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CROSS-REFERENCE TO RELATED APPLICATIONS
Priority of U.S. Provisional Patent Application Ser. No. 60/400,496, filed Aug. 1, 2002, incorporated herein by reference, is hereby claimed.
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 all terrain vehicles. The present invention more particularly relates to an improved all terrain vehicle that can automatically eliminate water that might accumulate in the air filter housing or transmission housing when the vehicle is used in inundated areas.
2. General Background of the Invention
All terrain vehicles are used in many different types of terrain. Some of these vehicles are subjected to use in inundated areas such as rice fields, marshes, swamps, streams, river bottoms and the like. When used in such an environment, these vehicles (particularly those with automatic transmissions) inadvertently intake water than can find its way to the transmission housing and/or the air filter housing. In such a situation, the vehicle can become dangerous to operate and/or operable.
BRIEF SUMMARY OF THE INVENTION
The present invention solves these prior art problems and shortcomings by providing an all terrain vehicle that has an improved transmission housing and air intake housing arrangement that automatically drains any water that is inadvertently ingested.
In the preferred embodiment, the transmission housing and/or the air intake housing are provided with a valve that automatically discharges any water that might be inadvertently ingested, and while in use.
The present invention is directed to an improved all terrain vehicle that has a chassis, front and rear wheels, an engine mounted in between the front and rear wheels, a seat to be occupied by a driver during use, and handlebars for enabling the user to steer the two front wheels.
The apparatus includes an inclined intake conduit that has a forward air intake opening and a housing air intake that communicates air from the forward air inlet to the transmission housing for cooling purposes. Air is discharged from the transmission housing via an air discharge passageway. Both the forward air intake passageway and the rear air discharge passageways that communicate with the transmission housing are preferably inclined. The intake opening and discharge opening are each at the highest possible location to lessen the chance that they will make contact with a body of water such as a stream, pond, lake, flooded field, marsh, swamp or with splashing water.
BRIEF DESCRIPTION OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
FIG. 1 is a partially cut away elevation view of the preferred embodiment of the apparatus of the present invention;
FIG. 2 is a partially cut away fragmentary view of the preferred embodiment of the apparatus of the present invention;
FIG. 3 is a fragmentary perspective view of the preferred embodiment of the apparatus of the present invention;
FIGS. 4A and 4B are sectional fragmentary views illustrating the valve portion of the preferred embodiment of the apparatus of the present invention; and
FIG. 5 is a partial sectional elevation view of the preferred embodiment of the apparatus of the present invention illustrating the valve and its connection to the transmission housing, and illustrating the air intake passageway and air discharge passageway that supply air for cooling purposes to the transmission housing.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1–4B show the preferred embodiment of the apparatus of the present invention, designated generally by the numeral 10 in FIG. 1 . All terrain vehicle 10 has a chassis 11 to which is mounted two front wheels 12 that are steerable wheels 12 and a pair of rear wheels 13 . A seat 14 is positioned generally in between the front 12 and rear 13 wheels.
Handlebars 15 are mounted in front of seat 14 and enable an operator to steer the vehicle 10 . An engine 16 is provided in between the front 12 and rear wheels 13 and generally below the seat 14 . A transmission housing 17 is provided with a known automatic transmission that transfers power from engine 16 to rear wheels 13 .
Transmission housing 17 has interior 18 . The known transmission includes pulleys and a belt 21 or belts. The pulleys can include forward pulley 19 and a rear pulley 20 as shown in FIGS. 1 and 5 . Belt 21 connects pulleys 19 , 20 .
Transmission housing 17 interior 18 receives cooling air from lower air intake passageway 22 . Air enters lower air intake passageway 22 through lower air intake opening 23 as indicated by arrow 24 in FIG. 1 . Air intake 24 communicates with housing 17 interior 18 at housing air inlet 25 . Air enters transmission housing 17 interior 18 for purposes of cooling the transmission parts that are contained in housing interior 18 . These parts are known in the art and can include pulleys 19 , 20 and belt 21 .
Air that is leaving transmission housing 17 interior 18 discharge via housing air exhaust 27 and air discharge passageway 28 . Arrow 29 schematically illustrates the exhaust of air that has traveled from intake 23 to housing interior 18 and then to rear air discharge opening 28 .
Another air intake at 35 is an upper air intake opening that provides air for the engine 16 carburetor. Air that enters intake 35 travels in the direction of arrow 37 via upper air intake passageway 36 to fitting 38 . In FIGS. 1 and 2 , fitting 38 communicates air to air filter element 31 inside air filter housing 30 where the air is filtered before it is discharged in the direction of arrow 33 into carburetor air flow channel 32 . The carburetor air flow channel 32 is a bore of conduit 39 that connects air filter housing 30 with the carburetor of the engine 16 .
The all terrain vehicle 10 , fitted with the improvements disclosed herein, can be a commercially available all terrain vehicle that has an automatic transmission such as the Yamaha® Grizzly or Kodiak models, as examples. Generally speaking, these models have been available in the time frame of 1999–2002.
Yamaha® Grizzly and Yamaha® Kodiak models having automatic transmissions (as well as other all terrain vehicles that have automatic transmissions) have suffered from a water intake problem when they are used in inundated areas. This problem can affect users that traverse streams, lakes, ponds, rice fields and the like. When the vehicle enters a rice field having a water level W, water in the form of drops 58 or other splashed water can enter either or both of the intakes 23 , 35 and be ingested by the apparatus 10 . In such a situation, the water drains downwardly in the inclined passageways 22 , 36 and can accumulate in either the interior 18 of transmission housing 17 or the interior of air cleaner housing 30 .
Each of the housings 17 , 31 is at an elevational position that is lower than or at the same level as the air intakes 23 , 35 respectively. For example, in FIG. 1 , air intake opening 23 is well above the interior 18 of automatic transmission housing 17 . Similarly, the air intake 35 is preferably at an elevation above all or part of air filter housing 30 .
In order to automatically and/or continuously remove water from either housing 17 , 18 during use, a valve structure 40 or 46 can be employed. This valve is preferably a one way valve, check valve, flapper valve or like valve that removes water from the housing 17 interior 18 during use, i.e. while the user is riding upon or using the vehicle 10 . Valve 40 that is attached to automatic transmission housing 17 is shown in FIG. 5 . Valve structure 40 includes an upper section 41 , lower section 42 , and is threadably attached to an internally threaded opening 44 of housing 17 . Upper section 41 of valve structure 40 provides external threads 43 that engage the internally threaded opening 44 .
The lower valve structure 42 is preferably a rubber or polymeric flapper valve that is similar to the construction of valve 46 shown in FIGS. 3 , 4 A and 4 B. The valves 40 and 46 each readily drain any water that collects above opening 44 or above opening 45 in FIG. 3 . Water simply drains through the valve structure 40 or 46 via gravity. However, each valve 40 or 46 is a one way valve or check valve that disallows entry of water to the housing 40 or 46 via the valve 40 or 46 . The lower valve element 42 and the valve member 46 can be of a rubber or polymeric construction and include, for example, a pair of opposed flat sections 53 , 54 with a slotted opening 55 there between that opens when water accumulates above the flat sections 53 , 54 . Water thus empties via slotted opening 55 in the direction of arrow 47 , as shown in FIGS. 2 and 4B .
At air cleaner housing 30 , opening 45 communicates with drain fitting 48 having annular shoulder 49 . Valve 46 has an annular groove 51 that receives hose clamp 50 . Valve 46 is shown in FIGS. 4A and 4B attached to fitting 48 . Hose clamp 50 attaches to annular groove 51 of valve 46 at a position above annular shoulder 49 of fitting 48 .
Similarly, the lower valve section 42 has a structure as shown in FIG. 4B that continuously drains any water that accumulates in housing 17 above internally threaded opening 44 . In FIG. 5 , an externally threaded upper section 41 is provided for threading attachment to opening 44 . In FIG. 2 , a hose clamp 50 is provided for attaching valve 46 to an unthreaded, generally cylindrically shaped fitting 48 .
PARTS LIST
The following is a list of suitable parts and materials for the various elements of the preferred embodiment of the present invention.
PART NO.
