movement along a surface to be cleaned, and further includes a handle pivotally mounted to the base for manipulation of the base along a floor surface to be cleaned. In yet another embodiment, the working air conduit includes a flexible hose which is joined at one end to the housing and further comprising a hand tool mounted to a free end of the flexible hose, and the suction nozzle and the elongated agitation brush are mounted in the hand tool. In this embodiment, a turbine motor can be mounted in the hand tool to drive the agitation brush.
Testing has shown that extraction type cleaning in combination with the brush configurations described herein provide an unexpected improvement in cleaning performance when compared to extraction cleaners with other types of agitation brushes.
BRIEF DESCRIPTION OF DRAWINGS
In the drawings:
FIG. 1 is a perspective view of an extraction cleaning machine according to the invention.
FIG. 2 is an exploded view of a base module of the extraction cleaning machine shown in FIG. 1 .
FIG. 3 is a partial sectional side view of the foot module of the extraction cleaning machine of FIG. 1 .
FIG. 4 is an exploded view of a floating brush assembly for the extraction cleaning machine of FIG. 1 .
FIG. 5 is a front view of an agitation brush according to the invention.
FIG. 6 is a partial cross-sectional view of another embodiment of a twist-wire brush according to the invention.
FIG. 7 is a perspective view of a further embodiment of an extraction cleaning machine according to the invention.
FIG. 8 is a front view of the extraction cleaning machine of FIG. 7 .
FIG. 9 is a perspective view of a hand-held attachment for an extraction cleaning machine according to the invention.
FIG. 10 is a bottom view of the hand-held attachment of FIG. 9 showing an agitation brush.
FIG. 11 is a perspective view of an agitation brush including a removable cover according to the invention.
DETAILED DESCRIPTION
Referring now to the drawings and to FIG. 1 in particular, an upright extraction cleaning machine 12 according to the invention is shown. The machine 12 is a portable surface cleaning apparatus including a base module 14 adapted to roll across a surface to be cleaned and an upright handle assembly 16 pivotally mounted to a portion of the base module 14 .
As best shown in FIGS. 1–3 , the base module 14 includes a lower housing portion 15 and an upper housing portion 17 , which together define an interior for housing components and a well 730 for receiving a tank assembly (not shown). The upper housing portion 17 receives a transparent facing 19 for defining a first working air conduit 704 and a suction nozzle 34 , which is disposed at a front portion of the base module 14 adjacent the surface being cleaned for recovering fluid therefrom. The handle assembly 16 has a closed loop grip 18 provided at the uppermost portion thereof and a combination hose and cord wrap 20 that is adapted to support an accessory hose 22 and a electrical cord (not shown) when either is not in use. A latch assembly 21 is pivotally mounted to the rear portion of the base module 14 adjacent the rotational union of the handle assembly 16 therewith for releasably locking the handle assembly 16 in its upright position.
As shown in FIG. 2 , the base module 14 houses a drive motor 196 that is connected to a source of electricity by the electrical cord. A motor compartment 500 within the base module 14 is a clamshell-shaped housing for holding a motor assembly in place and preventing rotation thereof. The clamshell motor compartment 500 includes an upper half 502 and a lower half 504 . The upper half 502 is removable from the lower half 504 , which is integral to the extraction cleaner base module 14 . Thus, a bottom wall of the lower half 504 is the bottom surface of the extraction cleaner base module 14 . An arm 651 extends upwardly from the motor housing 500 in the base module 14 to support the flow indicator 650 , which is mounted to an upper end thereof. An opening 653 in the upper housing portion 17 receives the flow indicator 650 when that portion is mounted to the lower housing portion 15 .
The motor compartment 500 includes a large circular impeller fan housing 510 and a smaller motor housing 512 , further having a generally T-shaped cross section. The impeller fan housing 510 surrounds an inner housing 41 defining a vacuum source 40 , which is created preferably by an impeller (not shown) disposed within the housing 41 . The housing 41 includes a large aperture 516 for mounting a vacuum intake duct 530 , which is sealed to the aperture 516 by a gasket 520 . The smaller motor housing 512 includes a small aperture 524 for receiving therethrough a motor drive shaft 198 . A stretch belt 204 is received on the motor drive shaft 198 outside of the clamshell motor compartment 500 .
The drive shaft 198 of the drive motor 196 is connected to an interim drive shaft 200 of a solution pump 202 by the stretch belt 204 , which in turn, is connected to a rotatably mounted agitation brush 606 by a timing belt 208 , as best illustrated in FIGS. 5 and 6 . On the opposite side of the motor 196 , the motor drive shaft 198 supports the impeller (not shown) within the impeller housing 41 , which provides the vacuum source 40 and is mounted inside the housing 510 of the motor compartment 500 . With this configuration, a single drive motor 196 is adapted to provide driving force for the impeller, the solution pump 202 , and the agitation brush 606 .
As best seen in FIGS. 2 , 3 , and 4 , the rotatably mounted agitation brush 606 is adapted for floor-responsive adjustment by a floating brush assembly 400 mounted within an agitation brush housing 26 disposed within a forward portion of the base module 14 . The floating movement of the agitation brush 606 is a horizontally oriented arcuate path for reciprocation toward and outward of the agitation brush housing 26 . Ends 452 of an agitation brush shaft 606 are received in bearings 454 , which in turn, are press fit into inwardly extending bosses 456 to provide a pair of opposed articulating arm members 458 . Alternatively, stub shafts (not shown) can extend from the arm members 458 and the ends 452 can be replaced with bearings similar to 454 for rotational installation of the brush 606 on the arm members 458 .
Each arm member 458 comprises a back plate 460 with a pivot pin 462 provided at the rear of the plate 460 . In addition, a laterally extending belt guard 466 is preferably integrally formed with the articulating arm 458 . The belt guard 466 , which extends laterally inwardly enough to cover the timing belt 208 , minimizes the lodging of threads and other foreign material in the timing belt 208 and protects the carpet or other surface positioned below the base assembly 14 from the rotating belt 208 .
As best shown in FIGS. 3 and 4 , the timing belt 208 is reeved through a pulley 216 mounted at one end of the brush 606 and a pulley 222 on the interim drive shaft 200 of the pump 202 , which includes a separate pulley 220 through which is reeved the stretch belt 204 , which, in turn, extends around the drive shaft 198 of the motor 196 . Further, the pulley 220 has a convex cross section of its periphery, whereby it is adapted to receive the smooth stretch belt 204 , while the pulley 222 has a toothed perimeter adapted for registration with the teeth in the timing belt 208 .
The pivot pins 462 of the arm member 458 are rotatably supported secured in a bearing (not shown) mount integrally formed with an internal wall of the agitation brush housing 26 . Further, the pivot pins 462 are held in the bearing by a support 478 on the non-belt side of the base module 14 and the arm 258 of the second belt access door 252 on the belt side of the base module. Both the arm 258 and support 478 are secured to the agitation brush housing 26 by a conventional fastener (not shown) inserted through an aperture in each part. The arm members 458 are preferably limited in their downward movement relative to the agitation brush housing 26 by the length of the timing belt 208 as well as the engagement of the brush guards 466 with the arm 258 and the support 478 . As the floating brush assembly 400 extends further and further downwardly, the belt 208 will stretch and resist further downward movement. Eventually, the brush guards 466 on each arm 458 will contact respectively the arm 258 and the support 478 , which prevents any further downward movement.
With this floating agitation brush assembly 400 , the cleaning machine 12 according to the invention can almost instantaneously adapt to varying carpet naps or other inconsistencies on the surface being cleaned. The arm members 458 also allow the rotating brush 606 to drop below the normal floor plane to, for example, provide contact with a bare floor.
The upright extraction cleaning machine described above is disclosed in more detail in U.S. Pat. No. 6,167,587, which is incorporated herein by reference in its entirety.
Referring now to FIG. 4 , arm member 458 includes a U-shaped slot 470 defining an integral resilient tab 472 . Resilient tab 472 includes a friction projection 474 extending from outer face of plate 460 . The plate 460 maintains a tight tolerance with the sidewall of the base module, such that friction projection 474 resiliently bears against the sidewall of the base module under the influence of resilient tab 472 . In this manner, the friction projection 474 resists transient vibrations of the agitation brush assembly such as brush “bounce” caused by contact of the brush assembly with an uneven floor surface.
Referring to FIGS. 3 and 4 , a torsion spring 476 is illustrated for mounting on pivot pins 462 to provide a rotational bias about pivot pins 462 to direct agitation brush 606 toward the surface being cleaned. In lieu of the torsion spring 476 , a forward ramped surface 414 of an elevator assembly 410 can be attached to a rearward portion of arm member 458 . Compression spring assembly 406 biases the elevator assembly 410 rearward relative to the base housing. In operation, when the upright handle 16 is placed in the upright position, the elevator assembly 410 is moved forward compressing the spring assembly 406 and lifting the arm member 458 . When the upright handle 16 is lowered, the spring assembly 406 forces the elevator assembly 410 rearward, pulling the arm member 458 with it, therefore biasing the brush 458 against the surface to be cleaned. The operation of the elevator assembly 410 is described more completely in U.S. Pat. No. 6,167,587 which is incorporated herein by reference in its entirety. In the alternative, it is anticipated that a compression spring situated between the brush housing and the arm member 458 , at an end of arm member 458 distal from pivot pins 462 , can provide the same downward bias to the agitation brush 606 . Likewise, a cantilever beam spring mounted to one of the arm member 458 and the brush housing and bearing against the other of the arm member 458 and the brush housing can provide a downward bias to the agitation brush 606 . A downward bias can also be accomplished by increasing the weight of the brush 606 to reduce its susceptibility to bounce or float away from the surface being cleaned, thus improving cleaning performance.
Referring to FIG. 5 , the agitation brush 606 comprises multiple rows 608 of bristles 610 formed in tufts 612 . The increase in the number and density of bristles on the surface of the agitation brush has been found to increase the cleaning effectiveness of the brush 606 . In the illustrated embodiment, there are four rows 800 , 802 , 804 , 806 of bristles in a generally longitudinally sinusoidal configuration. The number of rows 608 of bristles can vary depending on the function of the machine. We have discovered that at least three rows of bristles 608 has surprisingly enhanced cleaning compared with a single or even a double row of bristles. Typically, there will be 4–6 rows 608 of bristles, preferably five rows.
Referring now to FIG. 6 , a further embodiment of a twist-wire agitation brush 480 is shown comprising an array of continuous helical bristles 482 bound by a twist-wire spindle 484 . The twist-wire spindle 484 provides the advantage of a flexible brush 480 for conformance to the surface being cleaned and therefore equalization of the brushing force applied to the surface. The twist-wire agitation brush 480 also has the advantage of being lighter in weight, requiring lighter weight support structure and a less powerful brush drive motor. Especially in combination with the spring bias feature illustrated in FIG. 4 , the twist-wire brush 480 has the advantage of lower weight and better conformance to the surface being cleaned while maintaining firm contact to effectively clean the surface. The twist-wire spindle 484 can be formed of material such as galvanized steel, aluminum or stainless steel, the material selected in order to ensure compatibility with the preferred cleaning compounds for the application.
Referring to FIG. 11 , a further embodiment of an agitation brush according to the invention includes a removable/replaceable fabric cover 700 secured about multi-row bristle brush 606 . The fabric cover has an outer surface 702 for contacting a surface being cleaned. The fabric cover 700 is secured at a first end 704 to the brush roll by way of a slot or fastener 710 and wrapped firmly about the outside diameter of the rows of bristles 608 until it laps over itself and is secured by known fasteners 712 such as hooks, snaps, buttons or hook-and-loop fasteners. The fabric cover 700 can be formed of any one of a number of cloth or textile materials such as terry cloth, corduroy or other materials of varying porosity or surface texture. The fabric cover 700 is easily removable for cleaning or replacement. The fabric cover 700 can be fabricated to be reversible as a given side becomes dirty or worn, or with each side having a different texture. Fabric covers have been shown to provide cleaning advantages in some applications, but can become dirty or wear out quickly, requiring a ready method of removal and replacement.
A further application of the twist-wire brush 480 of FIG. 6 , the agitation brush 606 with multiple rows 608 of FIG. 5 , and fabric cover 700 of FIG. 11 is in a hand-held extraction cleaner, as shown in FIGS. 7 and 8 . It is anticipated that the twist-wire brush 480 , the agitation brush 606 , or the fabric cover 700 can be used in the hand-held extraction cleaner 1710 . Those features of the hand-held extraction cleaner 1710 shown in the figures but not further discussed herein are described in U.S. Provisional Application Ser. No. 60/239,670, filed Oct. 12, 2000 and U.S. Pat. No. 6,125,498 issued Oct. 3, 2000, all of which are incorporated herein by reference in their entirety.
A further application of the twist-wire brush 480 of FIG. 6 , the agitation brush with multiple rows 608 of FIG. 5 , and fabric cover 700 of FIG. 11 is in a hand-held attachment 1810 for an extraction cleaner, as shown in FIGS. 9 and 10 . The hand-held attachment 1810 attaches at a first end 1830 to a hose (not shown) fluidly connected to an extraction cleaner such as a canister extraction cleaner or an upper right extraction cleaner, the hose including a suction conduit and a fluid supply conduit. The suction conduit is selectively fluidly connected to a suction nozzle 1840 or to a turbine 1820 for driving an agitation brush 606 , the attachment 1810 including a selector slide 1825 for directing the suction air flow to the turbine 1820 or suction nozzle 1840 . The fluid supply conduit is fluidly connected to a spray nozzle 1850 . It anticipated that the twist-wire brush 480 can be used in place of the agitation brush 606 in the hand-held attachment 1810 .
While particular embodiments of the invention have been shown, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. Reasonable variation and modification are possible within the scope of the foregoing disclosure of the invention without departing from the spirit of the invention.
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An extraction cleaning machine has a solution dispensing system and a recovery system for applying a cleaning solution to a surface and recovering the solution from the surface, and an agitation brush assembly for agitating the surface. The agitation brush assembly can include friction-type or other dampers for reducing brush bounce, and biasing elements for maintaining a constant downward force on the brush. The brush can have multiple helical rows of tufted bristles, preferably at least four rows, or can comprise a continuous helix of bristles in a twisted-wire spindle. The brush can further have a removable fabric cover for mounting over a bristle brush for contacting a surface being cleaned. The brush assembly can function in an upright extraction cleaning machine with or without an above floor cleaning tool, a hand-held extractor, or a hand-held attachment to a canister extractor or an above floor tool in upright extractor.
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FIELD OF THE INVENTION
[0001] The present invention is generally directed to a novel device for sterilizing knives, kitchen tools and cutting boards which can come into contact with, and harbor, harmful microorganisms, including bacteria and viruses. The invention provides a safe, fast and convenient way to disinfect and store such items. The device permits exposure of items placed therein to ultraviolet light, and provides a convenient storage device for the items.
BACKGROUND OF THE INVENTION
[0002] Kitchens and other food preparation areas can have high levels of dangerous microorganisms, including bacteria, which thrive in warm, dark, moist environments. Kitchen items, including knives, tools and cutting boards, which contact meat, soft cheeses and other foods which harbor such microorganisms can spread such germs from one food to another, or from one tool to another. Ultimately, such microorganisms can be ingested in foods and cause serious illness, such as salmonella or e. coli infection. Vigilant cleaning with sufficiently hot water and soap and careful food preparation practices can minimize the risk. However, inconsistent cleaning habits, incorrect water temperature and lax food preparation practices can contribute to the growth of harmful microorganisms in the kitchen. Moreover, simple cleaning in soap and water is sometimes insufficient to kill all microorganisms on a given surface. Traditional cleaning with water also may be ineffective for items which cannot be completely submerged, such as wood, and items which can trap microorganisms in small spaces, such as knife handles. Heat, as from steam or microwaving, is undesirable as it may damage softer plastics, require cool-down time before use, or burn the user. Metal parts such as screws, handles and utensil parts make microwave activated sterilization impossible. Moreover, after such items are cleaned, they may come into contact with contaminated items, such as in a storage bin or drawer. Further, because such items contact food, it is important that they do not maintain any chemical residue from cleaning solutions.
[0003] Thus, it is important to provide a system for disinfecting kitchen equipment, such as knives, tools and cutting boards, which can come into contact with, and harbor, harmful microorganisms. Moreover, it is important to insure thorough and complete sterilizing of such items. It also is desirable to provide a storage container for such equipment to insure that after sterilizing, such equipment does not come into contact with other equipment which may harbor dangerous microorganisms.
[0004] The present invention addresses the need for a device for disinfecting kitchen equipment, such as knives, tools and cutting boards and provides a compact, attractive counter-top sterilizer which can accommodate a variety of kitchen equipment and which also provides an attractive and convenient storage container for such equipment.
[0005] The present invention attains each of these goals through the use of a compact and convenient sterilizer and storage unit which uses ultraviolet, or “UV” light. UV light is invisible radiation having a wavelength of between 100 to 320 nm. The most effective range for sterilization is within 200 nm to 290 nm, designated the UV-C band, with a bandwidth between 250 nm and 260 nm being optimal. At this wavelength, such light is capable of inactivating and destroying a variety of bacteria, viruses, mold and other microorganisms. When UV-C light hits a microorganism, the light is absorbed by the microorganism, which is destroyed. Because the items are “sterilized” by light, they are not wet by, or submerged in, water, soap or chemicals. Thus, no drying or extreme heat is required, and no potentially harmful chemicals or soaps are left behind on the item. Even items that are not suitable to be washed in water, such as wood, can be sterilized with UV light.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a novel device which comprises a housing, made of material suitable to contain UV radiation, which housing encloses a basket or receptacle made of a material or structure “transparent” to UV radiation, through which UV light may be transmitted for enclosing items to be sterilized, a knife block to receive knives to be sterilized, a source of UV light, reflective material to insure exposure of all surfaces to UV light and a door to seal the housing and prevent the leakage of UV light. When the system is activated, the UV light is directed through the receptacle and into the enclosure onto the items to be sterilized, insuring that UV light hits all surfaces of each piece of equipment to be sterilized. Internal surfaces of the device are coated with reflective material to insure exposure of all surfaces of knives, tools and cutting boards to UV light. The UV light destroys microorganisms on the surfaces of the equipment to be sterilized, but does not remain in or on the equipment.
[0007] The equipment is removed from the device in a sterilized state.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows a front view of an embodiment of the invention.
[0009] FIG. 2 shows a front view of the invention opened to show equipment therein.