DESCRIPTION
10
all terrain vehicle
11
chassis
12
front wheels
13
rear wheels
14
seat
15
handlebars
16
engine
17
transmission housing
18
interior
19
pulley
20
pulley
21
belt
22
lower air intake passageway
23
lower air intake opening
24
arrow
25
housing air inlet
26
housing air exhaust
27
air discharge passageway
28
rear air discharge opening
29
arrow
30
air filter housing
31
air filter element
32
carburetor air flow channel
33
arrow
34
housing cover
35
upper air intake opening
36
upper air intake passageway
37
arrow
38
fitting
39
conduit
40
valve
41
upper section
42
lower section
43
external threads
44
internally threaded opening
45
opening
46
valve
47
arrow
48
fitting
49
annular shoulder
50
hose clamp
51
annular groove
52
flexible section
53
flat section
54
flat section
55
slotted opening
56
57
water level
58
water drops
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A method and apparatus for continuously discharging inadvertently accumulated water from the automatic transmission housing and/or air filter housing of an all terrain vehicle is disclosed. The continuous water discharge system employs a one-way valve structure that is mounted at the lower end portion of either or both of the automatic transmission housing and air filter housing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to electronic components and more particularly, to a method of accommodating an electronic component in an outer casing, by which an element itself of the electronic component such as a piezoelectric resonator or the like subjected to mechanical vibration is sheathed or encapsulated in the hollow outer casing.
2. Description of the Prior Art
Conventionally, in methods of this kind, it has been so arranged that electronic components such as integrated circuits, etc. are sheathed, i.e., encapsulated, by transfer molding in which epoxy resin is charged into a mold. However, it has been difficult to sheathe or encapsulate, by the transfer molding, elements themselves of electronic components such as piezoelectric resonators, acoustic vibrators, etc. with sheathing casings in which space for allowing them to mechanically vibrate is required to be formed.
Thus, in order to sheathe or encapsulate the elements themselves of the electronic components of this kind, it has been conventionally so arranged that a pair of sheathing casings made of ceramic and having a hollow structure are bonded to each other by the use of low-melting glass, adhesive, etc. However, this prior art sheathing method has such inconveniences that it becomes difficult not only to apply low-melting glass, adhesive, etc. to mating surfaces of the sheathing casings, but to position the sheathing casings accurately when the sheathing casings become compact for sheathing electronic components small in size. Furthermore, the prior art sheathing method has such disadvantages as requirements for long curing time, high curing temperature, low production efficiency, etc.
Consequently, in order to eliminate the above described inconveniences of the prior art sheathing methods, an improved sheathing method was proposed in Japanese Patent Application No. 117315/1982 (Tokugansho 57-117315) filed on July 5, 1982, of which the present inventor is one of the co-inventors and which is assigned to the same assignee as the present case. In the proposed method, a terminal frame formed by a metallic plate having a shape of a frame for securing an electronic component thereto is interposed between a pair of sheathing casings made of thermoplastic resin. Each is formed with a recessed portion. The terminal frame is electrically heated, so that mating faces of the sheathing cases are attached to each other through melting thereof. More specifically, referring to FIGS. 1 to 3, in the proposed method, an acoustic vibrator 11 supported by a terminal frame 12 is accommodated in a pair of a first sheathing casing 13 and a second sheathing casing 14 attached to each other.
The acoustic vibrator 11 includes a square frame member 15 formed by blanking a metallic plate made of metals having a constant modulus of elasticity, such as elinvar, etc., a rectangular acoustic vibrator body 17 provided inside the frame member 15, and coupling pieces 16a, 16b, 16c and 16d for supporting, at node portions of vibration of the acoustic vibrator body 17, the acoustic vibrator body 17. The coupling pieces 16a and 16d and the coupling pieces 16b and 16c are, respectively, provided at opposite sides of the acoustic vibrator body 17 symmetrically. A piezoelectric film 18 made of piezoelectric materials such as zinc oxide, etc. is formed on upper faces of the acoustic vibrator body 17. The coupling piece 16a and one portion of the frame member 15 adjacent to the coupling piece 16a are shown in FIG. 1. It should be noted here that the hatching in FIG. 1 does not illustrate a cross-section of the acoustic vibrator 11, but is given only for depicting the piezoelectric film 18 for convenience. Furthermore, a drive electrode film 19a, a lead electrode film 19b and an outlet electrode film 19c are formed on the piezoelectric film 18. It is to be further noted that the piezoelectric film 18 disposed under the lead electrode film 19b and the outlet electrode film 19c functions as an insulating layer.
Meanwhile, the terminal frame 12 has a frame portion of substantially square annular shape and includes a pair of U-shaped projections 21a and 21d projecting outwardly from opposite ends of one side of the frame portion in parallel with each other, a pair of U-shaped projections 21b and 21c projecting outwardly from opposite ends of the other side of the frame portion in alignment with the projections 21a and 21d, respectively, supporting pieces 20a, 20b, 20c and 20d protruding inwardly from the terminal frame 12 and disposed adjacent to the projections 21a, 21b, 21c and 21d, respectively, and lead terminals 22a, 22b, 22c and 22d projecting outwardly from the projections 21a, 21b, 21c and 21d in the same directions as the projections 21a, 21b, 21c and 21d, respectively. The supporting pieces 20a and 20b are provided diagonally symmetrically with respect to the supporting pieces 20c and 20d, respectively. As shown in FIG. 2, the projections 21a, 21b, 21c and 21d have a pair of leg portions 21al and 21a2, a pair of leg portions 21bl and 21b2, a pair of leg portions 21cl and 21c2 and a pair of leg portions 21dl and 21d2, respectively.
The first sheathing casing 13 of FIG. 1 and the second sheathing casing 14 of FIG. 1 each are formed into a square plate by molding thermoplastic resin such as polycarbonate, polyacetal, polyethylene, etc. and have mating faces 13b and 14b formed at peripheral side edges thereof, respectively and square recessed portions 13a and 14a enclosed by the mating faces 13b and 14b, respectively, such that the acoustic vibrator 11 is accommodated in the recessed portions 13a and 14a, with the mating faces 13b and 14b confronting each other. It is to be noted here that the frame portion of the terminal frame 12 is arranged to correspond, in configuration, to the mating faces 13b and 14b.
As shown in FIG. 2, the terminal frame 12 having the acoustic vibrator 11 secured to the supporting pieces 20a to 20d by welding (not shown) or by the use of electrically conductive adhesive (not shown) is interposed between the first sheathing casing 13 and the second sheathing casing 14 such that the supporting piece 20a is connected to the outlet electrode film 19b by the use of solder, bonding agent or electrically conductive adhesive or through mere contact therebetween, with the terminal frame 12 being in contact with the mating faces 13b and 14b. Then, the terminal frame 12 is electrically conducted or subjected to induction heating so as to be heated. When the terminal frame 12 is heated, the mating faces 13b and 14b in contact with the terminal frame 12 melt. Thereafter, when heating of the terminal frame 12 is stopped so as to lower the temperature of the terminal frame 12, the first sheathing casing 13 and the second sheathing casing 14 are attached to each other by thermoplastic resin forming the first sheathing casing 13 and the second, sheathing casing 14, whereby the acoustic vibrator 11 of FIG. 1 is accommodated in the recessed portions 13a and 14a.
Subsequently, when, for example, the leg portion 21a2 disposed inwardly of the leg portion 21a2 of the projection 21a and the leg portion 21b2 disposed inwardly of the leg portion 21b1 of the projection 21b are cut off as shown in dotted lines in FIG. 2, the lead terminals 22a and 22b are electrically conducted to the drive electrode film 19a, and the lead terminals 22c and 22d are electrically conducted to the acoustic vibrator body 17.
When the projections 21a to 21d of the terminal frame 12 are bent at right angles to the frame portion of the terminal frame 12 towards the second sheathing casing 14 and then, the lead terminals 22a to 22d are cut to a proper length, an acoustic vibrating component having a dual in-line type terminal structure can be obtained.
Furthermore, when, for example, the projections 21b and 21c projecting from one side of the first sheathing casing 13 and the second sheathing casing 14 are cut off before the projections 21a to 21d are bent at right angles to the frame portion of the terminal frame 12 towards the second sheathing casing 14 as described above, an acoustic vibrating component having a single in-line terminal structure constituted by the lead terminals 22a and 22d projecting from the other side of the first sheathing casing 13 and the second sheathing casing 14 can be obtained.
Moreover, the terminal frame 12 can be replaced by a terminal frame 12' shown in FIG. 3. The terminal frame 12' includes supporting pieces 20c' and 20d' in place of the supporting pieces 20c and 20d of the terminal frame 12, respectively. Namely, the supporting piece 20c' projects inwardly from the terminal frame 12' in parallel with the supporting piece 20b, while the projecting piece 20d' projects inwardly from the terminal frame 12' so as to confront the supporting piece 20a.