[0010] FIG. 3 shows a front view of the invention opened to show equipment therein.
[0011] FIG. 4 shows an exploded view of an embodiment of the invention.
[0012] FIG. 5 shows a longitudinal cross-sectional view of the embodiment of FIG. 9 taken approximately along the line A-A of FIG. 9 .
[0013] FIG. 6 shows a top view of an embodiment of the invention.
[0014] FIG. 7 shows a bottom view of an embodiment of the invention.
[0015] FIG. 8 shows a side view of an embodiment of the invention.
[0016] FIG. 9 shows a rear view of an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] Reference will now be made in detail to the preferred embodiments of the invention, examples of which are also provided in the following description. Exemplary embodiments of this invention are described in some detail, although it will be apparent to those skilled in the relevant art that some features that are not particularly important to an understanding of the invention may not be shown for the sake of clarity.
[0018] The present invention is directed to a knife and kitchen tool sterilizer and holder. The housing of the sterilizer is constructed of material that is impervious to UV-C radiation, such as plastic, and contains knife holders for holding knives. The housing is sealed by a door, which provides access to inside the housing. The housing comprises a holder for placing articles to be sterilized, knife holders and a slot for a cutting board, a UV-C light source, a power source, and means for reflecting the UV-C light source such that all surfaces of all items placed therein are exposed to UV-C light.
[0019] FIG. 1 is a front view of the sterilizer 10 in a closed position. Support 12 enables sterilizer 10 to stand in a semi-upright position. As shown in FIG. 8 in a preferred embodiment, bottom 22 of sterilizer 10 is angled to enable sterilizer 10 to stand and tilt at an angle which is convenient for use. In one embodiment, the plane created by cover 14 in a closed position is maintained at an angle of 60 degrees from the surface on which sterilizer 10 is placed, for ease of use. Cover 14 enables the unit to be closed when it is activated and in a sterilization cycle or when items therein are being stored. UV activation switch 16 activates the UV-C light source located within the sterilizer and begins the sterilization cycle when depressed.
[0020] Housing 11 comprises two vertical shells and is made of a material that is impervious to UV-C radiation. In one embodiment housing 11 is formulated from plastic. In another embodiment, as shown in FIG. 2 , housing 11 is substantially rectangular in shape, with a rectangular protrusion 13 in the front of housing 11 to accommodate tool holder 27 (partially visible). Knife slots 18 are located in knife holders 20 and enable knives to be stored and sterilized in sterilizer 10 . In one embodiment, knife slots 18 are angled such that each knife is maintained at about a 40 degree angle from the horizontal plane created by the surface on which the sterilizer is placed to maximize exposure to UV light within sterilizer 10 . Knife holders 20 are fabricated from rigid material, such as plastic with a wood or plastic veneer to maintain the required angle. As shown in FIG. 6 , cover 14 is shaped to close over sterilizer 10 in a manner which does not interfere with access to knife holders 20 . Hinge 23 of cover 14 enables cover 14 to open and rotate about 270 degrees back behind sterilizer 10 in an open position. As seen in FIG. 2 , board slot 25 accommodates cutting board 26 for sterilization and storage. In one embodiment, shown in FIG. 2 , tool holder 27 is positioned inside a recess defined by board slot 25 , knife holders 20 and protrusion 13 of housing 11 .
[0021] As seen in FIG. 3 , in one embodiment, sterilizer 10 accommodates knives 28 and tools 30 as well as cutting board 26 (not visible) for sterilization or storage.
[0022] As shown in FIG. 4 , which is an exploded view of sterilizer 10 showing the main components, housing 11 comprises front shell 31 and back shell 32 . Back shell 32 contains back protrusion 46 which houses electrical ballast 35 , starter 36 , sockets 39 , reflectors 41 and UV-C light source 38 . Back shell 32 also contains vents 48 to prevent electrical components housed in back protrusion 46 from becoming overheated. Front shell 31 comprises holes 50 (one not visible) which receive the arms of support 12 . Tool holder 27 comprises apertures 51 which enable UV-C light to pass through tool holder 27 and contact items therein. Tool holder 27 comprises three partial holder walls 19 . In one embodiment, apertures 51 are symmetrically spaced throughout walls 19 and are of uniform size.
[0023] Tool holder 27 is made from material which is durable and not easily cut by sharp tools. In one embodiment, tool holder 27 is made of plastic mesh. The sides of tool holder 27 comprise ridges 52 on either side, each of which further comprises attachment tab 53 and screw hole 54 . Tool lever rod 45 is attached to tool cage lever 44 via fastener 47 . Tool floor 55 comprises a flat plate 56 rigidly fastened using standard techniques, such as welding, to a semicircular hinge 57 . In one embodiment, flat plate 56 and semi-circular hinge 57 are made of an integral piece of molded metal or plastic. Knife holders 20 are seated into collar 58 . In a preferred embodiment, collar 58 is fabricated from metal or plastic. In another embodiment, collar 58 contains a rubber sealing ring (not visible) around its inside rim 59 to provide a secure seal when sterilizer 10 is closed and to prevent leakage of UV-C rays.
[0024] In assembly, as shown in FIG. 1 , cover 14 is movably fitted into collar 58 and secured by a fastener, such as a clip, to form cover assembly 81 as shown in FIG. 6 . As shown in FIG. 4 , springs 21 are loaded into hinge 23 . Hinge caps 29 are then placed onto hinge 23 such that springs 21 exert outward tension on hinge caps 29 when the outward edges of hinge caps 29 are flush with the outside edges of hinge 23 . Hinge 23 , located on cover 14 is then seated between hinge caps 29 on rim 59 . The tension created by springs 21 inside hinge 23 movably secures cover 14 to rim 59 such that cover 14 can move in an arc of about 270 degrees around hinge 23 . While the arc may be decreased, an arc of about 270 degrees allows for ease of filling and emptying of tool holder 27 and removal and replacement of cutting board 26 . Activator 60 is electrically connected to activation switch 16 and is fastened into notch 61 on rim 59 via fastener 62 . Activation switch 16 is seated into notch 63 and rigidly attached thereto using standard techniques, such as soldering. Ballast 35 is fastened to ballast holder 36 using fasteners such as screws. Starter 36 is seated into starter holder 37 and fastened thereto using standard fasteners such as screws. UV-C light source 38 is fastened into sockets 39 .
[0025] In a preferred embodiment, UV-C light source 38 is cylindrical type G6T5, has a wattage of 6, a base diameter of 15 mm, lamp diameter of 15 mm, is 9 inches in length, has a two 2-pin ceramic bases and is constructed of hard glass quartz. Effective sources of UV-C light are low pressure mercury discharge lamps. A preferred lamp is manufactured by Osram Sylvania, Inc. Another is manufactured by Royal Philips Electronics. Intensity at 1 meter using a type G6T5 bulb 16.7 uW/cm 2 and 173 uW/cm 2 In a preferred embodiment, starting voltage of UV-C lamp 50 is 120 VAC @ 60 HZ, operational voltage is 120 VAC @ 60 HZ, UV output is 253.7 nm @ 100 hrs. The average life of a G6T5-type lamp is 6,000 hours.
[0026] Activator 60 is electrically connected to starter 36 . When pressed, activator 60 transmits an electrical signal to starter 36 which in turn activates UV-C light source 38 . UV-C light source 38 is electrically attached to ballast 35 , which provides resistance to stabilize current in the circuit created when sterilizer 10 is attached to a power source via power cord 69 . In a preferred embodiment, ballast 35 is operational with 100/200 VAC at 50/60 HZ.
[0027] Tool holder 27 is attached to front shell 31 by standard fasteners, such as screws, which are placed through attachment tab 53 and screwed into holes 72 on the inside sides of front shell 31 . Tool lever rod 45 is placed through hole 74 of back shell 32 and through hole 76 in rod 78 of tool lifter 80 , such that a portion of tool lever rod 45 protrudes from the outside of back shell 32 . Tool cage lever is attached to the protruding portion of tool lever rod 45 via fastener 42 . Screw ends 81 of support 12 are placed through front shell 31 and secured by screw 42 , as shown in FIG. 5 .
[0028] Front shell 31 is then engaged with back shell 32 in a vertical plane such that back shell 32 and front shell 31 form housing 11 and enclose tool holder 27 . Front shell 31 and back shell 32 are fastened together using standard fasteners, such as screws. As seen in FIG. 7 , bottom 22 is fastened to the bottom edge of back shell 32 and front shell 31 using bottom fasteners 82 . In one embodiment, bottom 22 may be covered in a fabric, such as felt, to prevent bottom 22 from scratching surfaces on which sterilizer 10 is placed.
[0029] As seen in FIG. 4 , cover assembly 81 is placed over and into tab 65 such that bar 67 on rim 59 engages lips 64 (partially visible) on tab 65 . Rim 59 can also be rigidly attached to tab 65 using standard fasteners, such as screws.
[0030] All internal surfaces of back shell 32 , front shell 31 , tool floor 55 and cover assembly 81 are coated with UV-C material by vacuum coating or electro-coating or are made of UV-C reflective material, such as polished aluminum or stainless steel, to increase UV-C reflectivity when sterilizer 10 is closed and undergoing a sterilization cycle.
[0031] In operation, sterilizer 10 is positioned to be resting on support 12 as seen in FIG. 1 , such that cover 14 can be easily accessed. Cover 14 is opened and rotated about 270 degrees to rest on the back of back shell 32 , as seen in FIG. 3 . As further seen in FIG. 3 , knives 28 are placed into knife slots 18 in knife holders 20 such that the blades of the knives 28 are positioned on the sides of tool holder 27 and maintained at about a 40 degree angle from the horizontal plane created by the surface on which sterilizer 10 is placed. For ease of loading, tool lever 44 is rotated such that tool floor 55 is in a raised position and substantially perpendicular to front shell 31 and back shell 32 . Kitchen tools 30 are arranged in tool holder 27 such that they rest against tool floor 55 . As seen in FIG. 2 , cutting board 26 is lowered into board slot 25 . Cutting board 26 is pushed down into board slot 25 such that the topmost edge of cutting board 26 is substantially flush with the top edge of back shell 31 . Tool lever 44 is then rotated such that tool floor 55 lowers, in turn lowering tools 30 into sterilizer 10 such that the tops of the tools 30 are substantially flush with the top edge of back shell 31 . Cover 14 is rotated forward toward front shell 31 and pressed down onto front shell 31 to form a seal, as shown in FIG. 1 .
[0032] Sterilizer 10 may be utilized in this manner as a storage unit for knives 28 , tools 30 and cutting board 26 . Such storage maintains these items in a clean, safe and convenient manner.
[0033] If it is desired to sterilize such items, cover 14 is closed fully then the activation switch 16 is depressed, completing the electrical circuit inside sterilizer 10 and causing UV-C light source 38 to be activated. UV-C light source 38 emits UV-C radiation, which is directed through apertures 51 and onto the surfaces of knives 28 , tools 30 and cutting board 26 . UV-C emissions also are reflected off the coated surfaces of back shell 32 , front shell 31 , tool floor 55 and cover assembly 81 randomly onto the surfaces of knives 28 , tools 30 and cutting board 26 . As the organic, or carbon based microorganisms on the surfaces of such items are exposed to the UV-C light, the molecular bonds in such microorganisms are broken, causing genetic damage and preventing such organisms from reproducing, rendering them harmless. The ability of UV-C light to disable such microorganisms in this manner is directly related to intensity of UV-C light and exposure time. In a preferred embodiment, activation switch 16 is attached to a timer which enables the sterilizing cycle to proceed for a pre-set period of time. After the time period ends, UV-C light source 38 ceases emitting light. A sterilizing cycle of fifteen minutes has been found to be sufficient to insure sterilizing of six tools, a cutting board and six knifes. After sterilization, cover 14 is opened and rotated behind back shell 32 . Lever 44 is rotated such that tool floor 55 is in a raised position and substantially perpendicular to front shell 31 and back shell 32 . Kitchen tools 30 are raised up and partially out of sterilizer 10 for ease of retrieval.
[0034] What has been illustrated and described herein is a knife and kitchen tool sterilizer and holder. While the invention has been illustrated and described with reference to certain preferred embodiments, the present invention is not limited thereto. In particular, the foregoing specification and embodiments are intended to be illustrative and are not to be taken as limiting. Thus, alternatives, such as structural or mechanical equivalents and modifications will become apparent to those skilled in the art upon reading the foregoing description. Accordingly, such alternatives, changes, and modifications are to be considered as forming a part of the present invention insofar as they fall within the spirit and scope of the appended claims.
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A sterilizer and storage container for kitchen tools, knives and cutting boards which sterilizes such items using ultraviolet light in the UV-C range. The sterilizer features a housing which encloses a receptacle made of a material or structure “transparent” to UV radiation for enclosing items to be sterilized, means for lifting and lowering utensils in said receptacle for ease of filling and emptying said receptacle, a source of UV light, a cover to seal the housing and prevent the leakage of UV light and a starter button to activate the UV light source. When the starter button is activated, UV light is directed through the receptacle and onto the items to be sterilized. The UV light destroys microorganisms on the surfaces of the items to be sterilized. The items are removed from the device in a sterilized state.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to boat anchors in general, and more specifically relates to a dynamic anchor. The anchor is a flat plate structure roughly corresponding in action to the fluke of a conventional anchor. A conventional anchor fluke is flat and pointed to easily penetrate the bottom structure. This invention differs in that a retractor will pull the fluke out of the water course bottom structure.
2. Description of the Prior Art
Generally, anchors are weighted, large, double hook objects to drag the sea floor and give stability to a vessel. Flukes are added at the point end of the hooks in order that the mass of the anchor, the leverage of the shank, and forward drag will cause the fluke to penetrate into the bottom material.
However, anchors vary anywhere from a heavy weight on a rope to stabilize the fisherman's rowboat, to a twenty-one thousand pound battleship anchor. In former times, the largest anchor, and the one on which most dependency was placed, was the "sheet" anchor. Then came the "bower", the "small bower", the "stream" anchor and the "kedge" anchor.
Except for the rowboat weight anchor, these are all devices acting on basically the same hook principle to hold a ship in a local position. The Brown patent U.S. Pat. No. 3,621,806 has hooks which are housed in a casing to be extended for active duty, and which are drawn back into the housing to free the anchor.
Although the Brown anchor could be activated after it becomes partially buried, there is no active interplay of parts to cause the anchor to retract from the bottom soil of the water course.
SUMMARY OF THE INVENTION
A dynamic anchor which is principally equipped to extract itself from the water course bottom, in contrast to one which is simply a weight and/or hook to drag the bottom and must be withdrawn by brute force.
This invention is composed of a main flat fluke plate, which, when buried in the bottom structure, offers significant holding capability other than by weight.
The anchor is composed of the plate and a secondary anchor which are coupled for longitudinal, relative shifting movement. The secondary anchor is equipped with angled ends which drag over the bottom structure to provide a working reference base. The plate is oppositely characterized. It will offer little resistance to slicing into the water course bottom structure or retracting therefrom, due to its broad flat configuration.
Drive means then are employed to use the secondary anchor to form a firm base to drive the flat plate from the structure of the water course bottom using the resistance of the secondary anchor against longitudinal shifting. Thus the flat plate is forced into the structure by forward pull, such as normal anchor function, and then is withdrawn by activating the cable that draws the two sections into a unitary position. Since the secondary anchor will resist movement, the tendency is for the fluke plate to withdraw and be freed from the bottom structure.
The foregoing has outlined rather broadly the more pertinent and important features of the present invention in order that the detailed description of the invention that follows may be better understood so that the present contribution to the art can be more fully appreciated. Additional features of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
FIG. 1 is a side view of the anchor in position on the bottom of a water course in position to begin a forward thrust;
FIG. 2 is a plan view of the anchor in FIG. 1 with phantom lines showing an advance of the anchor flukes;
FIG. 3 is a side elevation of the anchor;
FIG. 4 is a rear view of the anchor;
FIG. 5 is a top plan view with one of the secondary anchor sections removed to reveal a drive cable plan;
FIG. 6 is a sectional view along the line 6--6 of FIG. 5;
FIG. 7 is a section taken along line 7--7 of FIG. 2; and
FIG. 8 is a schematic of a cable drive system for actuating the dynamic anchor.
Similar reference characters refer to similar parts throughout the several views of the drawings.
DETAILED DESCRIPTION
This invention differs from the construction of conventional anchors wherein there is a hook formation with a long shank that produces the elongation necessary for the fluke of the anchor to impale the water course bottom. It also differs in a major concept in that the fluke of the anchor, once impaled into the bottom structure of a water course, is capable of backing out of the bottom structure without requiring a forcible tearing of the bottom structure. Conventional anchors must tear loose from the overburden whenever a lifting force is applied to the angled stem of the impaled anchor. This invention backs away and pulls the fluke of the anchor out in a clean knifing action.
To accomplish this superior anchoring function, a primary anchor fluke plate 10 is employed as the structure which cuts into the bottom structure in the manner of the fluke in a conventional anchor. A flat plate is driven in a forwardly and downwardly oriented direction to penetrate the water course bottom structure and provide the holding power for the vessel attached to the anchor. In FIG. 6 of the drawing, it will be noted that the forward edge of the plate 10 is tapered to a relatively fine penetrating end.
A conventional anchor is removed from the water course bottom by applying a vertical lifting force on the shank which then produces a component of force causing a rotation of the anchor about the juncture of the shank with the fluke, and thereby tears the anchor from the water course bottom.
This invention provides a retracting action. In theory, a single retractor 12 will suffice, but when the anchor is dropped into the water, there is no way to insure which side of the fluke plate 10 will be downwardly facing against the water course bottom. Accordingly, the retractor is provided as a mirror image double retractor embodying a second retractor 16. Retractor 12 is provided with an angled end 14 and the anchor retractor 16 is provided with an angled end 18. Therefore, as shown in FIG. 1, regardless of which end ultimately faces downwardly, one of the retractors will provide an elevated support for the rear of the anchor and cause a downwardly sloping attitude for the plate 10. This is illustrated best in FIG. 1 of the drawing.
FIG. 1 also illustrates that only one retractor and angled end is required for anchoring action, and the duplicate anchor retractor is provided simply to insure functional placement of the anchor on the bottom of the water course. Hence, it may be referred to as an anchor retractor in a singular when referring to the definition of the invention.
The anchor fluke plate 10 is slotted from the nose end inwardly along the longitudinal axis. This slot is indicated by reference character 20. Also, a similar axial slot 21 opens from the rear end of the plate. The two slots leave a remainder bridge area 22 to thereby unify the resultant bifurcated plate.