However, the above described method proposed in the Japanese Patent Application No. 117315/1982 has such inconveniences that, since the lead terminals 22a to 22d of the terminal frame 12 are used as terminals for electrical conduction for heating the terminal frame 12, electric current is caused to flow through the lead terminals 22a to 22d when the terminal frame 12 is electrically conducted so as to be heated, with the result that solder deposited on the lead terminals 22a to 22d are removed therefrom, etc.
SUMMARY OF THE INVENTION
Accordingly, an essential object of the present invention is to provide an improved method of accommodating an electronic component in a casing, in which at least two electrically conductive terminals are provided on a substrate portion of a terminal frame for securing the electronic component thereto and the substrate portion is interposed between a pair of casings made of thermoplastic resin such that a predetermined voltage is applied between the electrically conductive terminals so as to subject the substrate portion to resistance heating, whereby mating faces of the casings are attached to each other through melting thereof, with substantial elimination of the disadvantages inherent in conventional methods of this kind and the Japanese Patent Application No. 117315/1982 referred to above. Another important object of the present invention is to provide an improved method as described above which is highly reliable in actual use and can be readily applied to electronic components and the like at low cost.
In accomplishing these and other objects according to one preferred embodiment of the present invention, there is provided an improved method of accommodating an electronic component in a casing, comprising the steps of: forming said casing by a pair of first and second casings such that a mating face of said first casing and a corresponding mating face of said second casing confront each other; providing a terminal frame having a substrate portion formed into a shape of frame, a plurality of lead terminals and at least two electrically conductive terminals such that said lead terminals and said electrically conductive terminals project outwardly from said substrate portion; securing said electronic component to said substrate portion or integrally forming said electronic component with said substrate portion; interposing opposite faces of said substrate portion between said mating face of said first casing and said corresponding mating face of said second casing; and establishing electrical conduction between said electrically conductive terminals so as to heat said substrate portion such that said mating face of said first casing and said corresponding mating face of said second casing are attached to each other through melting thereof, whereby said electronic component is accommodated in said first casing and said second casing attached to each other.
In accordance with the present invention, electric current for heating the terminal frame is prevented from flowing through the electronic component and even molded casings compact in size can be easily used for accommodating the electronic components therein.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the present invention will become apparent from the following description taken in conjunction with the preferred embodiment thereof with reference to the accompanying drawings, in which:
FIG. 1 is an exploded perspective view of casings for accommodating therein an electronic component attached to a terminal frame, which are employed in a method proposed in Japanese Patent Application No. 117315/1982 (already referred to);
FIG. 2 is a view explanatory of assembly of the electronic component accommodated in the casings of FIG. 1 (already referred to);
FIG. 3 is a top plan view of a terminal frame which is a modification of the terminal frame of FIG. 1 (already referred to);
FIG. 4 is an exploded perspective view of casings for accommodating therein an electronic component attached to a terminal frame, which are employed in a method according to one preferred embodiment of the present invention;
FIG. 5 is a view explanatory of assembly of the electronic component accommodated in the casings of FIG. 4; and
FIG. 6 is a top plan view of a terminal frame plate for connecting a plurality of the terminal frames of FIG. 4.
Before the description of the present invention proceeds, it is to be noted that like parts are designated by like reference numerals through several views of the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 4 to 6, in a method for accommodating an electronic component in a casing, according to one preferred embodiment of the present invention, an acoustic vibrator 60 secured to a terminal frame 52 is accommodated in a pair of a first sheathing casing 70 and a second sheathing casing 72 attached to each other.
The terminal frame 52 is formed into a one-piece construction by blanking a thin metallic plate. As shown in FIG. 6, the terminal frame 52 is formed into a terminal frame plate 51 in which a plurality of the terminal frames 52 are connected to each other in a row. As shown in FIG. 4, the terminal frame 52 includes a substrate portion 53 having a shape of a substantially square annular frame constituted by one pair of opposite sides 53a and 53a' and the other pair of opposite sides 53b and 53b', a pair of lead terminals 54-1 and 54-2 projecting outwardly and horizontally from the side 53a at right angles thereto, a pair of lead terminals 54-3 and 54-4 projecting outwardly and horizontally from the side 53a' at right angles thereto and in alignment with the lead terminals 54-1 and 54-2, respectively, a pair of eleotrically conductive terminals 55-1 and 55-2 projecting outwardly and horizontally from the sides 53a and 53a' at right angles thereto and in alignment with each other between the lead terminals 54-1 and 54-2 and between the lead terminals 54-3 and 54-4, respectively, a pair of supporting pieces 56-1 and 56-2 projecting inwardly and horizontally from the side 53b at right angles thereto and a pair of supporting pieces 56-3 and 56-4 projecting inwardly and horizontally from the side 53b' at right angles thereto and in alignment with the supporting pieces 56-1 and 56-2, respectively. The supporting pieces 56-3 and 56-4 extend longer than the supporting pieces 56-1 and 56-2. Furthermore, a pair of grooves or slots 57-1 and 57-2 of substantially U-shaped configuration are, respectively, formed at a coupling portion between the electrically conductive terminal 55-1 and the side 53a of the substrate portion 53 and at a coupling portion between the electrically conductive terminal 55-2 and the side 53a' so as to traverse the sides 53a and 53a' from inner side edges thereof into the electrically conductive terminals 55-1 and 55-2.
Meanwhile, although the electrically conductive terminals 55-1 and 55-2 function also as coupling members for connection each terminal frame 52 to the terminal frame plate 51, it can be so arranged that other coupling members are provided separately instead of the electrically conductive terminals 55-1 and 55-2.
The acoustic vibrator 60 is constituted by a plate member 61 integrally formed by blanking a metallic plate made of metals having a constant modulus of elasticity, such as elinvar, etc. The plate member 61 includes a square frame portion 62, a rectangular vibrator body 63 provided inside the frame portion 62 and coupling pieces 64-1, 64-2, 64-3 and 64-4 for supporting, at node portions of vibration the vibrator body 63. A piezoelectric film 65 made of piezoelectric materials such as zinc oxide, etc. is formed on upper faces of the vibrator body 63, the coupling pieces 64-1 and 64-3 and one portion of the frame portion 62 being shown in FIG. 4. It should be noted here that the hatching in FIG. 4 does not illustrate a cross-section of the acoustic vibrator 60, but is given only for depicting the piezoelectric film 65 for convenience. Furthermore, an electrically conductive film 66 is formed on some portions of the piezoelectric film 65 and includes a drive electrode portion 66a, a pair of lead electrode portions 66b and a pair of outlet electrode portions 66c.
The first sheathing case 70 and the second sheathing casing 72 are formed into a square shape by molding thermoplastic resin such as polycarbonate, polyacetal, PBT, PPS, etc. The first sheathing casing 70 and the second sheathing casing 72 are of an identical configuration and have peripheral side walls 70b and 72b formed at peripheral side edges thereof, respectively, recessed portions 71 and 73 enclosed by the peripheral side walls 70b and 72b, respectively and mating faces 70a and 72a formed on a lower face of the peripheral side wall 70b and an upper face of the peripheral side wall 72b, respectively, such that the mating faces 70a and 72a confront each other. Thus, when the mating face 70a of the first sheathing casing 70 and the mating face 72a of the second sheathing casing 72 are brought into contact with each other, a cavity is defined by the recessed portions 71 and 72. The peripheral side wall 70b of the first sheathing casing 70 and the peripheral side wall 72b of the second sheathing casing 72 are so shaped as to overlap the opposite sides 53a', 53b and 53b' of the terminal frame 52.
Hereinbelow, the method of the present invention for accommodating the acoustic vibrator 60 in the first sheathing casing 70 and the second sheathing casing 72 attached to each other will be described. Firstly, the acoustic vibrator 60 is secured to the substrate portion 53 of the terminal frame 52 so as to be disposed inside the substrate portion 53. At this time, as shown in FIG. 4, portions 67-1 and 67-2 of the acoustic vibrator 60 marked with small circles are, for example, spot welded to a portion 68-1 of the supporting piece 56-3 and a portion 68-2 of the supporting piece 56-4 each marked with a small circle, respectively. Meanwhile, the outlet electrode portions 66c of the acoustic vibrator 60 are, for example, soldered under pressure to the supporting pieces 56-1 and 56-2 of the terminal frame 52, respectively.