The two anchor retractors 12 and 16 are then joined by spacer fastener posts 23 which also act as guides to permit longitudinal shifting movement of the composite anchor retractor 12 and 16 with respect to the bifurcated fluke plate 10.
The illustrated embodiment is obviously subject to vast modifications of means for producing an anchor retractor couple and means to mount the primary fluke plate and the anchor retractor couple together for relative longitudinal shifting movement along a common axis.
Cables 25 and 26 are carried in a sheath 28, at least for a distance from the anchor and sheath 28 is pivotally attached at 30 to the forward end of the composite anchor retractor. The cable 25 exits from the sheath 28 into the space between the retractors 12 and 16 and extends to a turnpost 32 positioned about the point of departure of the angled ends 14 and 18. Cable 25 then returns around post 32 to an anchor point 34 on the bridge 22. In actual practice, the thickness of the bridge 22 is sufficient that a longitudinal bore may preferably be provided through the bridge and the anchored end placed in that bore, but the grounding of the cable at point 34 is more efficiently illustrated as shown in FIG. 5 of the drawing.
Likewise the cable 26 passes through the sheath 28 and exits between the retractors 12 and 16, and proceeds directly to anchor point 35 carried on the bridge 22. Again, a longitudinal bore is preferably provided through the bridge for the terminal end of the cable 26, but is better illustrated for teaching purposes as shown in FIG. 5.
The operation of the structure as thus far described is quite apparent. As the anchor reaches the bottom of the water course, it may be pulled forward by the cable 26 and due to the angulation as shown in FIG. 1, will knife downwardly into the bottom structure until firm anchoring is achieved. When the forward motion of the force applied through the cable 26 causes the anchor to move forwardly, drag on the bottom water course by the anchor end which is against the bottom structure will cause a longitudinal sliding movement of the relative parts to extend the flukes into the water course bottom structure but separate the retractors into a rearwardly extended position as shown in FIG. 5. The forwardly placed relative position is shown in the phantom in FIG. 2 for comparison.
The terminal attachment 30 on the forward end of the retractor will cause a pivoting effect on the anchor as is best shown in FIG. 1. The further back the attachment of the sheath is with respect to the anchor, the more the tendency will be to stand the anchor nose down. Hence it is not desirable to have the retractor couple place the pivot point as far as the center of the total anchor structure. Such extreme placement would likely cause the anchor to completely flip over rather than knife into the structure. Hence, it is desired that the retractor couple permit the maximum leverage point to proceed not more than about one-third rearwardly of the length of the anchor fluke plate 10.
Because of the structure thus described, the anchor will lie angled down from the angled ends of the retractors to the opposite end. The angled ends will provide a drag effect on the water course bottom structure as the forward drive through the cables takes place. This drag will cause the fluke plate to shift to a greater extent than the retractor is shifted by actuation of the means which drives the parts in the shifting movement.
Therefore, release of this new and improved anchor is accompanied by a reversal of the insertion of the fluke into the water course bottom structure rather than tearing and forcibly lifting overburden with the fluke. The natural result is a much more easily retracted anchor without the often experienced snagging on objects difficult to physically displace, especially on smaller boats and anchors.
In certain types of bottom structures, it is conceivable that the anchor could lie completely on its side and require considerable forward drag before righting itself and impaling the water course bottom structure. Therefore, stabilizer arms 36 are riveted at 37 to the rear portion of the anchor fluke plate 10 in those models and variations of the invention where stability is to be assured. Even with stabilizer 36, the plate 10 could possibly angle to one side or the other, but would be operative even if a full upright position were not fully regained.
Although this invention is capable of obvious modifications from the preferred embodiment as illustrated, it has been found that the illustrated structure is capable of manufacturing economies as well as efficient functional capability.
The dynamic anchor is for water craft, and the fluke plate is preferably composed of two lateraly spaced flukes connected into planar relationship, although a solid fluke plate is conceivable with a modified anchor retractor.
The retractor illustrated is carried on the fluke plate by being guided in the forward and rear slots described, and the cables as illustrated in this drive, establish a reciprocal shifting capability between a first position wherein the plate and retractor are essentially telescoped together, and an extended position wherein the angled ends of the retractor are positioned well behind the end of the fluke plate.
The cable connection around the turnpost 32 produces a reaction drive of the plate and retractor and moving the parts from the extended to the telescoped position. When the anchor is first introduced into the water course bottom, a straight-forward drag is placed on the anchor and the angled ends of the retractor drag the bottom course and the retractor is not restricted in position with respect to the fluke. Hence the fluke plate will advance with respect to the retractor.
However, when removal of the anchor is desired, and the cable 25 is actuated, a reaction drive of the plate and retractor is introduced in moving the parts from the extended to the telescoped position, whereby the part with the greater resistance to movement will drive the mated member. In this case, when the anchor is on the bottom structure, the angled ends of the retractor will dig into the anchor structure and enhance the capability of the retractor to cause the fluke plate retraction from the anchored condition. It is not necessary that the fluke plate be entirely retracted if the retractor angled end is not capable of biting into the water course sufficiently, it will nevertheless cause some retraction of the fluke plate and materially enhance the capability of lifting the fluke plate from the overburden remaining.
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A dynamic anchor composed of two laterally positioned anchor flukes for facile penetration into the bottom structure of a water course, and a retractor to withdraw the flukes from the bottom. The retractor is mounted for relative reciprocal movement along the longitudinal axis of between the flukes. Two anchor cables are employed. The first cable is connected directly to the fluke plate and is used to anchor the craft. By pulling the first cable, the fluke plate is pulled forward to dig in and hold the craft. The second cable is reaved around a pivot carried by the retractor and is secured to the fluke plate. Thus when the second cable is pulled in, there is created a force to pull the retractor and fluke plate in opposite directions in order to cause the flukes to be removed from the water course bottom.
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FIELD OF THE INVENTION
This invention relates to novel reactive azo dyes.
BACKGROUND OF THE INVENTION
Up to now, the dyeing of cellulose fiber was carried out with a reactive dye at pH 10 and over in the presence of an acid capturing agent such as sodium carbonate, potassium carbonate, sodium hydroxide and the like and an electrolyte such as sodium chloride, sodium sulfate and the like at a temperature of about 100° C. and below.
However, since in recent years the demand for the mixed spinning of cellulose with other fibers, especially polyester fiber, is increasing, it is necessary to employ dyes and dyeing conditions suitable for cellulose and polyester fibers respectively, for dyeing of such cellulose/polyester mixed fiber (hereinafter merely referred to as c/p fiber). This is because the dye and dyeing conditions for polyester fiber are considerably different from those for cellulose fiber. That is, it is necessary to use a disperse dye for the dyeing of polyester fiber at a temperature of about 130° C.
If the c/p fiber above is dyed in the same process at once, for example, the dyeing has to be carried out by using two different dyes and by means of a combination of a reactive dye and a disperse dye, but it has some problems. For example, in order to exhaust the cellulose fiber part fully with a reactive dye, the pH value has to be kept at 10 and over by the addition of an acid capturing agent. However, the presence of the acid capturing agent accelerates the decomposition of the disperse dye to give poor exhaustion of the polyester fiber part. On the other hand, a high temperature condition is required in order that the polyester fiber part is exhausted by a disperse dye. However, the hydrolysis of the disperse dye is accelerated under the high pH value stated above and the high temperature, and thus, exhaustion of the cellulose fiber becomes extremely inferior. Accordingly, the two-bath method, that is, one of cellulose or polyester fiber is dyed first and then the other is dyed by another bath, has been generally employed for dyeing of c/p fiber.
SUMMARY OF THE INVENTION
The object of this invention is to provide novel reactive azo dyes being able to dye cellulose fiber under the condition and pH value which are employed for dyeing of polyester fiber with a disperse dye.
That is, this invention relates to reactive azo dyes represented by the general formula (I) or (II): ##STR6## wherein M is a hydrogen atom or an alkali metal, R 1 is a hydrogen atom, a chlorine atom, a lower alkyl group, a lower alkoxy group, a nitro group or a carboxyl group, R 2 and R 8 are a lower alkyl group, a lower alkoxy group or a sulfonic acid group, R 3 , R 7 and R 9 are a hydrogen atom, a lower alkyl group, a lower alkoxy group, an acetylamino group or a sulfonic acid group, R 4 and R 5 are a hydrogen atom, a methyl group, a methoxy group or a sulfonic acid group, R 6 is a hydrogen atom, a lower alkyl group, a lower alkoxy group or a sulfonic acid group, Z 1 is a chlorine atom, a fluorine atom, an aliphatic or aromatic amino residual group, a methoxy group or a phenoxy group, Z 2 is the same one as Z 1 when Z 3 is ##STR7## Z 2 is a chlorine atom or a fluorine atom when Z 3 is an aliphatic amino residual group, an aromatic amino residual group except ##STR8## a methoxy group or a phenoxy group, Z 3 is ##STR9## an aliphatic amino residual group, an aromatic amino residual group except ##STR10## a methoxy group or a phenoxy group, m is 1, 2 or 3, m' is 2 or 3, n is 0 or 1, the benzene rings A, B and C may be naphthalene rings.
DETAILED DESCRIPTION OF THE INVENTION
In the reactive azo dyes of this invention represented by the general formula (I) or (II), a sodium and potassium can be employed as an alkali metal represented by M. As lower alkyl and alkoxy groups represented by R 1 , R 2 , R 3 , R 6 , R 7 , R 8 and R 9 , alkyl and alkoxy groups having 1 to 4 carbon atoms can be illustrated. As aliphatic or aromatic amino residual groups represented by Z 1 , Z 2 and Z 3 , an amino group, an alkylamino group having 1 to 4 carbon atoms, an ethanolamino group, a β-cyanoethylamino group, a β-sulfoethylamino group, a glycine residual group, an anilino group and an anilino group substituted with a sulfo group, a chlorine atom, a lower alkyl group, a lower alkoxy group, a nitro group and a carboxyl group can be illustrated.
The reactive azo dye represented by the general formula (I) stated above can be prepared by the following procedure: For example, the usual diazotization and coupling can be carried out with the compound represented by the general formulae (III) and (IV): ##STR11## to give the monoazo compound represented by the general formula (V). ##STR12##
On the other hand, the compounds represented by the general formulae (VI), (VII) and (VIII): ##STR13## can be condensed each other in an aqueous medium in any order to prepare the compound represented by the general formula (IX). ##STR14##
Then, the monoazo compound of the general formula (V) can be converted to the diazonium compound by the usual diazotization, and the diazonium compound is coupled with the compound represented by the formula (IX) to obtain the reactive azo dyes of the general formula (I) stated above.
The reactive trisazo dyes represented by the general formula (II) stated above involve two kinds of the compounds represented by the general formulae (II-1) and (II-2). ##STR15## wherein X is a chlorine atom or a fluorine atom, Y is an aliphatic amino residual group, an aromatic amino residual group except ##STR16## a methoxy group or a phenoxy group, and R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , M Z 1 , m' and n are the same meanings as defined hereinbefore.
The trisazo compound represented by the general formula (II-1) stated above can be prepared by the following procedure: For example, the usual diazotization and coupling can be carried out twice with the compounds represented by the general formulae (X), (XI) and (XII): ##STR17## to give the disazo compound represented by the general formula (XIII). ##STR18##
Then, the disazo compound of the general formula (XIII) stated above can be converted to the diazonium compound in water-acetic acid medium by diazotization, and then the diazonium compound obtained is coupled with the compound represented by the general formula (IX) stated above to obtain the trisazo compound of the general formula (II-1) stated above.
Also, the trisazo compound represented by the general formula (II-2) can be prepared by the following procedure: For example, the compounds represented by the following formulae (XIV), (XV) and (XVI): ##STR19## can be condensed each other in an aqueous medium in any order to prepare the compound represented by the general formula (XVII): ##STR20##
Then, the disazo compound of the general formula (XIII) stated above can be converted to the diazonium compound in water-acetic acid medium by diazotization, and the diazonium compound obtained can be coupled with the compound represented by the general formula (XVII) stated above to obtain the trisazo compound of the general formula (II-2) stated above.
As fibers which can be dyed with reactive azo dyes of this invention, cellulose fiber such as cotton, viscose rayon, cupra ammonium rayon and hemp, can be illustrated. Also, cellulose fiber in mixed cellulose fibers with polyester, triacetate, polyacrylonitrile, polyamido, wool, silk and the like can be excellently dyed.
In dyeing method for fibers using reactive azo dyes of this invention, dyeing can be carried out by adding a dyestuff which is needful for dyeing of fibers other than cellulose, e.g., a disperse dye and the like stated in Color Index (Third Edition), into the bath at the same time.
In case of dyeing of cellulose fibers with a reactive azo dye of this invention, for example, a bath can be prepared by adding a reactive azo dye represented by the general formula (I) or (II), a buffer which is required to keep the bath at pH 5 to 10 (for example, in general, about 0.5 to 5.0 g of an acid such as carbonic acid, phosphonic acid, citric acid and the like, a sodium salt or a potassium salt with these acid or a mixture thereof per liter), and if necessary, by adding an electrolyte (in general, about 1 to 150 g of sodium chloride, sodium sulfate and the like per liter), and a cellulose fiber is put in the bath, and then dyeing can be carried out by heating the bath for 30 to 50 minutes at temperature of 100° to 150° C.
When mixed fiber and knitted goods made by spinning or knitting cellulose fiber with other fibers, for example, polyester fiber, are dyed, the cellulose and polyester fibers can be dyed at the same time by adding a reactive azo dye represented by the general formula (I) or (II) and a disperse dye stated in Color Index into the bath above according to one-bath one-process method.
Furthermore, in the case of dyeing the mixed fiber and knitted goods above, the one-bath two-process method heretofore in use, that is, either fiber is dyed and then the other fiber is dyed, may be applied to dye cellulose and other fibers in each bath by combination of dyeing method using a reactive azo dye of this invention with dyeing method for other fibers other than cellulose.
The method of this invention is described in detail later by means of examples but is not limited to the examples.
EXAMPLE 1
10 g of unmercerized cotton knitted goods are put in a path at pH 7 which is prepared by adding 0.2 g of the reactive azo dye in free form represented by the following formula: ##STR21## 16 g of sodium sulfate, 0.4 g of Na 2 HPO 4 .12H 2 O as a buffer and 0.1 g of KH 2 PO 4 into 200 ml of water, and the bath is heated to 120° C. for 30 minutes. After dyeing for 60 minutes at the same temperature, the goods dyed are washed with water, soaped, washed with water and dried to give the dyed goods in clear red. The degree of exhaustion of the present dye is very excellent, and the color of dyed goods obtained is extreme density. Each of their light fastness, fastness to chlorine and fastness to light perspiration is fine.
Further, the reactive azo dye used in the present example can be prepared by the following procedure: The monoazo compound represented by the following formula: ##STR22## can be prepared by the usual diazotization and coupling of 30.3 g of 2-naphthylamine-4,8-disulfonic acid with 17.3 g of 1-aminobenzene-2-sulfonic acid. On the other hand, after condensing of 23.9 g of 2-amino-5-hydroxynaphthalene-7-sulfonic acid with 18.5 g of cyanuric chloride at 5° C. below, the compound obtained is further condensed with 28.1 g of sulfonic acid ester of 4-(β-hydroxyethyl)sulfonylaniline at 30° to 35° C. to prepare the compound represented by the following formula: ##STR23## and then to this reaction solution, the diazo solution prepared from the monoazo compound stated above by the usual diazotization is added. After coupling, the reaction mixture is salted out with potassium chloride to obtain the reactive disazo dye stated above.
EXAMPLE 2
10 g of undyed silk cotton knitted goods are put in a bath which is prepared by adding 0.2 g of reactive azo dye in free form represented by the following formula: ##STR24## 16 g of sodium sulfate, 0.5 g of Na 2 HPO 4 .12H 2 O as a buffer and 0.02 g of KH 2 PO 4 into 200 ml of water, the bath is heated to 130° C. for 30 minutes. After dyeing for 30 minutes at the same temperature, the goods dyed are washed with water, soaped, washed with water and dried to give the dyed goods in deep blue. The pH of the bath is maintained at 8 from the beginning to the end of dyeing. The color of the dyed goods is extreme density, and each of their light fastness, fastness to chlorine and fastness to light perspiration is fine.
Further, the reactive azo dye used in the present example can be prepared by the following procedure: The monoazo compound represented by the following formula: ##STR25## can be prepared by the usual diazotization and coupling of 25.3 g of aniline-2,5-disulfonic acid with 13.7 g of 2-methoxy-5-methylaniline. On the other hand, after condensing of 23.9 g of 2-amino-5-hydroxynaphthalene-7-sulfonic acid with 18.5 g of cyanuric chloride at 5° C. below, the compound obtained is further condensed with 28.1 g of sulfonic acid ester of 3-(β-hydroxyethyl)sulfonylaniline at 30° to 35° C. to prepare the compound represented by the following formula: ##STR26## and then to this reaction solution, the diazo solution prepared from the monoazo compound stated above by the usual diazotization is added. After coupling, the reaction mixture is dried with spray to give the reactive disazo dye used in the present example.
EXAMPLE 3
10 g of mixed fiber of polyester with cotton (50:50) are put in a bath which is prepared by adding 0.2 g of the reactive dye in free form represented by the following formula: ##STR27## 0.2 g of the monoazo dye represented by the following formula: ##STR28## 12 g of sodium sulfate, 0.4 g of Na 2 HPO 4 .12H 2 O as a buffer and 0.1 g of KH 2 PO 4 into 200 ml of water, the bath is heated to 130° C. for 30 minutes. After dyeing for 60 minutes at the same temperature, the goods dyed are washed with water, soaped, washed with water and dried to give the dyed goods in blue having a fine color equality. The pH of the bath is maintained at 8 from the beginning to the end of dyeing. Their exhaustibility is very fine, and the color of the dyed goods is extreme density. Each of their light fastness, fastness to chlorine and fastness to light perspiration is fine.
Still more, the reactive disazo dye used in the present example can be prepared by the following procedure: The monoazo compound represented by the following formula: ##STR29## can be prepared by the usual diazotization and coupling of 38.3 g of 2-naphthylamine-3,6,8-trisulfonic acid with 13.7 g of 2-methoxy-5-methylaniline. On the other hand, after condensing of 31.9 g of 1-amino-8-hydroxynaphthalene-3,6-disulfonic acid with 18.5 g of cyanuric chloride at 5° C. below, the compound obtained is further condensed with 28.1 g of sulfonic acid ester of 3-(β-hydroxyethyl)sulfonylaniline to prepare the compound represented by the following formula: ##STR30## and then to this reaction solution, diazo solution prepared from the monoazo compound stated above by the usual diazotization is added. After coupling, the reaction mixture is salted out with potassium chloride to obtain the reactive dye stated above.
EXAMPLE 4
By a similar method to Example 1 cottons are dyed with reactive disazo dyes represented by the general formula (I), and results obtained are shown in Table 1.
TABLE 1 ##STR31## [I] No. ##STR32## ##STR33## ##STR34## Z.sup.1 ##STR35## color of cotton (water)λmax (nm)4-1 ##STR36## ##STR37## ##STR38## Cl ##STR39## violet 564 4-2 ##STR40## ##STR41## ##STR42## Cl ##STR43## reddish blue 575 4-3 ##STR44## ##STR45## ##STR46## ##STR47## ##STR48## reddish violet 535 4-4 ##STR49## ##STR50## ##STR51## Cl ##STR52## blue 590 4-5 ##STR53## ##STR54## ##STR55## F ##STR56## violet 560 4-6 ##STR57## ##STR58## ##STR59## NH.sub.2 ##STR60## violet 552 4-7 ##STR61## ##STR62## ##STR63## NHCH.sub.2 CH.sub.2 SO.sub.3 H ##STR64## bluish red 523 4-8 ##STR65## ##STR66## ##STR67## NHCH.sub.2 COOH ##STR68## red 520 4-9 ##STR69## ##STR70## ##STR71## NH.sub.2 ##STR72## violet 561 4-10 ##STR73## ##STR74## ##STR75## Cl ##STR76## violet 561 4-11 ##STR77## ##STR78## ##STR79## OCH.sub.3 ##STR80## blue 590 4-12 ##STR81## ##STR82## ##STR83## ##STR84## ##STR85## violet 563 4-13 ##STR86## ##STR87## ##STR88## F ##STR89## bluish red 526 4-14 ##STR90## ##STR91## ##STR92## Cl ##STR93## blue 578 4-15 ##STR94## ##STR95## ##STR96## NHC.sub.2 H.sub.4 OH ##STR97## bluish red 525 4-16 ##STR98## ##STR99## ##STR100## NHC.sub.2 H.sub.4 CH ##STR101## violet 565 4-17 ##STR102## ##STR103## ##STR104## ##STR105## ##STR106## bluish red 524 4-18 ##STR107## ##STR108## ##STR109## ##STR110## ##STR111## bluish red 534 4-19 ##STR112## ##STR113## ##STR114## ##STR115## ##STR116## blue 585 4-20 ##STR117## ##STR118## ##STR119## ##STR120## ##STR121## violet 560 4-21 ##STR122## ##STR123## ##STR124## ##STR125## ##STR126## blue 588 4-22 ##STR127## ##STR128## ##STR129## ##STR130## ##STR131## violet 560 4-23 ##STR132## ##STR133## ##STR134## ##STR135## ##STR136## bluish red 525 4-24 ##STR137## ##STR138## ##STR139## Cl ##STR140## blue 575
EXAMPLE 5
10 g of undyed silk cotton knitted goods are put in a bath which is prepared by adding 0.2 g of the reactive trisazo dye in free form represented by the following formula: ##STR141## 16 g of sodium sulfate, 0.4 g of Na 2 HPO 4 .12H 2 O as a buffer and 0.1 g of KH 2 PO 4 into 200 ml of water, the bath is heated to 120° C. for 30 minutes. After dyeing for 60 minutes at the same temperature, the goods dyed are washed with water, soaped, washed with water and dried to give the dyed goods in greenish deep blue. The degree of their exhaustion is very excellent, and the color of the dyed goods obtained is extreme density. Each of their light fastness, fastness to chlorine and fastness to light perspiration is fine.
Further, the trisazo compound used in the present example can be prepared by the following procedure: The disazo compound represented by the following formula: ##STR142## can be prepared by the usual diazotization and coupling of 13.7 g of 2-methoxy-5-methylaniline with the monoazo compound prepared by the usual diazotization and coupling of 38.3 g of 2-naphthylamine-3,6,8-trisulfonic acid with 13.7 g of 2-methoxy-5-methylaniline. On the other hand, after condensing of 31.9 g of 1-amino-8-hydroxynaphthalene-3,6-disulfonic acid with 18.5 g of cyanuric chloride at 5° C. below, the compound obtained is further condensed with 28.1 g of sulfonic acid ester of 3-(β-hydroxyethyl)sulfonylaniline at 30° to 35° C. to prepare the compound represented by the formula: ##STR143## and then to this reaction solution, the diazo solution prepared from the disazo compound stated above by diazotization in water-acetic acid medium is added. After coupling, the reaction mixture is salted out with potassium chloride to obtain the trisazo compound stated above.
EXAMPLE 6
10 g of undyed silk cotton knitted goods are put in a bath which is prepared by adding 0.2 g of the trisazo compound in free form represented by the following formula: ##STR144## 16 g of sodium sulfate, 0.5 g of Na 2 HPO 4 .12H 2 O as a buffer and 0.02 g of KH 2 PO 4 into 200 ml of water, and the bath is heated to 130° C. for 30 minutes. After dyeing for 30 minutes at the same temperature, the goods dyed are washed with water, soaped, washed with water and dried to give the dyed goods in deep blue. The pH of the bath is maintained at 8 from the beginning to the end of dyeing. The color of the dyed goods is extreme density and each of their light fastness, fastness to chlorine and fastness to light perspiration is fine.
Further, the trisazo compound used in the present example can be prepared by the following procedure: The disazo compound represented by the following formula: ##STR145## can be prepared by the usual diazotization and coupling of 18.0 g of 2-methoxy-5-acetylaminoaniline with the monoazo compound prepared by the usual diazotization and coupling of 30.3 g of 2-naphthylamine-4,8-disulfonic acid and 22.3 g of 1-naphthylamine-7-sulfonic acid. On the other hand, after condensing of 23.9 g of 2-amino-5-hydroxynaphthalene-7-sulfonic acid with 18.4 g of cyanuric chloride, the compound obtained is further condensed with 28.1 g of sulfonic acid ester 3-(β-hydroxyethyl)sulfonylaniline to prepare the compound represented by the following formula: ##STR146## and then after diazotization and coupling of this compound with the disazo compound prepared previously, the reaction mixture is dried with spray to obtain the trisazo compound used in the present example.
EXAMPLE 7
10 g of mixed fiber of polyester with cotton (50:50) are put in a bath which is prepared by adding 0.2 g of the trisazo dye in free form represented by the following formula: ##STR147## 0.2 g of the monoazo dye represented by the following formula: ##STR148## 12 g of sodium sulfate, 0.4 g of Na 2 HPO 4 .12H 2 O as a buffer and 0.1 g of KH 2 PO 4 into 200 ml of water, the bath is heated to 130° C. for 30 minutes. After dyeing for 60 minutes at the same temperature, the goods dyed are washed with water, soaped, washed with water and dried to give the dyed goods in deep blue having a fine color equality. The pH of the bath is maintained at 8 from the beginning to the end of dyeing. Their exhaustibility is very fine, the color of the dyed goods is extreme density. Each of their light fastness, fastness to chlorine and fastness to light perspiration is fine.
Further, the trisazo compound used in the present example can be prepared by a similar manner to Example 6 except that 13.7 g of 2-methoxy-5-methylaniline is used in place of 18.0 g of 2-methoxy-5-acetylaminoaniline used in Example 6.
EXAMPLE 8
By a similar manner to Example 5 cottons are dyed with the trisazo compounds represented by the general formula (II-1), and the results obtained are shown in Table 2.
TABLE 2 ##STR149## (II-1) No. ##STR150## ##STR151## ##STR152## ##STR153## Z.sup.1 ##STR154## cottoncolor of (nm)(water) λmax 8-1 ##STR155## ##STR156## ##STR157## ##STR158## Cl ##STR159## deep blue 566 8-2 ##STR160## ##STR161## ##STR162## ##STR163## Cl ##STR164## greenishdeep blue 594 8-3 ##STR165## ##STR166## ##STR167## ##STR168## Cl ##STR169## greenishdeep blue 586 8-4 ##STR170## ##STR171## ##STR172## ##STR173## NH.sub.2 ##STR174## greenishdeep blue 584 8-5 ##STR175## ##STR176## ##STR177## ##STR178## NHC.sub.2 H.sub.4 SO.sub.3 H ##STR179## deep blue 572 8-6 ##STR180## ##STR181## ##STR182## ##STR183## Cl ##STR184## reddishdeep blue 561 8-7 ##STR185## ##STR186## ##STR187## ##STR188## F ##STR189## greenishdeep blue 586 8-8 ##STR190## ##STR191## ##STR192## ##STR193## Cl ##STR194## reddishdeep blue 562 8-9 ##STR195## ##STR196## ##STR197## ##STR198## NHCH.sub.2 COOH ##STR199## green 595 8-10 ##STR200## ##STR201## ##STR202## ##STR203## ##STR204## ##STR205## deep blue 565 8-11 ##STR206## ##STR207## ##STR208## ##STR209## Cl ##STR210## deep blue 564 8-12 ##STR211## ##STR212## ##STR213## ##STR214## Cl ##STR215## green 602 8-13 ##STR216## ##STR217## ##STR218## ##STR219## ##STR220## ##STR221## deep blue 563 8-14 ##STR222## ##STR223## ##STR224## ##STR225## NHC.sub.2 H.sub.4 OH ##STR226## green 601 8-15 ##STR227## ##STR228## ##STR229## ##STR230## Cl ##STR231## deep blue 570 8-16 ##STR232## ##STR233## ##STR234## ##STR235## Cl ##STR236## greenishdeep blue 588 8-17 ##STR237## ##STR238## ##STR239## ##STR240## Cl ##STR241## greenishdeep blue 588 8-18 ##STR242## ##STR243## ##STR244## ##STR245## Cl ##STR246## reddishdeep blue 560 8-19 ##STR247## ##STR248## ##STR249## ##STR250## Cl ##STR251## deep blue 568 8-20 ##STR252## ##STR253## ##STR254## ##STR255## Cl ##STR256## reddishdeep blue 566 8-21 ##STR257## ##STR258## ##STR259## ##STR260## Cl ##STR261## deep blue 576 8-22 ##STR262## ##STR263## ##STR264## ##STR265## Cl ##STR266## greenishdeep blue 582 8-23 ##STR267## ##STR268## ##STR269## ##STR270## Cl ##STR271## deep blue 564 8-24 ##STR272## ##STR273## ##STR274## ##STR275## Cl ##STR276## greenishdeep blue 578 8-25 ##STR277## ##STR278## ##STR279## ##STR280## Cl ##STR281## greenishdeep blue 580 8-26 ##STR282## ##STR283## ##STR284## ##STR285## Cl ##STR286## greenishdeep blue 585 8-27 ##STR287## ##STR288## ##STR289## ##STR290## NHC.sub.4 H.sub.9 (n) ##STR291## greenishdeep blue 586 8-28 ##STR292## ##STR293## ##STR294## ##STR295## ##STR296## ##STR297## deep blue 568 8-29 ##STR298## ##STR299## ##STR300## ##STR301## Cl ##STR302## deep blue 579 8-30 ##STR303## ##STR304## ##STR305## ##STR306## F ##STR307## deep blue 562 8-31 ##STR308## ##STR309## ##STR310## ##STR311## Cl ##STR312## deep blue 556 8-32 ##STR313## ##STR314## ##STR315## ##STR316## ##STR317## ##STR318## deep blue 552 8-33 ##STR319## ##STR320## ##STR321## ##STR322## Cl ##STR323## deep blue 562 8-34 ##STR324## ##STR325## ##STR326## ##STR327## Cl ##STR328## green 590 8-35 ##STR329## ##STR330## ##STR331## ##STR332## Cl ##STR333## deep blue 586 8-36 ##STR334## ##STR335## ##STR336## ##STR337## ##STR338## ##STR339## deep blue 560 8-37 ##STR340## ##STR341## ##STR342## ##STR343## Cl ##STR344## deep blue 576 8-38 ##STR345## ##STR346## ##STR347## ##STR348## NHC.sub.2 H.sub.4 CN ##STR349## green 593 8-39 ##STR350## ##STR351## ##STR352## ##STR353## F ##STR354## green 602 8-40 ##STR355## ##STR356## ##STR357## ##STR358## ##STR359## ##STR360## deep blue 567 8-41 ##STR361## ##STR362## ##STR363## ##STR364## Cl ##STR365## deep blue 562 8-42 ##STR366## ##STR367## ##STR368## ##STR369## ##STR370## ##STR371## reddishdeep blue 560 8-43 ##STR372## ##STR373## ##STR374## ##STR375## Cl ##STR376## deep blue 590 8-44 ##STR377## ##STR378## ##STR379## ##STR380## Cl ##STR381## reddishdeep blue 568 8-45 ##STR382## ##STR383## ##STR384## ##STR385## ##STR386## ##STR387## greenishdeep blue 595 8-46 ##STR388## ##STR389## ##STR390## ##STR391## NHC.sub.3 H.sub.7 (i) ##STR392## deep blue 585 8-47 ##STR393## ##STR394## ##STR395## ##STR396## Cl ##STR397## deep blue 563
EXAMPLE 9
10 g of undyed silk cotton knitted goods are put in a bath at pH 7 which is prepared by adding 0.2 g of the trisazo dye in free form represented by the following formula: ##STR398## 16 g of sodium sulfate, 0.4 g of Na 2 HPO 4 .12H 2 O as a buffer and 0.1 g of KH 2 PO 4 into 200 ml of water, and the bath is heated to 120° C. for 30 minutes. After dyeing for 60 minutes at the same temperature, the goods dyed are washed with water, soaped, washed with water and dried to give the dyed goods in greenish deep blue. Their exhaustibility is very fine, the color of the dyed goods is extreme density. Each of their light fastness, fastness to chlorine and fastness to light perspiration is fine.
Further, the trisazo compound used in the present example can be prepared by the following procedure: The disazo compound represented by the following formula: ##STR399## can be prepared by the usual diazotization and coupling of 13.7 g of 2-methoxy-5-methylaniline with the monoazo compound prepared by the diazotization and coupling of 38.3 g of 2-naphthylamine-3,6,8-trisulfonic acid with 13.7 g of 2-methoxy-5-methylaniline. On the other hand, after condensing of 31.9 g of 1-amino-8-hydroxynaphthalene-3,6-disulfonic acid with 13.5 g of cyanuric fluoride at 0° C. below, the compound obtained is condensed with 17.3 g of 4-aminobenzenesulfonic acid at 20° C. to prepare the compound represented by the following formula: ##STR400## and then to this reaction solution, the diazo solution prepared from the disazo compound stated above by the usual diazotization in water-acetic acid medium is added. After coupling, the reaction mixture is salted out with potassium chloride to obtain the trisazo compound stated above.
EXAMPLE 10
10 g of undyed silk cotton knitted goods are put in a bath which is prepared by adding 0.2 g of the trisazo compound in free form represented by the following formula: ##STR401## 16 g of sodium sulfate, 0.5 g of Na 2 HPO 4 .12H 2 O as a buffer and 0.02 g of KH 2 PO 4 into 200 ml of water, the bath is heated to 130° C. for 30 minutes. After dyeing for 30 minutes at the same temperature, the goods dyed are washed with water, soaped, washed with water and dried to give the dyed goods in deep blue. The pH of the bath is maintained at 8 from the beginning to the end of dyeing. The color of the dyed goods is extreme density. Each of their light fastness, fastness to chlorine and fastness to light perspiration is fine.
Further, the trisazo compound used in the present example can be prepared by the following procedure: The disazo compound represented by the following formula: ##STR402## can be prepared by the usual diazotization and coupling of 18.0 g of 2-methoxy-5-acetylaminoaniline with the monoazo compound prepared by the usual diazotization and coupling of 25.3 g of aniline-2,5-disulfonic acid with 13.7 g of 2-methoxy-5-methylaniline. On the other hand, after condensing of 23.9 g of 2-amino-5-hydroxynaphthalene-7-sulfonic acid with 13.5 g of cyanuric fluoride, the compound obtained is further condensed with 17.3 g of 4-aminobenzenesulfonic acid to prepare the compound represented by the following formula: ##STR403## and then after diazotization and coupling of this compound with the disazo compound obtained previously, the reaction mixture is dried with spray to obtain the trisazo compound used in the present example.
EXAMPLE 11
10 g of mixed fiber of polyester with cotton (50:50) are put in a bath which is prepared by adding 0.2 g of the trisazo dye in free form represented by the following formula: ##STR404## 0.2 g of the monoazo dye represented by the following formula: ##STR405## 12 g of sodium sulfate, 0.4 g of Na 2 HPO 4 .12H 2 O as a buffer and 0.1 g of KH 2 PO 4 into 200 ml water, the bath is heated to 130° C. for 30 minutes. After dyeing for 60 minutes at the same temperature, the goods dyed are washed with water, soaped, washed with water and dried to give the dyed goods in deep blue having a fine color equality. The pH of the bath is maintained at 8 from the beginning to the end of dyeing. Their exhaustibility is very excellent and the color of the dyed goods is extreme density. Each of their light fastness, fastness to chlorine and fastness to light perspiration is fine.
Further, the trisazo compound used in the present example can be prepared by a similar manner to Example 10 except that 22.3 g of 1-naphthylamine-7-sulfonic acid is used in place of 13.7 g of 2-methoxy-5-methylaniline used in Example 10.
EXAMPLE 12
By a similar manner to Example 9 cottons are dyed with the trisazo compounds represented by the general formula (II-2), and the results obtained are shown in Table 3.