After the acoustic vibrator 60 has been secured to the terminal frame 52 as described above, the mating face 70a of the first sheathing casing 70 and the mating face 72a of the second sheathing casing 72 are, respectively, brought into contact with opposite faces of the sides 53a, 53a', 53b and 53b' of the substrate portion 53 of the terminal frame 52 such that the sides 53a, 53a', 53b and 53b' are brought into alignment with the peripheral side wall 70b of the first sheathing casing 70 and the peripheral side wall 72b of the second sheathing casing 72, so that the acoustic vibrator 60 is accommodated in the cavity defined by the recessed portion 71 of the first sheathing casing 70 and the recessed portion 73 of the second sheathing casing 72 and, at the same time, the substrate portion 53 is interposed between the mating face 70a of the first sheathing casing 70 and the mating face 72a of the second sheathing casing 72 under a predetermined pressure. Thereafter, when a predetermined voltage is applied between the electrically conductive terminals 55-1 and 55-2 of the terminal frame 52, electric current is caused to flow through the electrically conductive terminal 55-1, the substrate portion 53 and the electrically conductive terminal 55-2. Accordingly, the substrate portion 53 is heated in accordance with its resistance value, so that the mating face 70a of the first sheathing casing 70 and the mating face 72a of the second sheathing casing 72 are heated so as to be molten, whereby the mating faces 70a and 72a are attached to each other through melting thereof.
Meanwhile, since electric current does not flow through the supporting pieces 56-1 to 56-4 and the lead terminals 54-1 to 54-4, such undesirable phenomena do not take place that the acoustic vibrator 60 is damaged or solder deposited on the lead terminals 54-1 to 54-4 is removed therefrom by electric current for heating the substrate portion 53. By the above described operations, the acoustic vibrator 60 can be accommodated in the first sheathing casing 70 and the second sheathing casing 72 in a few seconds.
Subsequently, the electrically conductive terminals 55-1 and 55-2 of the terminal frame 52 sheathed by the first sheathing casing 70 and the second sheathing casing 72 are cut off along the one-dot chain lines in FIG. 5, whereby the lead terminals 54-1 and 54-3 are, respectively, electrically insulated from the lead terminals 54-2 and 54-4 by the grooves 57-1 and 57-2.
Meanwhile, the first sheathing casing 70 has opposite side faces 70c and 70c' which are, respectively, disposed adjacent to the lead terminals 54-1 and 54-2 and the lead terminals 54-3 and 54-4. The lead terminals 54-1 and 54-2 and the lead terminals 54-3 and 54-4 are, respectively, bent substantially vertically towards the side faces 70c and 70c' along the one-dot chain lines in FIG. 5, and thus, the acoustic vibrator 60 of the so-called dual in-line type molding is obtained.
It is to be noted here that, although the method according to the above described embodiment of the present invention is applied to the acoustic vibrator 60, the method of the present invention is not exclusively applied to the acoustic vibrator 60 but can be widely applied to various electronic components which make mechanical vibrations, such as a piezoelectric resonator, a reed switch, a reed relay, a bimetal, a pressure sensor, etc.
Meanwhile, as shown in FIG. 6, it can be so arranged that one electronic component is secured to or integrally formed with each of the terminal frames 52 coupled to each other in the terminal frame plate 51 and then, a plurality of the terminal frames 52 are fed to subsequent predetermined processes at a time or one by one such that the first sheathing casing 70 of FIG. 5 and the second sheathing casing 72 of FIG. 5 are attached to each of the terminal frames 52 through melting thereof, whereby the electronic component is accommodated in each pair of the first sheathing casing 70 and the second sheathing casing 72 attached to each other.
As is clear from the foregoing description, in accordance with the present invention, at least two electrically conductive terminals are provided on the substrate portion of the terminal frame having the electronic component secured thereto so as to be electrically conducted therebetween such that the mating faces of the first sheathing casing and the second sheathing casing both made of thermoplastic resin and having the substrate portion interposed therebetween are attached to each other through melting thereof, whereby electric current for heating the substrate portion is advantageously prevented from flowing through the electronic component and the electronic component can be accommodated in the first sheathing casing and the second sheathing casing remarkably efficiently and at low cost.
Although the present invention has been fully described by way of example with reference to the accompanying drawings, it is to be noted here that various changes and modifications will be apparent to those skilled in the art. Therefore, unless otherwise such changes and modifications depart from the scope of the present invention, they should be construed as included therein.
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A method of accommodating an electronic component in a casing, comprising the steps of: forming the casing by a pair of first and second casings made of thermoplastic resin; providing a terminal frame having a substrate portion, a plurality of lead terminals and at least two electrically conductive terminals; securing the electronic component to the substrate portion or integrally forming the electronic component with the substrate portion; interposing the substrate portion between the first and second casings; and establishing electrical conduction between the electrically conductive terminals so as to heat the substrate portion such that the first and second casings are attached to each other through melting thereof.
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RELATED APPLICATIONS
[0001] This Application claims priority to Indian Application No. 999/MUM/2004 dated 17.09.2004.
BACKGROUND OF INVENTION
[0002] The present invention relates to a process for preparing a non-woven cellulosic structure and the non-woven cellulosic structure prepared therefrom. Particularly, the present invention relates to a process for preparing a consolidated multiple/single layer, absorbent, durable or disposable composite non-woven cellulosic structure comprising of at least one layer that is made from bio-degradable, continuous cellulosic material.
[0003] More particularly, the present invention relates to a process for preparing a non-woven cellulosic structure comprising of continuous, randomized cellulosic fibers and the composite non-woven cellulosic structure prepared therefrom.
[0004] 1. Introduction
[0005] Consolidated non-woven structure may comprise of Viscose Fibers, Lyocell Fibers, Cellulose acetate, and/or its blends with synthetic fibers. Lyocell fiber is a man made fiber based on dissolving non-derivatized cellulose directly in an organic solvent. Lyocell fibers are produced by regeneration of cellulosic fiber from a solution of cellulose in an organic solvent like N Methyl Morpholine N Oxide.
[0006] 2. Prior Art
[0007] The process of manufacturing cellulosic fibers is known in the prior art. U.S. Pat. No. 3,600,379 discloses a process of manufacturing Viscose fibers wherein the wood pulp is utilized as a raw material. It is steeped either as sheets or slurry with 17-22 percent NaOH solution. The excess steeping liquor is removed by pressing. The alkali cellulose is shredded and aged. The aged alkali cellulose is xanthated with an amount of carbon disulphide. The xanthate is dissolved in NaOH solution forming Viscose solution. The viscose is ripened and filtered once or several times either during or after ripening. The viscose solution can then be spun through fine orifices in acidic spin bath to form regenerated cellulosic filaments/fibers/tow. Viscose/Rayon spinning is almost 100 years old technology and hence described in brief only. Similarly preparation of non-derivatized cellulose solution through solvent spinning route is also known.
[0008] Indian Patent No. 189773 mentions a process of preparing cellulose solution for spinning fibers/films. The process includes introducing cellulose material into an aqueous solution of tertiary amine oxide to prepare a suspension. Later the suspension is subjected to high shear equipment heating under reduced pressure.
[0009] U.S. Pat. Nos. 4,144,080 and 4,246,221 disclose a method of preparation of amine oxide solution by extruding ground tertiary Amine Oxide solution and Cellulose. Also disclosed is the method of producing fibers by spinning the solution through fine orifices in air, orienting the same by mechanical stretching and regenerating the cellulose from the solution bay allowing the spun filaments to pass through a bath of a nonsolvent.
[0010] Once filaments are formed either through Viscose process or by any other process, the tow is washed and fibers cut into staple length. Conventionally the staple fibres are dried and baled (if non-wovens are prepared at different location). The dried staple fiber bale is opened, blended if required and carded to form a fibrous mat. This mat is directly or after cross lapping bonded to form a non-woven material.
[0011] Methods cited in U.S. Pat. Nos. 3,833,438 and 3,906,130 explain a process to make non-woven and perforated textile fabrics from continuous cupramonium rayon, viscose rayon and the like fiber filaments. In this process primarily the continuous filaments are cast on a conveyor, which is caused to oscillate laterally along with forward motion. The spinning units describe respective parallel and sinusoidal curves. Later, consolidation is achieved by water jets. Cupramonium rayon is an expensive method to produce absorbent cellulosic non-woven. Method involves mechanical moving parts like cam/crank mechanisms, which are prone to breakdown/maintenance. The limiting oscillation speed (cycles/min) limits the filament feed velocity and hence the production rate.