TABLE 3 ##STR406## No. ##STR407## ##STR408## ##STR409## ##STR410## X Y cottoncolor of (nm)(water)λmax 12-1 ##STR411## ##STR412## ##STR413## ##STR414## Cl ##STR415## deep blue 571 12-2 ##STR416## ##STR417## ##STR418## ##STR419## Cl ##STR420## greenishdeep blue 604 12-3 ##STR421## ##STR422## ##STR423## ##STR424## Cl ##STR425## greenishdeep blue 591 12-4 ##STR426## ##STR427## ##STR428## ##STR429## F ##STR430## greenishdeep blue 594 12-5 ##STR431## ##STR432## ##STR433## ##STR434## F ##STR435## deep blue 582 12-6 ##STR436## ##STR437## ##STR438## ##STR439## Cl ##STR440## reddishdeep blue 566 12-7 ##STR441## ##STR442## ##STR443## ##STR444## F ##STR445## greenishdeep blue 596 12-8 ##STR446## ##STR447## ##STR448## ##STR449## Cl ##STR450## reddishdeep blue 567 12-9 ##STR451## ##STR452## ##STR453## ##STR454## F NH.sub.2 green 605 12-10 ##STR455## ##STR456## ##STR457## ##STR458## F NHC.sub.4 H.sub.9 (n) deep blue 575 12-11 ##STR459## ##STR460## ##STR461## ##STR462## Cl ##STR463## deep blue 569 12-12 ##STR464## ##STR465## ##STR466## ##STR467## Cl ##STR468## green 607 12-13 ##STR469## ##STR470## ##STR471## ##STR472## F ##STR473## deep blue 573 12-14 ##STR474## ##STR475## ##STR476## ##STR477## F NHCH.sub.2 COOH green 607 12-15 ##STR478## ##STR479## ##STR480## ##STR481## F ##STR482## deep blue 580 12-16 ##STR483## ##STR484## ##STR485## ##STR486## Cl ##STR487## greenishdeep blue 593 12-17 ##STR488## ##STR489## ##STR490## ##STR491## Cl ##STR492## greenishdeep blue 592 12-18 ##STR493## ##STR494## ##STR495## ##STR496## F ##STR497## reddishdeep blue 570 12-19 ##STR498## ##STR499## ##STR500## ##STR501## F ##STR502## deep blue 579 12-20 ##STR503## ##STR504## ##STR505## ##STR506## Cl NHCH.sub.2 CH.sub.2 SO.sub.3 H reddishdeep blue 571 12-21 ##STR507## ##STR508## ##STR509## ##STR510## Cl ##STR511## deep blue 580 12-22 ##STR512## ##STR513## ##STR514## ##STR515## Cl ##STR516## greenishdeep blue 586 12-23 ##STR517## ##STR518## ##STR519## ##STR520## F OCH.sub.3 deep blue 572 12-24 ##STR521## ##STR522## ##STR523## ##STR524## F ##STR525## greenishdeep blue 585 12-25 ##STR526## ##STR527## ##STR528## ##STR529## Cl ##STR530## greenishdeep blue 586 12-26 ##STR531## ##STR532## ##STR533## ##STR534## Cl ##STR535## greenishdeep blue 589 12-27 ##STR536## ##STR537## ##STR538## ##STR539## F ##STR540## greenishdeep blue 593 12-28 ##STR541## ##STR542## ##STR543## ##STR544## F ##STR545## deep blue 575 12-29 ##STR546## ##STR547## ##STR548## ##STR549## Cl ##STR550## deep blue 583 12-30 ##STR551## ##STR552## ##STR553## ##STR554## F NHC.sub.2 H.sub.4 OH deep blue 572 12-31 ##STR555## ##STR556## ##STR557## ##STR558## Cl NHC.sub.2 H.sub.4 CN deep blue 561 12-32 ##STR559## ##STR560## ##STR561## ##STR562## F ##STR563## deep blue 562 12-33 ##STR564## ##STR565## ##STR566## ##STR567## Cl OCH.sub.3 deep blue 571 12-34 ##STR568## ##STR569## ##STR570## ##STR571## Cl ##STR572## deep blue 593 12-35 ##STR573## ##STR574## ##STR575## ##STR576## F ##STR577## deep blue 589 12-36 ##STR578## ##STR579## ##STR580## ##STR581## F ##STR582## deep blue 568 12-37 ##STR583## ##STR584## ##STR585## ##STR586## Cl ##STR587## deep blue 581 12-38 ##STR588## ##STR589## ##STR590## ##STR591## F NHC.sub.2 H.sub.5 deep blue 598 12-39 ##STR592## ##STR593## ##STR594## ##STR595## F NH.sub.2 deep blue 612 12-40 ##STR596## ##STR597## ##STR598## ##STR599## F ##STR600## deep blue 575 12-41 ##STR601## ##STR602## ##STR603## ##STR604## Cl ##STR605## deep blue 567 12-42 ##STR606## ##STR607## ##STR608## ##STR609## F NHC.sub.2 H.sub.4 SO.sub.3 H reddishdeep blue 570
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.
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Reactive azo dyes represented by the general formula (I) or (II): ##STR1## wherein M is a hydrogen atom or an alkali metal, R 1 is a hydrogen atom, a chlorine atom, a lower alkyl group, a lower alkoxy group, a nitro group or a carboxyl group, R 2 and R 8 are a lower alkyl group, a lower alkoxy group or a sulfonic acid group, R 3 , R 7 and R 9 are a hydrogen atom, a lower alkyl group, a lower alkoxy group, an acetylamino group or a sulfonic acid group, R 4 and R 5 are a hydrogen atom, a methyl group, a methoxy group or a sulfonic acid group, R 6 is a hydrogen atom, a lower alkyl group, a lower alkoxy group or a sulfonic acid group, Z 1 is a chlorine atom, a fluorine atom, an aliphatic or an aromatic amino residual group, a methoxy group or a phenoxy group, Z 2 is the same one as Z 1 when Z 3 is ##STR2## Z 2 is a chlorine atom or a fluorine atom when Z 3 is an aliphatic amino residual group, an aromatic amino residual group except ##STR3## a methoxy group or a phenoxy group, Z 3 is ##STR4## an aliphatic amino residual group, an aromatic amino residual group except ##STR5## a methoxy group, or a phenoxy group, m is 1, 2 or 3, m' is 2 or 3, n is 0 or 1, and the benzene rings A, B and C may be naphthalene rings.
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FIELD OF THE INVENTION
This invention relates generally to a method and circular knitting machine for knitting jacquard pile fabric and more particularly to such a method and machine in which the jacquard pile fabric includes two or more pile yarns of different colors selectively forming single or multiple wale pile loops incorporated in each body or ground yarn course of the fabric. This type of jacquard pile fabric is formed by providing two dial hook elements in each groove of the dial of the knitting machine. The dial hook elements are selectively moved outwardly to pick up the pile yarns fed thereto at successive pile yarn feeding stations while the cylinder needles are selectively raised at the pile yarn feeding stations to catch the yarn as the dial hook elements are withdrawn inwardly into the dial.
BACKGROUND OF THE INVENTION
In the knitting of circular knit pile fabric, it is the normal practice to knit a single pile yarn and a body or ground yarn together in plated relationship at every knitting station while forming pile or terry loops of the pile yarn. The pile or terry loops are formed by advancing sinkers between adjacent cylinder needles so that the pile or terry loops are formed over the upper nibs of the sinkers while the body yarn stitch loops are drawn over the lower stitch drawing ledge of the sinkers. After the terry loops are formed in this manner, the fabric is sheared to produce pile extending outwardly from one surface of the knit fabric. However, the length of the pile or terry loops formed in this manner is limited by the height of the upper nib of the sinkers. This knit fabric is rather heavy and bulky since the pile yarn is knit in plated relationship with the body of ground yarn in the needle loops and it is not possible to easily change the height of the pile or terry loops being formed. Also, the plating of the pile yarn with the body yarn may not be accurately controlled so that portions of the pile yarn may be visible and may extend inwardly on the inside or back of the fabric.
Recognizing these deficiencies of pile fabric formed with the use of sinkers, the Mishcon U.S. Pat. No. 2,796,751 discloses the formation of a circular knit pile fabric by employing hooked loop jacks in the dial of the circular knitting machine so that the height of the pile or terry loops can be varied by merely varying the amount the hooked loop jacks are withdrawn or retracted into the dial, after picking up the pile yarn therein. This patent also discloses eliminating the problem of plating of the pile yarn with the body yarn by inlaying the pile yarn in the knit fabric formed by the body yarn. However, this patent discloses utilizing half the number of hooked loop jacks as the number of cylinder needles and forming plain jersey stitch loops of body yarn on alternate cylinder needles while forming the pile or terry loops of the pile yarn on every hooked loop jack at each knitting station. The pile fabric produced in accordance with this patent thus includes a pile or terry loop extending inwardly and between every wale of the plain jersey stitch loops of each course of the body yarn.
U.S. Pat. No. 5,016,450, dated May 21, 1991, a circular knit pile fabric and method is disclosed in which the successive courses of body yarn include pile yarn inlaid in every other wale while pile or terry loops extend inwardly and across the remaining wales, and wherein the pile or terry loops in alternating single courses are staggered walewise relative to the pile or terry loops in intervening single courses. The disclosed method of knitting the circular knit pile fabric of my copending application is carried out on a circular knitting machine including a plurality of circularly arranged cylinder needles movable vertically between latch clearing and stitch drawing positions. A single dial hook element is supported in each groove of the dial and the number of dial hook elements is equal to the number of cylinder needles.
The pile fabric produced in accordance with my copending application does permit the pile loops of the pile fabric to be formed of any desired length and the length of the pile loops is not determined by the height of the various ledges of the sinkers. However, the pile fabric produced in accordance with my copending application is limited to a single color of pile yarn in each course of the body or ground yarn.
SUMMARY OF THE INVENTION
With the foregoing in mind, it is an object of the present invention to provide a method and circular knitting machine for knitting a pile jacquard fabric with two or more pile yarns of different colors selectively forming single or multiple wale pile loops incorporated in each body or ground course, and wherein the circular knitting machine includes needles supported for vertical movement in a needle cylinder, first and second dial hook elements supported in each groove of a dial for horizontal movement in a radial direction and between selected cylinder needles, and a plurality of groups of spaced-apart yarn feeding stations.
The pile jacquard fabric knit in accordance with the method and machine of the present invention includes successive courses of wales of stitch loops knit of ground or body yarn. Each successive ground yarn course includes a first pile loop yarn inlaid with the ground yarn in selected needle wales and forming a pile loop therebetween. A second pile loop yarn is inlaid with the ground yarn in other needle wales and forming a pile loop therebetween. Floats of the first pile loop yarn extend above the pile loops in the corresponding selected needle wales, and floats of the second pile loop yarn extend above the pile loops in the corresponding other needle wales. The upstanding pile loops and floats are adapted to be cut in a shearing operation to form a patterned velour jacquard fabric. Additional pile yarns can also be incorporated with the ground yarn in each course of the pile jacquard fabric.
In accordance with the present invention, at least two dial hook elements are provided between cylinder needles which operate to draw yarn and form wale pile loops or floats around selected cylinder needles. The option is provided of transferring the pile loops and floats formed on the dial hook elements at one pile loop yarn feed station to other dial hook elements at a successive pile loop yarn feed station. After ground yarn is fed to the cylinder needles and the fabric is formed, the pile loops and floats are released by the outward movement of the dial hook elements.
The present method of knitting a pile jacquard fabric is carried out on a circular knitting machine including needles supported for longitudinal movement to form stitch loops of ground yarn fed thereto, first and second pile yarn loop forming elements supported between each of the needles for longitudinal movement at substantially right angles to the longitudinal movement of the needles, and a plurality of groups of successive spaced-apart yarn feeding stations. The longitudinal movement of the pile yarn loop forming elements and the needles cross each other along a crossing or verge line.
In its broadest aspect, the present method includes the sequential steps of moving selected of the pile yarn loop forming elements beyond the crossing line and feeding a first pile yarn thereto, moving selected needles beyond the crossing line, and then moving at least certain of the selected pile yarn loop forming elements inside of the crossing line at a first yarn feeding station to draw loops of the first pile yarn between the selected needles. A second pile loop yarn is fed to selected pile yarn loop forming elements at a second yarn feeding station, selected needles are moved beyond the crossing line, and selected pile yarn loop forming elements are moved inside of the crossing line to draw loops of the second pile yarn between the selected needles. Selected of the needles are then moved beyond the crossing line to a clearing level and the ground yarn is fed thereto, and then selected needles are moved inside of the crossing line and to a knitting level to form a course of ground yarn stitch loops with the first and second pile loop yarns incorporated with the ground yarn in selected needle wales.
More specifically, one embodiment of the method includes the sequential steps of moving each of the first dial hook elements outwardly at the first yarn feeding station and feeding the first pile yarn thereto while raising selected needles above the level of the dial hook elements. The first dial hook elements are then withdrawn at the first yarn feeding station to draw an inward loop of the first pile yarn. As the first dial hook elements are withdrawn, the loops formed by their hooks may be transferred into the hooks of the second dial hook elements so that the drawn loops are engaged by the hooks of both the first and second dial hook elements. Each of the second dial hook elements is moved outwardly at the second pile yarn feeding station and the second pile yarn is fed thereto while other selected needles are raised above the level of the dial hook elements and the second dial hook elements are withdrawn to draw an inward loop of the second pile yarn. All of the cylinder needles are raised to a clearing level at the third yarn feeding station and the ground yarn is fed thereto. All of the needles are then lowered to knitting level at the third yarn feeding station to form a course of plain jersey stitches of the ground yarn with individual pile loops of the first pile yarn extending upwardly from between the corresponding selected needle wales and with individual pile loops of the second pile yarn extending upwardly from between the corresponding other needle wales. Floats of the first pile yarn extend above the pile loops of the second pile yarn and floats of the second pile yarn extend above the pile loops of the first pile yarn.
In other disclosed embodiments, both the first and second dial hook elements are moved outwardly to pick up the first pile yarn at the first pile yarn feeding station while only the first dial hook elements are moved outwardly to pick up the second pile yarn at the second pile yarn feeding station (FIG. 10). In another embodiment (FIG. 11), both the first and second dial hook elements are moved outwardly to pick up the first pile yarn at the first pile yarn feeding station while only the second dial hook elements are drawn inwardly and the first dial hook elements are not drawn inwardly until they pass the second pile yarn feeding station. In a further embodiment (FIG. 12), only the first dial hook elements are moved outwardly and inwardly at both the first and second pile yarn feeding stations while the second dial hook elements remain in an inward position as they pass both pile yarn feeding stations. Additionally, third and fourth pile yarn feeding stations are provided (FIGS. 15 and 16) so that jacquard knit fabrics can be formed with more than two colors of pile yarn incorporated in each course. Thus, the outward and inward movements of the first and second dial hook elements can be selectively varied at each of the pile yarn feeding stations.
The first and second dial hook elements have downwardly and inwardly extending hooks on their outer ends which extend below the level of the lower sliding edge of the dial hook elements. These downwardly extending hooks each have an inwardly inclined outer cam surface which operates to cause the outwardly moving second dial hooks to cam the pile yarn caught by the inwardly moving first dial hooks down below the outwardly moving second dial hooks. At this time, the inwardly moving first dial hooks hold the pile yarn loops and floats which were picked up by the first dial hooks at a previous pile yarn feed.
The provision of the pairs of dial hook elements in each slot or groove of the dial, and the selective raising of the cylinder needles at successive pile yarn feeding stations permits a wide variety of different colors of pile yarns to be incorporated in the knit fabric. The selective formation of individual pile loops and multi-wale floats of each of the pile yarns in a single body or ground course permits the knitting of a wide variety of different types of patterned velour jacquard fabrics.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages will appear as the description proceeds when taken in connection with the accompanying drawings, in which --
FIG. 1 is a somewhat schematic illustration of one manner in which the cylinder needles and the dial hook elements form the pile jacquard fabric at three successive yarn feeding stations;
FIGS. 2-6 are fragmentary vertical sectional views taken along the respective section lines 2--2 through 6--6 in FIG. 1, illustrating the relative positions of the needles and the dial hook elements at the indicated locations;
FIG. 7 is a fragmentary plan view illustrating the manner in which the first dial hook elements are extended outwardly to pick up the first pile yarn at the first pile yarn feeding station;
FIG. 8 is a view similar to FIG. 7 but illustrating the manner in which the second dial hook elements are extended outwardly and pick up the second pile yarn at the second pile yarn feeding station;
FIGS. 9-12 illustrate different selected movements of the dial hook elements at the successive yarn feeding stations;
FIG. 13 is an isometric view of the first and second dial hook elements supported for radial sliding movement in each groove of the dial;
FIG. 14 is a greatly enlarged fragmentary isometric view of one course of one illustrative type of pile jacquard fabric produced in accordance with the present invention;
FIG. 15 is a view similar to FIG. 1 but showing three pile yarn feeding stations; and
FIG. 16 is a view similar to FIG. 15 but showing four pile yarn feeding stations.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The circular knitting machine employed in the practice of the present invention includes latch needles N supported for vertical movement in the grooves of a needle cylinder 10 (FIGS. 2-6). Respective first and second pile yarn loop forming elements, shown as respective dial hook elements H, H' (FIG. 13), are supported in each radial slot or groove of a dial 11 (FIGS. 2-6) for horizontal movement in a radial direction and between adjacent cylinder needles N. Longitudinal movement of the dial hook elements H, H' is at substantially right angles to the longitudinal movement of the needles N and they are adapted to at times cross each other along a crossing or verge line.
As illustrated in FIG. 1, a plurality of groups of four successive spaced-apart stations, indicated broadly at A-D are positioned around the needle cylinder 10. The first two successive spaced-apart stations A, B will be referred to as pile yarn feeding stations, the station C will be referred to as a body or ground yarn feeding and knitting station, and the fourth station D will be referred to as a pile loop and fabric shedding or hold-down station. A first pile yarn feed finger 12 is positioned at the first yarn feeding station A for feeding a first pile yarn P-1 to the dial hook elements and to the needles. A second pile yarn feeding finger 13 is positioned at the second yarn feeding station B for feeding a second pile yarn P-2 to the dial hook elements and the needles. A body or ground yarn feeding finger 14 is positioned at the third yarn feeding station C for feeding a body or ground yarn G to the cylinder needles N. A fabric and loop hold-down plate 15 is supported at the fourth station D and includes a horizontal inwardly extending portion 16 (FIG. 6) which overlies the upper end of the needle cylinder 10 and is used to hold the fabric down and to positively insure that the pile loops are removed from the dial hook elements H, H' and maintained in an innermost position inwardly of the described.