[0012] U.S. Pat. Nos. 3,620,903 and 4,069,563 disclose a method to produce light weight, non patterned non-woven fabrics by treating fibrous sheet of materials with fine, essentially one or more columnar streams of liquid jetted from orifices, under high pressure. A layer of fiber web is supported on a surface and traversed with the streams to entangle the fibers in a manner which imparts strength and stability without the need for binder.
[0013] The aforesaid patents describe the processes wherein the cellulosic solution is spun using a solvent spun method. The cellulosic fibers are spun and cut into staple lengths. Subsequently, they are treated with water and/or other chemicals. These wet fibers are then dried. In order to manufacture a non-woven product, the mat is opened by use of an opener, carded and then hydro entangled to obtain a spun laced product. The said product is re-dried to achieve a cellulosic non-woven fiber. This is a conventional and well-accepted method to produce cellulosic non-woven fiber. However, the process involves drying the said fiber twice, thereby increasing the costs. Also strength of the said non-woven fiber is not high since it comprises of short (staple) length fibers.
SUMMARY OF PRESENT INVENTION
[0014] The present invention discloses a process of manufacturing continuous cellulosic filaments obviating the aforesaid drawbacks.
[0015] The present invention relates to a process for preparing a non-woven cellulosic structure comprising the steps of extruding filaments from a cellulosic solution; passing the extruded filaments through a regenerating liquid to attenuate the filaments and laying the attenuated filaments into a web and to the non-woven cellulosic structure prepared therefrom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] The present invention will now be described with reference to the figures accompanying the specification, wherein the same numerals denote the same parts and wherein:
[0017] FIG. 1 shows the isometric view of the assembly for spinning the non-woven cellulosic material.
[0018] FIG. 2 shows the exploded isometric view of the spinning box as shown in FIG. 2 .
[0019] FIG. 3 shows the isometric view of the set up showing the laying of the curtain.
[0020] FIG. 4( a ) to 4 ( e ) show various options for preparation of a composite structure.
[0021] Referring to FIGS. 1 and 2 , the cellulose solution at required temperature and constant flow rate is fed into a spinneret assembly ( 7 ), preferably a rectangular assembly. A spinning box ( 3 ) is kept below the rectangular spinneret assembly. The spinning box ( 3 ) is used to attenuate the filaments and also to randomly lay down the filaments, thereby maintaining the rectangular configuration of the web. The regeneration liquid is fed with the help of a regeneration liquid feed pipe ( 4 ). The location of the regeneration liquid feed pipe can be either from the top or from the bottom of the spinning box. The spinning box ( 3 ) comprises of a funnel shaped sides which form a funnel shape till a certain length, the rest of the portion remaining straight. The funnel is meant to allow the regeneration liquid to pass from top to bottom. Top part of the funnel ( 5 ) may have perforations in the side plate so that as the regeneration liquid starts filling up the spinning box ( 3 ), the fluid comes out from the perforations and passes through the funnel. Flow from the regeneration liquid feed pipe ( 4 ) is regulated to maintain a constant level of the liquid. The height of the water column in the spinning box makes the liquid flow from the funnel ( 5 ) at a high speed, due to gravitational acceleration. High speed fluid imparts a drag to the filaments fed from the spinneret assembly and get attenuated. Stretched filaments are allowed to fall by way of its own energy gained by the fluid flow on to a collection belt conveyor ( 8 ). Since the collection belt ( 8 ) moves at a slower speed as compared to the filament drop down speed, the filaments lay down randomly on the belt forming a fairly entangled non-woven web. The entire conveyor is placed within a regeneration liquid collection tank ( 9 ). The regeneration liquid by gravity flows out of this tank to the recovery section and the recycle section. Laying is attained by a vacuum system ( 10 ), which is provided below the collection belt just under the filament outlet. Vacuum allows the filaments to retain its random orientation on the belt, thereby reducing the effect of water force.
[0022] FIG. 3 shows one of the preferred laying options. Curtain ( 11 ) formed by the aforedescribed method is brought to the feeding box ( 12 ). The feeding box may have a mechanically driven twin roll arrangement to draw the curtain and feed it below. The feeding box ( 12 ) is pivoted by a swing arrangement, which lays down the curtain in folds ( 13 ) on to the moving collecting belt ( 14 ). Depending upon the coverage required, the speed of the swing, the drop down rate and the belt conveyor speed can be adjusted. Similarly, one or more feeding boxes ( 12 ) in combination with collecting belt ( 14 ) may operate such that web structure like that of a cross lapper is obtained. A cross lapped web may have a higher coverage and better tensile strength in cross direction (CD) as compared to the CD tensile strength of the web made as shown in FIG. 3 .
[0023] FIG. 4( a ) shows a typical un-consolidated laid mat made from Viscose continuous filaments ( 1 ) randomized by fluid assisted randomizer. FIG. 4( b ) shows a typical un-consolidated laid mat made from Lyocell continuous filaments ( 2 ) randomized by fluid assisted randomizer. The above two structures may be consolidated by known methods described. FIG. 4( c ) is a representative sketch of a non-woven composite structure prepared by the aforesaid process prior to consolidation. In this case the bottom layer is cellulosic non-woven Viscose or Lyocell or the like ( 1 ) or ( 2 ) prepared by the process described above, while the top layer may be either cellulosic non-woven or synthetic non-woven web (x). The structure may be consolidated by known methods described above to form a consolidated structure. FIG. 4( d ) is a representative sketch of a non-woven composite structure prepared by the process described above prior to consolidation. In this case the bottom layer may be either cellulosic non-woven or synthetic non-woven web (x), while the top layer is cellulosic non-woven Viscose or Lyocell or the like ( 1 ) or ( 2 ) prepared by the process described above. The structure may be consolidated by known methods. FIG. 4( e ) represents a composite structure with multiple layers of either cellulosic or synthetic non-wovens (x 1 , x 2 . . . ) with at least one layer of cellulosic non-woven Viscose or Lyocell or the like ( 1 ) or ( 2 ) prepared by the process described above. Presence or absence of either of the layers ( 1 ) or ( 2 ) may be decided upon the desired performance of the composite structure. The structure may then be consolidated by known methods.
Solvent Spinning Route (Lyocell):
[0024] Pulp preferred for use for making the solution is soft wood pulp having high alpha cellulose content (89-93%) and low semi-cellulose content. DP (Degree of Polymerization) of the pulp is in the range of 600 to 1100, preferred range would be 700 to 1000. Cellulose concentration to achieve a spin able solution can be in the range of 5% to 28%. Preferably 7% to 20%, most preferred values of the cellulose concentration are 10% to 15%. NMMO (N-Methyl Morpholine N-Oxide) as available in the market is of 50% concentration has to be pre-concentrated to 77% prior to dissolution of cellulose by conventional distillation process. Blending of small pieces of pulp with pre-concentrated solvent is carried out at about 100° C. in a double blade sigma mixer where in vacuum of 400 mm Hg is applied. After duration of 1.5 hours a homogeneous solution is obtained, which is allowed to cool down to solid condition. Other methods available for making cellulose solutions on a continuous basis are available like use of high shear blender, thin film device or a devolatalizing type counter rotating twin screw extruders. A method described in Indian Patent No. 189773 may also be followed.
[0025] A spinning die with multiple holes arranged in a rectangular configuration having aspect ratio of length to breadth around 1.2 to 200, which has spinning hole diameters ranging from 50 micron to 150 micron, preferably 55 to 100 microns, is utilized to extrude filaments. The above given aspect ratio allows for providing 10 to 60 rows of holes.
[0026] During spinning of Lyocell polymer at 90 to 110 deg C., adequate air gap and air flow in cross direction is provided. Depending upon the size of the spinneret and the stretch ratio, filaments from sub denier to 5 deniers can be spun.
[0027] Filaments coming out in the form of a curtain retain their rectangular configuration by the virtue of a special device, which contains the regeneration bath. Central portion of the box has a funnel type arrangement. The funnel may be perforated from the top and plain below a certain distance. Internal are so arranged such that a slit is provided at the bottom of the funnel, which serves as an outlet for the regeneration solution as well as outlet for spun filament. The funnel is sealed and isolated from the sides so that the regeneration liquid from the bottom of the box cannot enter the funnel. The inlet of the regeneration liquid is provided at the bottom. As the liquid fills the box and level is raised beyond the plain portion of the funnel, the liquid reaches to the perforated portion of the funnel. Liquid enters the funnel. Flow in the box is so adjusted that the outlet level matches with the inlet and always keeps the regeneration box full up to the brim. The velocity of the extruded filaments is 8 m/min to 80 m/min.
[0028] Flow of liquid inside a small width accelerates the filaments from the spinneret. The regeneration liquid is sent for solvent recovery process. Velocity of the regeneration liquid attained at the outlet of the spinning box is governed by the relation:
[0000] V 2 =2× g×h
Where g—force of gravitational acceleration in m/sec 2
[0029] h—height of regeneration liquid from funnel bottom opening in m
[0030] V—velocity of regeneration liquid in m/sec.
[0031] The velocity of the regenerating liquid is kept between 50 m/min to 250 m/min, preferably between 100 m/min to 200 m/min.
[0032] Flow rate of regeneration liquid required to maintain the level in the spinning box is governed by the relation:
[0000]
Q=L×W×V
Where L—Length of the funnel measured at the bottom in m
[0033] W—Opening of the funnel bottom in m
[0034] Q—Quantity of regeneration liquid required to maintain the level in m 3 /Hr.
[0035] From the above relations it can be observed that for a given width of spinneret, water flow depends mainly on 2 parameters, viz. the height and the funnel bottom opening. Trials conducted on various funnels showed that higher the liquid height, higher is the flow rate and higher is the drag (stretch) imparted to the filaments. On the other side of it, higher the water flow rate means higher water energy at the funnel outlet position. Higher the water energy higher is the disturbance imparted to filaments. Therefore while-designing a spinning box funnel one should keep both these factors into consideration. Examples cited show different funnel configurations.
[0036] When the extruded filaments are passed through the regenerating liquid, the filaments are attenuated.
[0037] The said filaments formed by the method described above are brought to the belt conveyor where filaments may get additionally randomized due to flow of regenerating liquid. As an alternative for belt conveyor, collection of web may be done on a rotary vacuum drum system. The feeding box may have a mechanically driven twin roll arrangement to draw the web and feed it below. The feeding box has a variable speed drive and is pivoted by a swing arrangement which lays down the web in folds on to the moving collecting belt. Step less adjustment of the swing amplitude and the swing speed can also be provided. Depending upon the coverage required the speed of the swing, the amplitude of the swing, the drop down rate and belt conveyor speed can be adjusted so as to get webs with coverage from 10 to 600 gsm. Filament mat can also be formed without swinging the feeding box also. Then the only variables would be the conveyor and the curtain drop down speed.
[0038] Yet another laying option is cross lapping. The method is similar to the one shown in FIG. 3 . However, there are one or more than one boxes feeding the belt conveyor in cross direction. Swing boxes lay down the web along the width of the conveyor giving a cross lapping type laying, as well as they may lay it along the direction of the moving belt conveyor as shown in FIG. 3 if required, such a web may have higher coverage and better tensile strength in cross direction as compared to the CD tensile strength shown in FIG. 3 . The laying options cited above are especially beneficial when cellulosic fibers are to be mixed with other fibers. When a composite structure is required, web of 1 or more fiber is brought in to form a multi layer structure. The resultant web would be a composite structure of cellulosic and the other fibers.
[0039] The un-bonded web then passes through consolidation step, which may include hydro-entanglement, chemical bonding, needle punching system, etc., which consolidates the mat fibers together to produce a bonded consolidated non-woven material.
[0040] Wet non-woven bonded material is thereafter treated for, bleaching, further washing, dyeing, soft finishing, etc. and then passed through a dryer that expels excess moisture. Subsequently the web is collected on the winder and rolled. The said web has a soft handle and good strength and may be used for many different applications of semi-durable or disposable segment.
Viscose Spinning Route:
[0041] Properly aged, filtered, ripened and deaerated viscose is fed at right temperature to the spinning machine. Spinneret holder may remain same or needs to be modified suitable to the cluster plate which has circular precious metal eyes fitted and arranged in the form of a rectangular shape. Each eye is drilled with required number of spinning orifices following the conventional triangular pitch and configuration.
[0042] Spinneret is dipped in the spin bath maintained at desired temperature and concentration level in the bottom down position, i.e. the spinning orifices face downwards. The only difference between Lyocell route and Viscose route is that in Lyocell route, an air gap is maintained between the regeneration liquid and spinneret, while in case of Viscose route, spinneret is immersed in the regeneration bath, since Viscose spinning is a wet spinning process. Thus a viscose web is formed. Cross section of the cellulosic fibers may be altered by using different spinnerets to obtain tri-lobal, Y-shaped, or other shapes to impart specific properties to the structure. Subsequent steps are same as mentioned above for the solvent spinning route for the formation of a non-woven material. Only the hydro entanglement/consolidation operating parameters might differ for Viscose.
[0043] Understanding the filament behavior when they are laid down is necessary. Hence an analogy of a thread is considered. When a thread is laid down perpendicularly on to a moving belt, the laid down form taken by the thread is determined by the filament properties (linear density, bending rigidity and torsional rigidity, height of the feed point and feed to belt speed ratio). Further, important variables apart from the filament properties in the process of lay down are filament velocity, belt speed, water velocity, height of the spinning box from the belt, vacuum below the collecting belt and design of the spinning box.
Consolidation:
[0044] Once the curtain of randomized/laid continuous cellulosic filaments is obtained, next process is to consolidate the curtain into a non-woven web. There are numerous options available (as shown in FIGS. 4( a ) to 4 ( e )) to the non-woven manufacturer once a curtain of randomized/laid continuous cellulosic filaments is obtained. Layer/Layers of melt blown or spun bonded, mono/bi-component melt spin able thermoplastic polymers like Polyethylene, polypropylene, ethyl vinyl acetate, polyester, polyurethane, ethylene methyl acrylate, nylon or the like may be used. Depending upon the desired end product performance characteristics the layer/layers are selected. One may also use a carded staple fiber mat formed out of viscose, Lyocell or other melt spin able thermoplastic polymers as mentioned above to form a part of the non-woven structure along with at least one layer of the curtain produced by method disclosed in this invention. After laying all the layers in the desired positions, the un-bonded non-woven structure is consolidated using various processes known to those skilled in the art. Process may include hydro entanglement, needle punching, thermal bonding, spot bonding, melt stabilization, latex or chemical bonding. Type of bonding/consolidation process used may be decided based on the desired end product/product characteristics.
Testing:
[0045] Test procedures used to determine the properties of the consolidated non-woven structure and products made by the disclosed process are known to those well versed in the non-woven field.
Tensile Tests:
[0046] A sample of 200 mm length and 2.5 cm wide can be stretched in an Instron equipment at a rate of 100 mm/min obtains the point at which the structure yields. This figure when represented in N/2.5 cm value describes the value of tensile strength of a non-woven. Values obtained are shown in the table No. 1.
Fiber Orientation Distribution:
[0047] This test is a measure of randomization of filaments in a non-woven structure. Two example graphs as shown below: Graph: 1 represents a non-woven structure which has more number of filaments in a particular direction—representing a low degree of randomization, while Graph: 2 shows a non-woven structure with a higher degree of randomization. One can thus determine the amount of randomization of the web structure.
[0048] Other tests which are essential to understand the performance of the product are: Basis weight, Elongation at break, tear strength, web abrasion resistance test, drop absorbency test, absorbent capacity test, vertical wicking rate, drip capacity test, dry lint release test. Procedure for these tests can be obtained from any non-woven handbook.