The knitting of a very simple vertically striped jacquard pile fabric, of the type illustrated in FIG. 14, will be described. However, it is to be understood that other more complicated jacquard pile fabrics can be knit in accordance with the present invention. Referring to FIG. 1, the first dial hook elements H are moved outwardly beyond the crossing line with the cylinder needles N as they pass the first pile yarn feeding station A while the second dial hook elements H' remain in a withdrawn position in the dial 11, as illustrated in FIGS. 2 and 7. The first dial hook elements H are moved outwardly and then inwardly and inside of the crossing line with the cylinder needles N along the path of travel indicated at 20 in FIGS. 1 and 7 and above the level of the first pile yarn feed finger 12. Selected needles N are raised and moved beyond the crossing line with and above the level of the hooks of the first dial hook elements H at the first yarn feed station A and are then lowered as they pass along a pathway indicated at 21. As the first dial hook elements H are withdrawn, the first pile yarn P-1 is caught by the downwardly extending hooks to draw a single pile yarn loop between raised needles while drawing a multi-wale float of the pile yarn P-1 over those cylinder needles N which were not raised at the first yarn feeding station, as illustrated in FIG. 7.
As will be noted in FIGS. 2-6 and 13, the dial hook elements H, H' have downwardly extending hooks on their outer ends which extend below the level of the lower sliding edges of the dial hook elements. These downwardly extending hooks each have an inwardly inclined outer cam surface 32 which cam the pile yarn downwardly, in a manner to be described, so that the pile yarn is at times transferred from the hook of one dial hook element to the hooks of another or both dial hook elements.
As illustrated in the right-hand portion of FIG. 7, the first pile yarn P-1 is drawn inside of selected needles N by the first dial hook elements H while the second dial hook elements H' begin their outward movement. As these second dial hook elements H' move outwardly, the inclined outer cam surface 32 engages and pushes the pile yarn P-1 downwardly so that the hook of the second dial hook element H' rides over the pile yarn P-1. Thus, the pile yarn P-1 is also positioned inside of the hook of the second dial hook element H' as the second dial hook element H' is moved outwardly at the right-hand portion of FIG. 7.
The second dial hook elements H' are moved outwardly beyond the crossing line with the cylinder needles N at the second pile yarn feeding station B and are then drawn inwardly inside of the crossing line with the cylinder needles N, as indicated by the travel path 22 in FIGS. 1 and 8, to pick up the second pile yarn P-2 from the second pile yarn feed finger 13. At this second yarn feeding station B, other pairs of adjacent needles N are raised and moved beyond the crossing line with and above the level of the hooks of the second dial hook elements H' and are then lowered, along a path of travel indicated at 23. As the second dial hook elements H' are withdrawn at the second yarn feeding station, an inward pile loop of the second yarn P-2 is drawn between the adjacent needles which have been raised at the second yarn feeding station and a multi-wale float of the yarn P-2 is formed above the needles which were not raised at this second pile yarn feeding station B.
As illustrated in the right-hand portion of FIG. 8, the second pile yarn P-2 is drawn inside of selected needles N by the second dial hook elements H' while the first dial hook elements H remain inwardly and hold the loops and floats of the pile yarn P-1. The second dial hook elements H' are drawn inwardly while the first dial hook elements H are moved outwardly and inwardly so that both the first and second pile yarns P-1, P-2 are held in the hooks of the first and second dial hook elements H, H'. Thus, the first and second pile yarns P-1 and P-2 are held in the hooks of both the first and second dial hook elements H, H', as indicated in the right-hand portion of FIG. 8.
At the third body or ground yarn feeding and knitting station C, all of the dial hook elements H and H' are maintained in a withdrawn position while all of the cylinder needles N are raised to a clearing level along a pathway 24 (FIG. 1) and then lowered while the body or ground yarn G is fed thereto to form plain as indicated in FIG. 14. As indicated in FIG. 14, the first pile yarn P-1 forms individual pile loops between the needle wales W-6, W-5 and W-2, W-1 and forms a multi-wale float across the needle wales W-3, W-4. The second pile yarn P-2 forms an individual pile loop between the needle wales W-4 and W-3 and forms multi-wale floats across the needle wales W-6, W-5 and W-1, W-2.
If desired, it is possible to hold the fabric down and to strip the pile loops and multi-wale floats from the dial hook elements H, H' after the cylinder needles N have been lowered to knitting position at the third body yarn feeding and knitting station C. However, it is possible to positively strip the pile loops from the dial hook elements H, H' and to maintain the pile loops inside of the needles N (FIG. 6). To this end, the cylinder needles N are again lowered at the fourth station D (FIGS. 1 and 6) while the dial hook elements H, H' are moved outwardly along a path of travel indicated at 30 in FIG. 1. Thus, the loops of the pile yarns P-1 and P-2 are positively stripped from the hooks of the dial hook elements H, H', and the fabric is held down by the plate 16 (FIG. 6) when the needles N are again raised.
As shown in FIG. 1, the first dial hook elements H are drawn inwardly after they pass the station A, as indicated by the path of travel 20, while the second dial hook elements H' are moving outwardly with their paths of travel crossing, as indicated at 33 in FIG. 1. When this occurs, the first pile yarn P-1, being drawn inwardly by the dial hook element H, is engaged by the cam surface 32 on the adjacent dial hook element H' and is lowered by the cam surface 32 so that the pile yarn loop passes inside of the hooks of both of the dial hook elements H, H'. Following the pile yarn feeding station B, the same action takes place as the dial hook elements H' are moving inwardly, as indicated by the path of travel 22, and the dial hook elements H are moving outwardly, with their paths of travel crossing, as indicated at 34 in FIG. 1.
While two different colors of pile yarns P-1 and P-2 are described as being fed to the dial hook elements at the first two yarn feeding stations A and B, to form a rather simple jacquard pile fabric, it is to be understood that additional colors of pile yarns could be fed to the dial hook elements at additional yarn feeding stations while the needles are selectively raised to form additional individual pile loops and multi-wale floats in the jacquard knit fabric. The feeding of additional pile yarns at additional pile yarn feeding stations is illustrated in FIGS. 15 and 16, to be presently described. Since the pile yarns may be inlaid in the courses of the body yarn, each course of the jacquard fabric is of a lighter weight construction than a similar type of fabric in which the pile yarns are knit in plated relationship with the body yarn in each course. However, it is to be understood that the pile yarns can be knit in plated relationship with the body or ground yarn. Also, the inlaying of the pile yarns with the body yarn in each course of the fabric eliminates the plating problem which can occur in this type of fabric when the pile yarns are knit in plated relationship with the body yarn.
FIGS. 9-12 illustrate some of the various types of selected movements which may be imparted to the first and second dial hook elements H, H' at the successive pile yarn feeding stations A and B. In FIG. 9, only the first dial hook elements H are moved outwardly and then inwardly at the first pile yarn feeding station A while only the second dial hook elements H' are moved outwardly and then inwardly at the second pile yarn feeding station B. This embodiment corresponds with the selected movement described above in connection with FIGS. 1, 7 and 8. In FIG. 10, both the first and second dial hook elements H, H' are moved outwardly and then inwardly at the first pile yarn feeding station A while only the first dial hook elements H are moved outwardly and then inwardly at the second pile yarn feeding station B. In FIG. 11, both the first and second dial hook elements H, H' are moved outwardly at the first pile yarn feeding station A while only the second dial hook elements H' are withdrawn at the first pile yarn feeding station A. The first dial hook elements H remain in the outer position until they pass the second pile yarn feeding station B, where they are drawn inwardly. In FIG. 12, the first dial hook elements H are moved outwardly and then inwardly at both the first and second pile yarn feeding stations A and B while the second dial hook elements H' remain in an inward position at both the first and second pile yarn feeding stations A and B.
FIGS. 15 and 16 illustrate the manner in which more than two colors of pile yarns can be incorporated in the fabric in accordance with the present invention. The formation of a three-color fabric is shown in FIG. 15 where selected dial hook elements are moved outwardly and then inwardly along a path of travel 40 at a first pile yarn feeding station to pick up a first pile yarn P-10 being fed by a first pile yarn feeding finger 42. Selected dial hook elements are moved outwardly and then inwardly along a path of travel 50 at a second pile yarn feeding station to pick up a second pile yarn P-20 being fed by a second pile yarn feeding finger 52. Selected dial hook elements are moved outwardly and then inwardly along a path of travel 60 at a third pile yarn feeding station to pick up a third pile yarn P-30 being fed by a third pile yarn feeding finger 62. These three pile yarns are then incorporated in the single course of fabric as body or ground yarn G' is fed to the needles by a ground yarn feed finger 14'.
The formation of a four-color fabric is shown in FIG. 16 where the action described in connection with FIG. 15 is repeated at the first three pile yarn feeding stations, with the prime notation being added to the corresponding reference characters. Selected dial hook elements are moved outwardly and then inwardly along a path of travel 70 at a fourth pile yarn feeding station to pick up a fourth pile yarn P-40 being fed by a fourth pile yarn feeding finger 72. Then all four pile yarns are incorporated in the single course of fabric as the ground yarn G' is fed to the needles by the ground yarn feed finger 14'.
In each of the described embodiments the jacquard pile fabric can be knit with a single body or ground yarn forming plain jersey stitch loops in each course, and with the pile yarns being either inlaid or knit in plated relationship with the ground yarn. However, it is to be understood that two or more body or ground yarns can be selectively fed to the needles to form other than plain jersey types of stitch loops, such as knit/welt or knit/tuck stitch loops in each course.
While needles with pivoted latches are illustrated as being used as the cylinder needles N, it is to be understood that compound sliding latch type needles may be used. Also, needles with latches or compound needles may be used in place of the illustrated dial hook elements H, H' and the illustrated positions of the needles and dial hook elements may be reversed. The first and second dial hook elements H, H' are illustrated as being positioned in the same groove of the dial 11 but could each be supported in closely spaced adjacent grooves.
In the drawings and specification there has been set forth the best mode presently contemplated for the practice of the present invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.
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Two or more pile yarns of different colors selectively form single or multiple wale pile loops in each body or ground yarn course of the fabric. First and second pile yarn loop forming elements, in the form of dial hook elements, are supported in the dial and are selectively moved outwardly to pick up the pile yarns fed thereto at successive yarn feeding stations while the cylinder needles are selectively raised at the successive yarn feeding stations to catch the pile yarn as the dial hook elements are withdrawn inwardly into the dial. The selective outward and inward movement of the first and second dial hook elements makes it possible to send one dial hook element outwardly and bring back a pile yarn to be engaged in the hooks of both the first and second dial hook elements. Ground or body yarn is fed to the needles and the needles form stitch loops to form a course of fabric with the pile loops of the first and second pile yarns incorporated in the stitch loops of the ground yarn. The pile loops are adapted to be cut in a shearing operation to form the patterned velour jacquard fabric.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation of international application PCT/EP03/01486 filed 14 Feb. 2003 and designating the U.S. The disclosure of the referenced international application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a texturing machine for draw texturing a plurality of synthetic multi-filament yarns. A texturing machine of this general type is disclosed in DE 100 26 942 A1 and Patent Publication US 2002/0088218A1.
[0003] For draw texturing a plurality of yarns, texturing machines of the described type possess a corresponding plurality of side by side processing stations. Each of the processing stations comprises a plurality of processing units, such as, for example, feed systems, false twist texturing units, and takeup devices, which serially advance, texture, draw, and wind the yarn to a package.
[0004] To drive the processing units, basically two different variants are known. In a first variant, all processing units of a group, for example, all first feed systems of the processing stations together are synchronously driven by one drive. However, this variant has in general the disadvantage that it does not permit an individual control of the processing stations. To avoid such disadvantage, the above cited documents disclose a variant of the drive, which uses individual drives to drive the processing units within the processing stations. In this process, a group frequency changer activates the individual drives of a group of processing units of adjacent processing stations, such as, for example, all individual drives of the first feed systems. However, it has now been found that the individual activation of the processing stations results in that the individual drives of the processing units are more often connected and disconnected separately from one another. In this connection, it must be ensured that in the operating state, each of the individual drives of a group of processing units have the same operating parameters, for example, drive speed.
[0005] It is therefore an object of the invention to further develop a texturing machine of the initially described type in such a manner that even after shutting down certain individual drives, it is always possible to operate the processing units of a functional group of a plurality of processing stations in a certain operating state without requiring a larger number of control systems.
SUMMARY OF THE INVENTION
[0006] The above and other objects and advantages of the invention are achieved by providing a texturing machine composed of a plurality of side by side processing stations, and wherein at least one of the processing units of each station is driven by an electrical individual drive. Also, the electric individual drive of the processing unit comprises an asynchronous unit for starting up to a predetermined desired frequency and a synchronous unit for maintaining the predetermined desired frequency.
[0007] The invention thus has the advantage that a group frequency changer may be provided which permits activating the individual drives in a simple manner so that only a desired frequency is applied to each individual drive. In this connection, the desired frequency forms the operating state (e.g. rotational speed) that is necessary for the processing unit. In the individual drive, the asynchronous unit sees to it that after starting up, the individual drive starts operating directly until the desired frequency is reached. Upon reaching the desired frequency, the synchronous unit of the individual drive becomes operative and prevents the processing unit from being driven with a frequency that deviates from the desired frequency. The processing unit thus reaches automatically an operating state that corresponds to the desired frequency. With that, it is possible to use a group frequency changer for controlling a plurality of individual drives in a simple manner. After each connection, it is thus possible to operate the processing units of a functional group in the operating state reliably with the respectively predetermined desired parameters. This ensures an identical treatment of all yarns in the processing stations.
[0008] The electric individual drives may be constructed both as asynchronous motors and as synchronous motors. In the case that the asynchronous motor forms the asynchronous unit of the individual drive, the asynchronous motor includes a field magnet which forms part of a synchronous unit. The field magnet is formed preferably by a plurality of permanent magnets, which are mounted on the rotor of the asynchronous motor. With that, it is accomplished that the asynchronous motor can automatically maintain the predetermined desired frequency after the acceleration phase. The field magnet ensures that the rotor operates synchronously with the rotating field of the stator of the asynchronous motor. This further development of the invention is suitable in particular for processing units, which require a relatively high starting torque.
[0009] It is preferred to form the synchronous unit by a synchronous motor, which comprises as an asynchronous unit an auxiliary winding arranged on the rotor. This ensures that during an activation of the individual drive at a constantly predetermined desired frequency, the synchronous motor starts up without delay, until the rotor of the synchronous motor is in sync with the rotating field of the stator.
[0010] To enable an individual startup and shutdown of the processing stations independently of one another, a very advantageous further development of the invention proposes to connect each of the individual drives of the group of processing units to the group frequency changer via a controllable switching element. This makes it possible to shut down one or more of the individual drives associated to the group frequency changer without influencing adjacent individual drives and processing units.
[0011] Moreover, it will be of advantage, when each of the individual drives comprises a sensor for monitoring the rotational speed. This sensor connects to a control unit that controls the switching elements. Thus, it is possible to avoid with advantage an overload of the individual drives by a comparison of actual and desired values.
[0012] For example, to switch from a threading speed to an operating speed, while threading the yarns in the processing stations, a particularly preferred further development of the invention proposes to connect the control unit and the group frequency changer to an overriding central machine control system.
[0013] With the use of a plurality of individual drives for a plurality of processing units, one frequency changer each is associated to the individual drives of a group of processing units, with all group frequency changers being coupled with the machine control system. To increase the flexibility of a texturing machine, a further advantageous embodiment of the invention proposes to divide the plurality of processing stations into one or more sections, with each section comprising a plurality of processing stations. In this case, the group frequency changers of the section connect to a field control system that is connected to the section. The processing units of the processing stations in the particular section can thus be controlled independently of the processing units of the processing stations of adjacent sections.
[0014] The processing units driven by individual drives may advantageously be formed for each processing station by a first feed system, and/or a second feed system, and/or a third feed system. This makes it possible to adjust and vary in an accurate manner both the yarn speed and the draw ratio for drawing the yarn.
[0015] The group of processing units, which are driven by individual drives, may also include in each processing station a drive roll of a takeup device and/or by a false twist texturing unit.
[0016] Basically, all rotatably driven processing units are suited for operating with a substantially predetermined desired frequency while draw texturing the yarns.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the following, embodiments of a texturing machine according to the invention are described in greater detail with reference to the attached drawings, in which:
[0018] FIG. 1 is a schematic side view of a first embodiment of a yarn texturing machine according to the invention;
[0019] FIG. 2 is a schematic fragmentary top view of a further embodiment of a yarn texturing machine;
[0020] FIG. 3 is a schematic view of an embodiment of an individual drive for a feed system;
[0021] FIG. 4 is a schematic view of a further embodiment of an individual drive for a feed system; and
[0022] FIG. 5 shows an embodiment of an individual drive for a drive roll of a takeup device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] FIG. 1 schematically illustrates a first embodiment of a yarn texturing machine according to the invention. The texturing machine comprises a feed module 3 , a processing module 2 , and a takeup module 1 , which are arranged in a machine frame composed of frame sections 4 . 1 , 4 . 2 , and 4 . 3 . The frame section 4 . 1 mounts the feed module 3 , and the frame section 4 . 3 mounts the processing module 2 and takeup module 1 . The frame sections 4 . 1 and 4 . 3 are interconnected by frame section 4 . 2 , which is arranged above the feed module 3 and processing module 2 . Between the processing module 2 and the feed module 3 , a service aisle 5 extends below the frame section 4 . 2 . In the frame section 4 . 2 , the processing module 2 is arranged on the side facing the service aisle 5 , and the takeup module 1 on the opposite side thereto.
[0024] A doffing aisle 6 is provided along the takeup module 1 . In its longitudinal direction (in FIG. 1 , the plane of the drawing corresponds to the transverse plane) the texturing machine comprises a plurality of side by side processing stations, one processing station for each yarn. Takeup devices 18 occupy a width of three processing stations. Therefore, three takeup devices 18 are superposed in the takeup module 1 in a column, as will be described in more detail further below.
[0025] The view of FIG. 1 shows the processing units of a processing station, which are accommodated respectively in the feed module 3 and processing module 2 . Each processing station thus comprises a plurality of processing units 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , and 18 , one following the other in the path of an advancing yarn.
[0026] A first group of the processing units is formed in each processing station by a first feed system 10 , which is mounted to the feed module 3 . The adjacent first feed systems of adjacent processing stations are arranged side by side (not shown). A feed yarn package 8 in a creel 7 is associated to each first feed system 10 . Next to the feed yarn package 8 , the creel 7 of each processing station accommodates a reserve package 43 . In each processing station, the first feed system 10 withdraws a yarn 36 via a plurality of yarn deflection guides 9 . 1 and 9 . 2 .