EXAMPLES
Example 1
[0049] 12% cellulose Lyocell polymer solution was fed at the rate of 0.06 grams/hole/min through a rectangular spinneret having 20 rows of 80 micron diameter holes, giving an extrusion speed of 10 m/min. Below the spinneret the spinning box maintaining a regeneration liquid column of 510 mm was installed in such a way that the gap between top most water surface and spinneret bottom is between 15 to 25 mm. 5 mm gap was provided in the funnel bottom portion. Regeneration liquid flow rate of 10 to 15 m3/hr was sufficient to maintain full level in spinning box. The velocity of the liquid is kept at 190 m/min. Although the water velocity at the outlet of the funnel is much higher, the drag imparted to the filaments made them to attenuate at 40 to 60 m/min speed, thus giving a draw ratio of 4 to 6. (Draw ratio is the ratio of filament speed to extrusion speed.) Collection belt operating at 10 m/min below the spinning box maintained a distance of 120 mm between the spinning box. Vacuum of 400 mm of water column was provided below the laying portion. Web obtained on the belt was washed clear off the solvent and sent to multi layering device and then for bonding. Different samples were prepared by varying the number of layers to get non-woven samples of different coverage. Non-wovens obtained had good strength, were soft and absorbent. Samples were tested for coverage in grams/square metre (gsm), water absorbency measured in gram/gram and tensile tests as described above in machine direction (MD) and in cross direction (CD) both in dry and wet condition. Key test results are tabulated below:
[0000]
TABLE NO. 1
CONVENTIONAL
PRESENT INVENTION
PROCESS
Sample
Sample
Sample
100% Viscose
60/40 V/P
Parameter
#1
#2
#3
staple fibre
staple fibre
Filament Denier
1.5
1.2
2
1.5
1.51
Nonwoven
111.6
82.8
100
112.9
80
coverage-gsm
Tensile strength
145.6
118.8
270.7
71.2
70.58
In the direction
of laying
(N/2.5 cm)
Water absorbency
7.46
8.32
4.94
5.58
7.5
(gm/gm)
Bonding method
Hydro-
Hydro-
Chemical
Hydro-
Hydro-
adopted
entangle-
entangle-
bonding
entangle-
entangle-
ment
ment
ment
ment
Example 2
[0050] 11% cellulose Lyocell polymer solution was fed at the rate of 0.01 grams/hole/min through a rectangular spinneret having 20 rows of 80 micron diameter holes, giving an extrusion speed of 1.72 m/min. Spinning box was maintained at regeneration liquid column of 170 mm. 4 mm gap was provided in the funnel bottom portion. Regeneration liquid flow rate of 7 m3/hr was sufficient to maintain full level in spinning box. The velocity of the liquid is kept at 109 m/min. Although the water velocity at the outlet of the funnel is much higher, the drag imparted to the filaments made them to attenuate at 8 m/min speed, thus giving a draw ratio of 4.6. Web laying speed was kept at 1 to 3 m/min to obtain a uniform non-woven. Vacuum of 255 mm of water column was provided below the laying portion. Web obtained on the belt was washed clear off the solvent and sent to multi layering device and then for bonding. Different samples were prepared by varying the number of layers to get non-woven samples of different coverage. Results obtained were very similar to those disclosed above.
[0051] The present invention can also be worked on viscose to achieve similar comparative results.
Benefits of this Invention:
[0052] a) For the same coverage, strength of the cellulosic non-woven fabric is higher by a factor of 1.5 to 2 as compared to staple fiber carded spun laced fabric and substantially higher as compared to Lyocell melt blown fabric. This means, keeping the material input same one can get a stronger fabric or for the same strength lower usage of material can serve the same purpose.
[0053] b) Process does not involve use of expensive high temperature air for spinning as done in Lyocell melt blowing. Entire process operates on lower temperatures, thus reduction in total energy consumed per Kg of fabric.
[0054] c) Attenuation of filaments does not need expensive high pressure air.
[0055] d) Randomization of filaments does not need injection of high pressure fluid and large vacuum levels. It uses low quantity and velocity of recyclable fluid.
[0056] e) Process from Viscose to Web or from Lyocell dope to Web involves only one step of drying (in the final stage after spun lacing), thus saving one complete step of drying as compared to non-woven webs made through staple fiber—carded spun laced route. This process also eliminates tow cutting, fiber opening and carding steps.
[0057] f) Once a randomized mat is produced, one can adopt other processes to consolidate the web, viz. needle punching, using binders, etc. without the use of additional equipments like cross lappers, etc.
[0058] g) Process uses only continuous fibers, hence no chances of short fibers resulting into linting, ideal for producing wipes for clean room application
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The present invention relates to a process for preparing a non-woven cellulosic structure comprising the steps of extruding continuous filaments from a cellulosic solution; passing the extruded filaments through a regenerating liquid to attenuate the filaments and laying the attenuated filaments into a web and to the non-woven cellulosic structure prepared therefrom.
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This invention relates to exercise apparatus, and is more particularly directed to aerobic exercise ergometers of the type that includes rowing machines or sculling machines. The invention is directed more specifically to pull-handle type machines in which a subject seated on the machine and, gripping a pull handle, pulls a cord to rotate a flywheel. The flywheel (of either an air-vane or friction type) produces a resistance to the stroking movement for the subject.
Rowing and sculling machines of this general type are described, e.g. in U.S. Pat. No. 4,396,188 and in U.S. Pat. No. 4,743,011. These machines provide an exercise movement that simulates rowing or sculling, the amount of resistance increasing with pace or stroke rate.
Canoeists have long desired an exercise machine on which a subject could exercise or train while simulating the stroke motions of canoe paddling. However, the nature of canoe paddling presents special problems. Canoes are paddled with the paddle on one side or the other of the canoe, and with the force of paddling being applied along line generally parallel to the axis of the canoe, but outside the canoe gunwale. Also, the canoeist typically will swing the paddle periodically from one side of the canoe to the other, paddling several strokes on the left, then several strokes on the right, and so forth.
Kayak paddling presents a problem for similar reasons, because that type of boat is paddled with alternate strokes of the paddle on opposite sides of the boat.
Previous attempts to use a canoe paddling technique on a standard pull-handle machine involved simply connecting the pull cord to the shaft of a paddle handle. With this arrangement, the cord extends back to the handle from a pulley or sheave that is directly in front of the subject. This means that the direction of resistance to the paddling stroke is angled across the bow of the machine, rather than in a line parallel to the machine. Also, because the cord is pulled out at an angle from this pulley, there is a tendency for the cord to jam, or to jump off the pulley. This also tends to abrade the cord.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of this invention to provide an exercise machine which permits a human subject to exercise by simulating the stroking motions of canoe paddling.
It is also an object of this invention to provide a canoe paddling exercise machine which provides a resistance to the stroking motion on a line that is parallel to the axis of the machine, and which changes the line of resistance from one side of the machine to the other to follow movement of the paddle handle from one side of the machine to the other.
It is a further object of this invention to provide an exercise rowing machine that can be easily converted by the user from a rowing configuration to a canoe paddling configuration, without requiring substantial modification, and without requiring special tools.
In accordance with an aspect of this invention, the exercise machine has a longitudinal frame with a flywheel mounted on it, preferably lying horizontally beneath the frame and behind the position of the rower or subject. A seat positions the subject on the machine for simulating canoe paddling motion using a paddling handle having an elongated shaft. A pull cord attaches at one end to the shaft of this handle, and passes over an outer pulley of a pulley arm at the front end of the machine frame. From here the cord passes to an inner pulley on the pulley arm and thence beneath the machine towards the flywheel. A chain and sprocket drive is connected to the pull cord and to the flywheel to rotate the latter when the handle is stroked aft; a spring return or elastic bungee cord is also coupled to the chain and sprocket drive and to the frame to withdraw the cord when the paddling handle recovers forward between strokes. There is an axial pivot on the front end of the machine on which the pulley arm is swingably mounted for motion about the frame axis from one side of the frame to the other. This permits the outer pulley to follow motion of the paddling handle so that the cord between the handle and the outer pulley is kept to the same side as the handle and more or less parallel to the frame axis. This ensures that the resistance force is on a line parallel to the machine and to one side, which is what is actually experienced in canoe paddling.
The pivot is preferably a hollow tube through which the pull cord passes, and the inner pulley is mounted on the pulley arm so that the pivot axis is on a tangent to the inner pulley. This ensures that the cord between the inner pulley and the flywheel stays on the same pathway regardless of the position of the outer pulley and the paddling handle.
In one practical embodiment, a fixed pulley arm is bolted to a front leg of the machine which is then configured as a rowing or sculling machine. The machine is reconfigured for canoe paddling by unbolting and removing the fixed pulley arm, and replacing it with the pivoting pulley arm assembly of this invention. Then a paddling handle is substituted for the rowing pull handle.
If desired, a non-sliding seat can be used in place of the rowing machine sliding seat, and the number of vanes on the flywheel can be changed. All these operations are carried out with simple tools such as a screwdriver, pliers, and an adjustable wrench.
A double pivoting arm assembly can be used to convert this machine to a kayak simulator.
The above and many other objects, features, and advantages of this invention will become apparent from the ensuing description of a preferred embodiment, when read in conjunction with the accompanying Drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a rowing machine according to the prior art, with certain portions exposed.
FIG. 2 is a perspective view of a canoe paddling machine according to one embodiment of this invention.
FIG. 3 is an exploded view of the pivotable pulley arm assembly of the FIG. 2 embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the Drawing, and initially to FIG. 1, a pull-handle type rowing machine 10 is in the form of an elongated frame with a human subject 12 for rower positioned on sliding seat 14 on the rowing machine frame. A pair of foot stretchers 16 position the subject's feet. The frame for the rowing machine 10 comprises a longitudinal rail 18 and a front vertical leg 20 that is T-shaped and has a transverse foot 22. There is another frame support on the rear end of the frame behind the rower, but that is hidden in this drawing figure.