[0027] In the following, the further processing units of a processing station are described with reference to the path of yarn 36 . In the direction of the advancing yarn, downstream of the first feed system 10 , an elongate primary heater 11 extends, through which the yarn 36 advances. In so doing, the yarn 36 is heated to a predetermined temperature. The primary heater 11 could be constructed as a high-temperature heater, whose heating surface has a temperature above 300° C. In the direction of the advancing yarn, downstream of the primary heater 11 , a cooling device 12 is provided. The primary heater 11 and cooling device 12 are arranged in one plane, one following the other, and supported by the frame section 4 . 2 above the service aisle 5 . In the inlet region of the primary heater 11 , a deflection roll 9 . 3 is arranged, so that the yarn 36 crosses the service aisle 5 in the configuration of an inverted V.
[0028] On the side of the service aisle 5 opposite to the feed module 3 , the frame section 4 . 3 mounts the processing module 2 . In the direction of the advancing yarn, the processing module 2 supports, one below the other, a false twist unit 13 , a second feed system 14 , and a third feed system 15 . In this arrangement, the yarn 36 advances from the outlet of the cooling device 12 , which is preferably formed by a cooling rail or a cooling tube, to the false twist texturing unit 13 . The false twist texturing unit 13 , which may be formed, for example, by a plurality of overlapping friction disks, is driven by a false twist drive 26 . The false twist drive 26 is constructed as an individual drive 27 , which is likewise arranged on the processing module 2 .
[0029] The second feed system 14 withdraws the yarn 36 from the false twist zone, which extends between the false twist texturing unit 13 and the first feed system 10 . The second feed system 14 and the first feed system 10 are driven at different speeds for drawing the yarn 36 in the false twist zone.
[0030] Downstream of the second feed system 14 , the third feed system 15 is positioned, which advances the yarn 36 directly into a secondary heater 16 . To this end, the secondary heater 16 is arranged on the underside of frame section 4 . 3 and, thus, below the processing module 2 and takeup module 1 . The secondary heater 16 represents the yarn passage from the processing module to the takeup module 1 . As a result of integrating in the frame section 4 . 3 , the processing module 2 , secondary heater 16 , and takeup module 1 , a very short yarn path is realized, which is substantially U-shaped. To this end, the underside of the takeup module 1 mounts a fourth feed system 17 , which withdraws the yarn 36 directly from the secondary heater 16 , and advances it after a deflection to the takeup device 18 .
[0031] The third feed system 15 and fourth feed system 17 may be driven at different speeds, so as to enable a shrinkage treatment of the yarn 36 within the secondary heater 16 . To this end, the secondary heater 16 may comprise a biphenyl-heated contact heater, which is inclined relative a horizontal by an angle α. The angle ranges from 5° to 45°. With that, it is made certain that within a heating channel of the secondary heater 16 , the yarn 36 undergoes a uniform heating caused by contact.
[0032] In the present embodiment, the takeup device 18 is schematically identified by a yarn traversing device 20 , a drive roll 19 , and a package 21 . The takeup device 18 also includes a tube magazine 22 for performing an automatic package doff. Auxiliary devices that are needed for doffing full packages are not shown in greater detail.
[0033] In the present embodiment, the feed systems 10 , 14 , 15 , and 17 are made identical. They are each formed by a godet 23 and a guide roll 24 associated therewith. The godet 23 is driven by a godet drive 25 . The guide roll 24 is supported for free rotation, so that the yarn 36 advances over godet 23 and guide roll 24 by looping them several times.
[0034] In the embodiment of the texturing machine shown in FIG. 1 , the godet drive 25 of the first feed system 10 is constructed as an individual drive 27 . The individual drive 27 , whose construction is described in greater detail in the following, is coupled with a group frequency changer 30 via a switching element 32 . The group frequency changer 30 is likewise associated to adjacent individual drives of adjacent first feed systems in adjacent processing stations not shown. Thus, it is possible to associate, for example, all individual drives of the first feed systems within a texturing machine to a common group frequency changer 30 . The group frequency changer 30 connects to a central machine control system 44 . Thus, the first feed system 10 represents a first functional group of processing units, which are driven within the machine by individual drives 27 .
[0035] A second functional group of processing units is formed by the false twist units 13 . The false twist drives 26 are likewise constructed as individual drives 27 , which are associated to a second group frequency changer 45 . Likewise, a switching element 32 is used to connect the individual drives 27 to the second group frequency changer 45 , which likewise connects to the machine control system 44 .
[0036] The drives and drive control of the remaining processing units are not described in greater detail. They could likewise be formed, for example, by individual drives with a control system via group frequency changers or by individually controlled drives.
[0037] In operation, the individual drives 27 of the feed systems 10 and false twist units 13 are controlled with a desired frequency that is defined by the machine control system 44 , so that the feed system 10 has a certain circumferential speed for advancing the yarn 36 , and so that the false twist unit 13 likewise reaches a drive speed that is needed for texturing the yarn. As is known, in the processing station, the yarn 36 is advanced, drawn, textured, and wound to a package 21 . In the case that a breakdown occurs in the illustrated processing station, for example, by a yarn break, the switching element 32 separates the individual drives 27 of the feed system 10 and the false twist unit 13 from their respective group frequency changer 30 or 45 . The first feed system 10 and the false twist unit 13 are shut down. Adjacent processing stations remain unaffected by this action. The individual drives associated to the group frequency changers 30 and 45 remain in an unchanged operating state.
[0038] After eliminating the breakdown in the processing station, a reconnection to the group frequency changers 30 and 45 will occur via the switching elements 32 , so that it is again possible to activate the individual drives 27 . With that, the desired frequency is applied to the individual drives 27 .
[0039] To enable the connection and disconnection as well as the startup and continuation in the operating state of the individual drives 27 without requiring a larger number of control means, each individual drive 27 includes a synchronous unit and an asynchronous unit. FIG. 3 illustrates a first embodiment of an individual drive 27 , which is constructed as an asynchronous motor 35 . The asynchronous motor 35 thus represents the asynchronous unit 29 that comprises a stator winding 39 and a rotor winding 41 . To this end, the rotor winding 41 is attached to a rotor 40 . Inside the stator winding 39 , the rotor 40 mounts a field magnet 36 , which represents the synchronous unit 28 together with the stator winding 39 . The field magnet 36 of this embodiment is formed by a plurality of permanent magnets, which are mounted on the circumference of the rotor 40 . With its end projecting from the motor casing, the rotor 40 connects to the godet 23 of the first feed system 10 .
[0040] To start up the asynchronous motor 35 , a desired frequency is applied via the group frequency changer 30 . After applying current to the stator winding 39 , the rotor 40 is accelerated. As soon as the rotational frequency of the rotor 40 corresponds to the desired frequency, a coupling occurs between the rotating field of the stator winding 39 and the rotational frequency of the rotor 40 by means of the field magnet 36 . In its operating state, the individual drive 27 performs similarly to a synchronous machine. With that, it is made sure that the desired frequency as determined by the group frequency changer 30 , is automatically adjusted by the activated individual drive 27 . This is important in particular for the processing units, which are arranged in the texturing machine in the form of feed systems. The yarn is thus advanced and drawn under identical conditions in each processing station.
[0041] FIG. 4 illustrates a further embodiment of an individual drive 27 with a synchronous unit 28 and an asynchronous unit 29 . Components having the same function are provided with identical reference numerals. The synchronous unit 28 is formed by a synchronous motor 38 . To this end, the synchronous motor 38 comprises a stator winding 39 and a rotor 40 with at least one permanent magnet 37 . In this case, the rotational frequency of the rotor 40 equals the desired frequency, so that the rotor 40 rotates in sync with the rotating field of the stator winding. To enable a startup without changing the desired frequency after a shutdown of the individual drive 27 , the synchronous motor 38 includes an asynchronous unit 29 , which is formed by an auxiliary winding 42 on the rotor and the stator winding 39 . The auxiliary winding 42 is arranged inside the stator winding 39 . This ensures that the rotor 40 is accelerated with a predetermined desired frequency of the stator winding 39 .
[0042] The embodiments of the individual drive as shown in FIGS. 3 and 4 are suited preferably for driving the feed systems of a texturing machine or for driving a false twist friction unit.
[0043] FIG. 5 illustrates a further embodiment of an individual drive 27 , which is suited preferably for driving a drive roll 19 in a takeup device 18 . To this end, the jacket of the drive roll 19 is directly driven by the individual drive 27 arranged inside the drive roll 19 . For this purpose, the individual drive 27 comprises a cylindrical rotor 40 . The inner side of the cylindrical rotor 40 mounts the rotor winding 41 . In facing relationship with the rotor winding 41 , a stationary axle 46 mounts a stator winding 39 . In the axial direction, the stator winding 39 extends beyond the rotor winding 41 to cover a field magnet 36 arranged on the cylindrical rotor 40 . The field magnet 36 and the stator winding 39 thus form the synchronous unit 28 of the individual drive 27 . As a result of construction, the asynchronous unit 29 is provided as an asynchronous motor 35 . The operation of the embodiment shown in FIG. 5 is identical with that described with reference to FIGS. 3 and 4 .
[0044] FIG. 2 illustrates a further embodiment of a texturing machine as a fragmentary top view thereof. The embodiment of FIG. 2 is made substantially identical with the preceding embodiment of FIG. 1 . In this respect, the arrangement of the processing units within a processing station is made identical, so that the foregoing description is herewith incorporated by reference.
[0045] The top view illustrated in FIG. 2 shows only the yarn feed to the machine with creel 7 and feed module 3 . The processing module 2 and takeup module 1 are not shown. As a whole, 12 processing stations are shown in side-by-side relationship. In this connection, the creel 7 accommodates in tiers the feed yarn packages 8 of three juxtaposed processing stations, with one package overlying the other, as can be noted from FIG. 1 . However, for the sake of clarity, the yarn path is not shown in FIG. 2 .
[0046] The feed module 3 mounts in side-by-side relationship the feed systems 10 , which withdraw each yarn 36 from respectively one feed yarn package 8 of the creel 7 . Each processing station is provided with one first feed system 10 . Each feed system 10 comprises an individual drive 27 , which is coupled with a godet 23 and a guide roll 24 associated thereto.
[0047] To control the individual drive 27 , the drive connects via a switching element 32 to a group frequency changer 30 . The group frequency changer 30 supplies the individual drives 27 of a total of six feed systems of a plurality of processing stations. In this connection, six processing stations form one section, which is controlled by means of a field control system 34 . 1 or 34 . 2 . Thus, the group frequency changer 30 connects to a field control system 34 . 1 of a first section I of processing stations. Accordingly, the individual drives 27 of the feed systems 10 of a second section II are controlled via a further group frequency changer 30 , which in turn is coupled with an associated field control system 34 . 2 .
[0048] The field control systems 34 . 1 and 34 . 2 connect to additional group frequency changers or control units or drive units for controlling the processing stations.
[0049] Furthermore, the individual drives 27 of a section are associated with a control unit 33 , which connects to each of the switching elements 32 associated to the individual drives 27 of a section. Each of the individual drives 27 also includes a sensor 31 , which connects to the control unit 33 . The control unit 33 is also coupled with the field control system 34 . 1 or 34 . 2 .
[0050] The field control systems 34 . 1 and 34 . 2 and additional adjacent field control systems connect to a central machine control system (not shown).
[0051] In the texturing machine shown in FIG. 2 , a group frequency changer 30 activates in the operating state, the individual drives 27 of the first feed systems 10 of each section with a predetermined desired frequency. To is this end, the field control system 34 . 1 or 34 . 2 applies both to the group frequency changer 30 and to the control unit 33 , the corresponding desired frequency, which corresponds to a certain withdrawal speed of the yarns from the feed yarn packages 8 . At the beginning of the process, each of the individual drives 27 is accelerated because of the asynchronous unit accommodated therein. As soon as the rotational frequency of the rotor reaches the desired frequency, the synchronous unit of the individual drives 27 maintains a predetermined circumferential speed on each of the feed systems 10 .
[0052] In the case that one of the individual drives 27 shows a malfunction, which indicates an unacceptable deviation from the desired frequency, the group frequency changer 30 shuts down the particular individual drive 27 via the sensor 31 , control unit 33 , and switching element 32 . To this end, a comparison occurs in the control unit 33 between the actual condition signaled by the sensor 31 and a desired condition that is set by the field control system 34 . 1 or 34 . 2 . In the case of an unacceptable deviation of the actual condition from the desired condition, the control unit 33 activates the respective switching element 32 . In this process, information is exchanged between the control unit 33 and the field control system. As soon as the malfunction is eliminated, the corresponding switching element is activated via control unit 33 for starting the individual drive. In this process, individual drives 27 adjacent the group frequency changer 30 remain unaffected in their control.
[0053] The synchronous units and asynchronous units formed in the individual drives 27 ensure an independent startup and adjustment of the desired circumferential speed on the feed systems. This achieves a great uniformity of the yarn treatment in each of the processing stations of the texturing machine without reducing the flexibility in the activation of the individual processing stations. With that, the texturing machine of the present invention combines the advantages of a group drive for processing units of the same function with the advantages of a processing station with individually driven processing units.
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A texturing machine for draw texturing a plurality of synthetic multi-filament yarns and which includes a plurality of side by side processing stations. Each of the processing stations comprises a plurality of processing units for advancing, texturing, drawing, and winding the yarn. At least one of the processing units is driven by an electrical individual drive, with the individual drives of the processing units of adjacent processing stations being controlled by a common group frequency changer. To enable a separate connection and disconnection of the individual drives with a simultaneous group control, the electrical individual drive of each processing unit includes an asynchronous unit and a synchronous unit. In the case of a predetermined desired frequency, this permits an automatic startup and maintenance of the desired frequency, which leads to a high degree of uniformity of the yarn treatment in each processing station.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the papermaking arts. More specifically, the present invention is a papermaker's fabric for use on the dryer section of the papermachine, such a fabric being commonly referred to as a dryer fabric.
2. Description of the Prior Art
During the papermaking process, a fibrous web is formed by depositing a fibrous slurry on a forming fabric in the forming section of a papermachine. A large amount of water drains from the slurry through the forming fabric during this process, leaving the fibrous web on the surface of the forming fabric.
The newly formed web proceeds from the forming section to a press section, which includes a series of press nips. The fibrous web passes through the press nips supported by a press fabric, or, as is often the case, between two such press fabrics. In the press nips, the fibrous web is subjected to compressive forces which squeeze water therefrom. This water is accepted by the press fabric or fabrics and, ideally, does not return to the web.
The web finally proceeds to a dryer section, which includes at least one series of rotatable dryer drums or cylinders, heated from within by steam. The web is directed in a sinuous path sequentially around each in the series of drums by one or more dryer fabrics, which hold the web closely against the surfaces of the drums. The heated drums reduce the water content of the web to a desirable level through evaporation.
The surface characteristics of the fabrics used in the forming and press sections of the papermachine have a direct bearing on the surface properties of the paper being produced. This is also true in the dryer section, where, as stated above, the dryer fabric holds the web closely against the surfaces of the heated dryer cylinders. To promote drying efficiency by increasing the surface area of the dryer fabric directly in contact with the web, and to reduce the marking of the web by the fabric, the dryer fabrics are typically woven to have surfaces which are as smooth as possible. In recent years, one approach that has been taken to provide dryer fabrics with such surfaces has been to include flat monofilament yarns in their woven structures.
While it is indeed clear that the inclusion of flat monofilament yarns on the paper-contacting surfaces of a dryer fabric increases the contact surface area between fabric and dryer cylinder, and therefore between web and dryer cylinder, such fabrics have been observed to be susceptible to wrinkling both during in-house processing and after installation on the dryer section of a papermachine. This is particularly the case when flat monofilament yarns are next, or contiguous, to one another on the surface of the dryer fabric.
Further, where the flat monofilament surface yarns are used to form seaming loops, the dryer fabrics have unacceptably short lives on the papermachine because of the heat and abrasion to which the surface yarns are exposed in the drying section.
For example, U.S. Pat. No. 4,290,209 shows a dryer fabric woven entirely from monofilament plastic polymeric warp and weft strands, wherein at least the warp strands are flattened in cross-section with the long axis of the flattened section extending parallel to the plane of the fabric. The warp strands extend in the machine direction of the fabric, and are provided in an approximately 100% warp fill, which implies that the warp strands are woven contiguously. The fabric does not include a separate system of machine-direction warp yarns, interior of the surface planes formed by the flat yarns, for use in seaming.
U.S. Pat. No. 4,621,663, and related U.S. Pat. No. 4,749,007, show a fabric for draining and drying paper webs. The fabric is formed by warp threads and weft threads, and further comprises a top layer of interlaced lengthwise strips and weft threads. The lengthwise strips are side-by-side one another. The fabric does not include a separate system of machine-direction warp yarns, protected within the interior of the fabric, for use in seaming.
U.S. Pat. No. 5,103,874, and related U.S. Pat. Nos. 5,117,865; 5,199,467; and 5,238,027, show a papermaker's fabric having a system of flat monofilament machine-direction yarns. The system of machine-direction yarns comprises upper and lower yarns which are vertically stacked. At least the upper machine-direction yarns are flat monofilament yarns woven contiguously with each other to reduce the permeability of the fabric and to lock in the machine-direction alignment of the stacking pairs of machine-direction yarns. A seam for the fabric comprised of loops formed from selected flat machine-direction yarns is provided to render the fabric endless during use in papermaking. The fabric does not include a separate system of machine-direction warp yarns, interior of the surface planes of the fabric, for use in seaming.
The present invention is a dryer fabric which may include flat monofilament yarns, but which is woven in a manner that leaves it less susceptible to the above-noted deficiencies of prior-art fabrics. The flat monofilament yarns are not woven contiguously and are not used to form seaming loops. Instead, a separate system of machine-direction warp yarns, interior of the surface planes of the fabric, is provided for use in seaming.
SUMMARY OF THE INVENTION
Accordingly, the present invention is a dryer fabric, although it may find application in any of the forming, press and dryer sections of a papermachine.
As such, the present invention is a papermaker's fabric for the forming, press and dryer sections of a papermachine. The fabric includes a first layer and a second layer of cross-machine-direction (CD) yarns. Interwoven with the CD yarns are a first system of machine-direction (MD) yarns and a second system of MD yarns.
The MD yarns in the first system of MD yarns are interwoven with the CD yarns in the first and second layers in a duplex weave and bind the first and second layers together.
The MD yarns in the second system weave with the CD yarns in either the first or the second layers. Specifically, some of the MD yarns in the second system weave with the CD yarns in the first layer, while the remainder of the MD yarns in the second system weave with the CD yarns in the second layer.
The MD yarns in the second system define the upper and lower surfaces of the fabric, and may be flat yarns having a substantially rectangular cross section. On the other hand, the MD yarns of the first system reside within the fabric with respect to its upper and lower surfaces. In other words, the knuckles formed where the MD yarns of the first system weave over (or under) the CD yarns of the first (or second) layer are interior of the surface planes formed by the MD yarns of the second system.
In a preferred embodiment, the CD yarns of the first layer are in a vertically stacked, paired relationship with the CD yarns of the second layer. Further, the MD yarns of the second system are in a vertically stacked, paired relationship with one another. That is to say, those MD yarns of the second system weaving with the CD yarns of the first layer are vertically stacked over those MD yarns of the second system weaving with the CD yarns of the second layer with which they are paired. Finally, a pair of MD yarns of the first system are between each stacked pair of MD yarns of the second system. As such, pairs of MD yarns in the first system alternate with vertically stacked pairs of MD yarns of the second system widthwise across the fabric.
The present invention will now be described in more complete detail with frequent reference being made to the drawing figures, which are identified above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the upper surface of the papermaker's fabric of the present invention.
FIG. 2 is a perspective view of the upper surface of the papermaker's fabric.
FIG. 3 is a cross-sectional view, taken in the machine direction as indicated by line 2--2 in FIG. 1, of the papermaker's fabric.
FIG. 4 is a cross-sectional view, similar to that shown in FIG. 3, illustrating the manner in which the papermaker's fabric may be seamed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to the figures, FIG. 1 is a plan view of the upper surface 12 of the papermaker's fabric 10 of the present invention. In FIG. 1, the machine direction (MD) and cross-machine direction (CD) are as indicated. While only the upper surface 12 is visible, it will be apparent from the description to follow that the lower surface 14 will have a similar appearance. The spacing between the yarns of the papermaker's fabric 10 in this and other figures is exaggerated for the sake of clarity.
FIG. 2 is a perspective view of the upper surface 12 of the papermaker's fabric 10, showing a more realistic spacing between adjacent yarns of the fabric.
FIG. 3 is a cross-sectional view, taken as indicated by line 2--2 in FIG. 1. It will be noted that fabric 10 includes two layers of CD yarns. A first layer 16 of CD yarns 18,18' is on the upper side of fabric 10, while a second layer 20, not visible in FIG. 1, of CD yarns 22,22' is on the lower side. It will be noted that CD yarns 18',22' are bound by MD yarns 24, while CD yarns 18,22 are not so bound. CD yarns 18,18' and CD yarns 22,22' may be provided in equal numbers, and, if so provided, may be in the vertically stacked, paired relationship shown in FIG. 3. That is to say, CD yarns 18,18' may be paired with and vertically stacked over CD yarns 22,22', respectively. Further, CD yarns 18,18',22,22' may be monofilament, multifilament or plied monofilament yarns of any of the synthetic polymeric resins used in the production of such yarns for papermachine clothing. Polyester and polyamide are but two examples of such materials. Other examples of such materials are yarns of polyphenylene sulfide (PPS), which is commercially available under the name RYTON®, and yarns of a modified heat-, hydrolysis- and contaminant-resistant polyester of the variety disclosed in commonly assigned U.S. Pat. No. 5,169,499, and used in dryer fabrics sold by Albany International Corp. under the trademark THERMONETICS®. U.S. Pat. No. 5,169,499 is incorporated herein by reference.
Finally, CD yarns 18,18',22,22' may be of uniform thickness, or may be of more than one thickness. For example, CD yarns 18',22' which are bound by MD yarns 24 may be thinner than those which are not so bound, CD yarns 18,22.
CD yarns 18',22' are interwoven by a first system of MD yarns 24. MD yarns 24 are monofilament yarns of either circular or rectangular cross section, although circular cross section yarns are preferred. As above, MD yarns 24 may be of any of the synthetic polymeric resins used in the production of yarns for papermachine clothing. Polyester and polyamide are but two examples, along with the polyphenylene sulfide and modified heat-, hydrolysis- and contaminant-resistant polyester yarns described above.
MD yarns 24 interweave with CD yarns 18',22' in a duplex pattern, such as that shown in FIG. 3. A duplex pattern is one in which multiple layers of filling yarns are interwoven with a single system of warp yarns. A MD yarn 24, for example, may weave over one CD yarn 18', between the next vertically stacked pair of CD yarns 18,22 under the next CD yarn 22', between the next vertically stacked pair of CD yarns 18,22, and over the next CD yarn 18' to repeat the pattern.
The MD yarns in a second system of MD yarns may be either thinner or thicker than MD yarns 24 of the first system, or they may be equal in thickness to MD yarns 24. The second system of MD yarns comprises MD yarns 26 and MD yarns 28.
MD yarns 26,28 are monofilament yarns of either circular or rectangular cross section, although those of rectangular cross section are preferred. As before, MD yarns 26,28 may be of any of the synthetic polymeric resins used in the production of yarns for papermachine clothing. Polyester and polyamide are again but two examples, along with the polyphenylene sulfide and modified heat-, hydrolysis- and contaminant-resistant polyester yarns described above.
MD yarns 26 interweave with CD yarns 18,18' to form the upper surface 12 of the fabric 10, while MD yarns 28 interweave with CD yarns 22,22' to form the lower surface 14 of the fabric 10. The knuckles formed when MD yarns 24 interweave with CD yarns 18',22' are within the surface planes defined by MD yarns 26,28, when the weave pattern shown in the figures is used. MD yarns 24 are thereby protected from degradation by heat and abrasion, and may be used to seam the fabric 10 into endless form by either pin or spiral seaming, as shown in FIG. 4. A fabric 10 having a prolonged useful life may thereby be obtained. MD yarns 26,28 may be either thicker or thinner than MD yarns 24, or they may be equal in thickness to MD yarns 24.
Preferably, MD yarns 24,26,28 are contamination- and heat-resistant yarns.
MD yarns 26 are interwoven with CD yarns 18,18', and MD yarns 28 are interwoven with CD yarns 22,22', to give the fabric 10 smooth upper and lower surfaces 12,14. MD yarns 26 may weave over three consecutive CD yarns 18,18',18, under the next CD yarn 18', and then over the next three consecutive CD yarns 18,18',18 to follow a repeating pattern. Similarly, MD yarns 28 may weave under three consecutive CD yarns 22,22',22, over the next CD yarn 22', and then under the next three consecutive CD yarns 22,22',22 to follow a repeating pattern. MD yarns 24 weave over the CD yarns 18' under which MD yarns 26 weave. Similarly, MD yarns 24 weave under the CD yarns 22' over which MD yarns 28 weave.
MD yarns 26,28 may also be in a vertically stacked, paired relationship, as shown in FIG. 3 and suggested by FIG. 1. Such stacked pairs, however, will not be contiguous with, or adjacent to, one another, as they will be separated by at least one MD yarn 24 binding the first and second layers 16,20 together. Preferably, two MD yarns 24 are between each stacked pair of MD yarns 26,28.
Because stacked pairs of MD yarns 26,28 are not contiguous with, or adjacent to, one another, and because the knuckles formed when MD yarns 24 interweave with CD yarns 18',22' are within the surface planes defined by MD yarns 26,28, lengthwise channels are defined by, and are disposed between, MD yarns 26,28 on the upper and lower surfaces 12,14 of the fabric 10. The lengthwise channels are conducive to the handling of air on a papermaking machine in their ability to channel it lengthwise therethrough and by providing void space for air to enter when the fabric 10 encounters and passes around a roll or cylinder on the machine.
Referring again to FIG. 4, an exaggeratedly short papermaker's fabric 10 is shown in cross section to illustrate the manner in which it might be seamed into endless form. MD yarns 24 may form loops 30 at the opposite lengthwise ends of the papermaker's fabric 10. The papermaker's fabric 10 may then be seamed into endless form by bringing the two ends of the fabric 10 together and by interdigitating the loops 30, thereby defining a more-or-less cylindrical passage or tunnel through which a seaming pin or pintle may be directed to join the ends together.
The following is an example of a preferred embodiment of the present invention. It is provided for purposes of illustration and should not be taken to limit the subject matter claimed in the appended claims in any way.
EXAMPLE
A papermaker's fabric 10 was woven according to the weave pattern shown in FIGS. 1 through 4 and described above. MD yarns 26,28 were flat monofilament yarns of substantially rectangular cross section of dimensions 0.30 mm thick by 1.20 mm wide (0.012 inch by 0.047 inch; 12 mil by 47 mil), the width being on the upper and lower surfaces 12,14 of the fabric 10. MD yarns 24 were monofilament yarns of circular cross section of diameter 0.50 mm (0.020 inch; 20 mil). It will be noted that MD yarns 24 were thicker than MD yarns 26,28. Nevertheless, as a consequence of the weave pattern used and illustrated herein, the knuckles formed where MD yarns 24 wrap over (or under) CD yarns 18',22' are within the surface planes defined by MD yarns 26,28.
CD yarns 18,22 were monofilament yarns of circular cross section of diameter 0.50 mm (0.020 inch; 20 mil), while CD yarns 18',22' were monofilament yarns of circular cross section of diameter 0.40 mm (0.016 inch; 16 mil). CD yarns 18,18' alternate with one another, and, likewise, CD yarns 22,22' alternate with one another. CD yarns 18 were paired with and vertically stacked over CD yarns 22; in like manner, CD yarns 18' were paired with and vertically stacked over CD yarns 22'. MD yarns 24 binded with CD yarns 18',22'.
The papermaker's fabric 10 of this example performed with good results when tested on the dryer section of a papermaking machine.
Modifications to the above would be obvious to those of ordinary skill in the art, but would not bring the invention so modified beyond the scope of the appended claims.
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A papermaker's fabric having a smooth surface and a prolonged life includes flat machine-direction yarns which define the upper and lower surfaces thereof. The fabric has two layers of cross-machine direction yarns, each of which is interwoven with the flat machine-direction yarns. Other machine-direction yarns, of round cross section, weave with the cross-machine-direction yarns in the two layers to bind the two layers together. The knuckles of these round machine-direction yarns are within the fabric with respect to the planes defined by the flat machine-direction yarns, and, as a consequence, are less susceptible to degradation by heat and abrasion. The round machine-direction yarns may be used to seam the fabric. A longer fabric life follows from the protection of the round machine-direction yarns by the flat. The papermaker's fabric is particularly useful as a dryer fabric on the dryer section of a papermachine.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to field of amusement devices, particularly teeter-totters. Specifically, the invention relates to a spring balanced single rider teeter-totter.
[0003] 2. Background
[0004] Teeter-totters, also known as seesaws, have long been popular items of playground equipment for children. Teeter-totters come in various configurations, but most are fundamentally similar. In the most basic configuration, a teeter-totter can be simply a plank supported near its center for pivotal movement.
[0005] A variation of the conventional two-rider teeter-totter is one adapted for use by a single rider. One-sided, single-rider teeter-totters typically consist of a pivoting seat with a counterbalance, such as a spring, to balance the rider's weight. The rider rides up and down on the seat in a bouncing manner against the elastic resistance of the spring or other counterbalance device. An early version of a single rider teeter-totter is shown in U.S. Pat. No. 1,586,254. This device has a board with a seat at one end and a pivot near the opposite end. A spring is attached at the extreme opposite end of the board to balance the rider's weight. The height of the pivot and, indirectly, the counterbalancing effect of the spring is adjusted by raising or lowering a pair of threaded boards that support the pivot. This is a cumbersome adjustment and weakens the structural integrity of the frame. Furthermore, there is no direct adjustment for the resistance of the spring, nor is there any safety cover for the spring.
[0006] Other prior art single rider teeter-totters, including, for example, the device shown in U.S. Pat. No. 3,968,962, disclose adjustments for the spring resistance, that require that the spring or springs be repositioned. The adjustment process requires that the seat be lifted to release any tension and that the spring then be disconnected and reattached at a different location. In some of the prior art devices, the spring or springs must be moved from one detent to another, or the point of attachment of the spring must be slid along a track. These prior art methods of adjusting the spring tension are both cumbersome and dangerous. If the springs become detached or dislocated during use of the teeter-totter, the counterbalancing force may be reduced or eliminated altogether causing the rider to strike the ground forcibly and unexpectedly. Furthermore, fingers can be easily pinched while manually adjusting the springs.
SUMMARY OF THE INVENTION
[0007] The present invention provides a safer, more user-friendly single rider teeter-totter. Manual adjustments are provided for both the vertical position of the spring, which adjusts the rest height of the seat, and the horizontal position of the spring from the pivot, which adjusts the counterbalance resistance. Adjustments are accomplished with lead screw mechanisms, which provide virtually infinite adjustment within the travel of the screw and which remain in a selected position without the need for locks or detents. Other embodiments may include a locking slide mechanism that positively locks in defined detent positions. A safety cover may be provided for the spring or other counterbalance mechanism. Indicators are provided for visual reference of the adjustments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a single rider teeter-totter in accordance with an embodiment of the present inventions.
[0009] FIG. 2 is a detailed view of the height adjustment for the counterbalance mechanism.
[0010] FIG. 3 is a detailed view of the position adjustment for the counterbalance mechanism.
[0011] FIG. 4 is a detailed view of an optional shroud for the counterbalance mechanism.
[0012] FIG. 5 is a detailed view of an optional secondary elastic counterbalance.
[0013] FIG. 6 is a detailed view of an alternative position adjustment for the counterbalance mechanism.
DETAILED DESCRIPTION OF THE INVENTION
[0014] In the following description, for purposes of explanation and not limitation, specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that the present invention may be practiced in other embodiments that depart from these specific details. In other instances, detailed descriptions of well-known methods and devices are omitted so as to not obscure the description of the present invention with unnecessary detail.
[0015] FIG. 1 is a perspective view of a single rider teeter-totter 10 in accordance with an embodiment of the present invention. A frame 12 comprises forward support member 14 and generally U-shaped rear support member 16 . The frame further comprises pivot support post 18 with pivot assembly 20 attached at the top thereof. Longitudinal beam 22 is coupled to pivot assembly 20 . Seat support member 24 is attached to beam 22 . The various components of frame 12 may be fabricated from tubular steel as is common for exercise and playground equipment, although other materials may be used if desired.
[0016] Seat 26 is attached to seat support member 24 . Seat 26 may be constructed of a molded foam or plastic material. A handle bar 28 is attached to the upper portion of seat support member 24 . The weight of a rider in the seat 26 is counterbalanced by springs 32 . A pair of springs is used in parallel so that if one of the springs fails, the second spring will still provide half of the counterbalancing force to prevent the teeter-totter from falling uncontrollably. In the event of a spring failure, or if the spring resistance is not properly adjusted, or if the rider is simply overly exuberant, impact with the ground is cushioned by bumper 30 attached to seat support member 24 . Furthermore, the design of generally U-shaped rear support member 16 ensures that the rider will not contact any of the frame members at the bottom limit of travel and also eliminates pinch points in the vicinity of the seat.
[0017] FIG. 2 illustrates the spring height adjustment mechanism, which sets the rest height of the seat and thereby also acts as a range of travel adjustment. This mechanism adjusts the lower attachment point of springs 32 and thereby adjusts the height of seat 26 off of the ground. Yoke 34 is attached to forward support member 14 and carries adjustment screw 36 . The lower ends of springs 32 are attached with chain links 33 to follower 38 , which is threadably engaged on adjustment screw 36 and slides within guides 39 . Knob 40 is used to manually rotate adjustment screw 36 , thereby raising or lowering follower 38 . A numerical indicator 41 may be provided to assist riders in setting the seat height at a desired level. Guides 39 prevent twisting of the springs 32 as the vertical position of follower 38 is adjusted. This type of a lead screw adjustment mechanism provides virtually infinite adjustment within the travel of follower 38 on screw 36 and remains in a selected position without the need for any additional locking or detent mechanism.
[0018] The chain links 33 constitute flexible couplings that communicate tensile forces, but not compressive forces. As the rider approaches the top of the range of movement, the springs become fully relaxed and the chain links allow for continued upward movement. The rider thus experiences a free-floating or weightless sensation at the top of the range of movement.
[0019] FIG. 3 is a detailed view of the counterbalance adjustment mechanism. Adjustment screw 42 is suspended below beam 22 . The upper ends of springs 32 are attached to follower 44 , which is threadably engaged on adjustment screw 42 . Knob 46 is used to manually rotate adjustment screw 42 , thereby moving follower 44 fore and aft in relation to beam 22 . When follower 44 is moved closer to pivot 20 , the effective resistance of springs 32 is reduced, which is desirable for use of the apparatus by a lighter rider. Conversely, a heavier rider would turn knob 46 to move follower 44 further away from pivot 20 , thereby increasing the effective resistance of springs 32 . A numerical indicator may be provided on beam 22 as illustrated to assist riders in setting the effective resistance to a desired value.
[0020] FIG. 4 shows an optional elastic shroud 50 that surrounds the springs 32 . This protects children from having their fingers or other parts of their bodies pinched by the springs as they stretch and relax.
[0021] FIG. 5 shows an optional secondary counterbalance 52 . This may be an elastic cord that provides additional counterbalancing force in the event that one or both of the springs breaks. Cord 52 is coupled in parallel with the springs 32 and may be threaded though the center of one of the springs if desired. Cord 52 could also be inelastic to serve as a safety tether to stop the downward movement of the seat before it strikes the ground.
[0022] FIG. 6 shows an alternative counterbalance adjustment mechanism. Here, longitudinal beam 22 ′ is notched with detents 65 along a portion of its length. Springs 32 are attached to slider 60 , which rides along beam 22 ′ and is configured to be gripped by hand. A trigger 62 is pivotally attached to slider 60 and is biased towards an engaged position by spring 64 . Squeezing trigger 62 releases detent lock 66 from engagement with detent 65 and allows slider 60 to be moved forward or rearward to a desired position. As in the previously described embodiment, a numerical indicator may be provided on beam 22 ′ as illustrated to assist riders in setting the effective resistance to a desired value.
[0023] It will be recognized that the above-described invention may be embodied in other specific forms without departing from the spirit or essential characteristics of the disclosure. Thus, it is understood that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims.
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A safer, more user-friendly spring-balance single-rider teeter-totter includes manual adjustments for both the vertical position of the spring, which adjusts the rest height of the seat, and the horizontal position of the spring from the pivot, which adjusts the counterbalance resistance. A safety cover may be provided for the spring or other counterbalance mechanism.
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