A fixed pulley arm is provided in the form of a tower 24 that is angled forward from the front end of the rowing machine 10. A shoe 26 is secured by bolts to the leg 20, and a beam 28 extends generally upwardly from the shoe 26. A lower pulley 30 and an upper pulley 32 are mounted at the base and at the top of the beam 28, respectively. A flexible pull cord 34 extends from a pull handle over the upper pulley 32, and from there down to the lower pulley 30, from which the cord extends rearwardly beneath the rail 18. The cord 34 is connected to a chain 38 that passes over a sprocket 40 which drives a flywheel 42 that is mounted horizontally beneath the rail 18 and rearward or aft of the subject 12. A number of vanes 44 are crimped in place over spokes on the flywheel 42 to induce an air draft upon rotation of the flywheel 42. A shock cord or bungee (not shown) is connected to the chain 38 to draw the chain 38 in the direction to withdraw the cord 34 and the handle 36 between strokes.
A removable shroud 46 is disposed over the flywheel 42 both for safety purposes and to control the air flow through the flywheel.
A paddling machine according to the present invention is shown in FIG. 2, and parts therein that are identical with those of the rowing machine of FIG. 1 are identified with the same reference numbers, so that a detailed description can be omitted. In this paddling machine 50, there is a swivel arm assembly 52 that is substituted in place of the pulley arm tower 24 of FIG. 1, and an elongated canoe paddle handle 54 is substituted for the rowing handle 36. In addition, minor changes can be effected in the number of vanes 44. That is, some of the vanes 44 can be removed to adjust the flywheel resistance. Also, the sliding seat 14 can be modified or adapted so as not to slide when the machine is used for canoe paddling.
In this case, the rowing machine 10 can be converted to the paddling machine 50 by unbolting the shoe 26 of the tower 24 from the front leg 20 of the machine, and replacing it with the swivel arm assembly 52. The rowing handle 36, which is attached to the end of the cord 34 by a bolt or clamp is simply removed from the cord, and the cord is attached to the paddling handle 54, for example by a user-adjustable sliding clamp 55.
The swivel arm assembly is basically comprised of a fixed swivel portion 56 that mounts on the front leg 20 of the frame, and a swing pulley arm portion 58 that pivots on the fixed swivel portion 56. The latter has a hollow tubular pivot 60 which the cord 34 passes. The swing arm 58 pivots on the axis of the rowing machine frame, and moves from side to side to follow the paddling handle 54 when the subject 12 changes sides. This means that the flywheel 42 and the cord 34 apply a resistance which is along the line that is parallel to the machine axis and to one side of the machine.
The swivel arm assembly 52 is shown in greater detail in FIG. 3. The fixed swivel portion 56 is comprised of a shoe 62 that fits over the leg 20 and attaches to it by bolts 64 and nuts 56 that pass through holes 68 in the vertical post of the leg 20 and also through corresponding holds 70 in side plates of the shoe 62. The tubular pivot 50 comprises an inner pivot tube 72 that is mounted onto one side plate of the shoe 62. A thrust plate 74 is attached proximally on the pivot tube 72 and a rear bearing 76 is disposed over the inner pivot tube 72.
The swing arm portion 58 has an outer pivot tube 78 that overfits the inner pivot tube 72, and another forward bearing 80 is disposed between the inner and outer pivot tubes 72, 78. A beam 82 projects radially outward from the outer pivot tube 78. A smaller leg 84 projects radially from the tube 78 in the direction opposite to the beam 82 and has a counterpoise or weight 86 which balances the weight of the beam 82.
A forward projecting leg 88 is disposed near the pivot and of the beam 82 and has a inner sheave or pulley 90 mounted thereon while an upper sheave or pulley 92 is mounted at the outer or free end of the beam 82. The sheaves 90 and 92 are pivoted on bolts 94 which are secured by nuts 96.
The leg 88 and lower sheave 90 are positioned such that the cord 34 which passes through the open core of the pivot tubes 72 and 78 is tangent to the sheave 90. This means that the cord that passes back beneath the frame from the inner sheave 90 to the flywheel will remain along the same path regardless of the angular position of the swing arm portion 58. The outer sheave or pulley 92 is free to move, by the swinging of the swing arm 58, from one side of the machine to the other to follow movements of the canoe paddling handle 54.
The length of the counterpoise leg 84 is smaller than the distance from the pivot tubes 72 and 78 to the lower side or base of the foot 22. This feature provides ground clearance for the counterpoise 86, thus permitting the swing arm portion 58 to move from one side of the frame to the other without interference.
Preferably, the paddling handle 54 has a T-shaped upper end and a number of holes through its main shaft so that the cord 34 can be connected in any of a number of positions along its length.
Also, a pacing computer 98 can be included as shown in FIGS. 1 and 2, to provide an indication of simulated canoe speed, paddling pace or rate, pulse rate, and so forth.
In addition, the principles of this invention could be employed to a kayak paddling machine, e.g. by having double pulling arms for two cords, each of which is connected to a respective end of a kayak paddling handle.
While this invention has been described in detail with reference to a preferred embodiment, it should be understood that the invention is not limited to that precise embodiment. Rather, many modifications and variations would present themselves to those skilled in the art without departing from the scope and spirit of this invention, as defined in the appended claims.
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An exercise canoe paddling machine has a frame, a pull cord that passes over an outer pulley and an inner pulley that are mounted on a pivotable pulley arm on the front of the machine, and thence under the machine to rotate a flywheel mounted beneath the frame. The cord is attached to an elongated canoe paddling handle. The pivoting pulley arm moves from side to side to follow movement of the paddling handle. The resistance that is produced during stroking of the handle is directed substantially parallel to the frame axis and to the same side thereof as the paddling handle.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of and claims priority to U.S. application Ser. No. 11/104,272, filed on Apr. 12, 2005, which application claims priority to U.S. Provisional Application No. 60/561,493, filed on Apr. 12, 2004. Both applications are hereby incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates to the treatment of cardiac arrest in pediatric populations with automatic external defibrillators (AEDs).
BACKGROUND
[0003] Automatic External Defibrillators (AEDs) are used by non-medical personnel to defibrillate victims of cardiac arrest the prevalence of which is approximately 600,000 people per year, worldwide. In the past, these AEDs had only been available for the adult population, and the pediatric arrest victims were forced to wait valuable minutes for the professional rescuers such as paramedics, doctors or nurses to arrive. AEDs are now available that are designed specifically to be compatible for use on children. Because defibrillation energies are lower with children, various methods have been developed to accommodate this fact and provide a means of switching defibrillation energies if a pediatric arrest victim is present. One method, described in U.S. Pat. No. 6,101,413, determines a pediatric arrest victim is present if the AED detects that electrodes specifically designed for use with children are attached to the device, in which case the energy levels and voice prompts associated with energy delivery are adjusted to conform with those most appropriate for children. U.S. Patent Application 2003/0195567A1 describes a method that determines a victim is a child based on user input form the AED operator. The energy levels are set based on such indirect means as a measurement of the patient, e.g., the length of an anatomical feature of the victim may be correlated within the AED to a specific energy level.
[0004] Resuscitation treatments for patients suffering from cardiac arrest generally include clearing and opening the patient's airway, providing rescue breathing for the patient, and applying chest compressions to provide blood flow to the victim's heart, brain and other vital organs. If the patient has a shockable heart rhythm, resuscitation also may include defibrillation therapy. The term basic life support (BLS) involves all the following elements: initial assessment; airway maintenance; expired air ventilation (rescue breathing); and chest compression. When all three [airway breathing, and circulation, including chest compressions] are combined, the term cardiopulmonary resuscitation (CPR) is used. In the case of pediatric arrest, CPR takes on a heightened prominence based on the fact that cardiac arrest is rare in children, and many more children are affected by respiratory arrest due to choking, drowning, poisoning and asthma.
[0005] There are many different kinds of abnormal heart rhythms, some of which can be treated by defibrillation therapy (“shockable rhythms”) and some which cannot (non-shockable rhythms”). For example, most ECG rhythms that produce significant cardiac output are considered non-shockable (examples include normal sinus rhythms, certain bradycardias, and sinus tachycardias). There are also several abnormal ECG rhythms that do not result in significant cardiac output but are still considered non-shockable, since defibrillation treatment is usually ineffective under these conditions. Examples of these non-shockable rhythms include asystole, electromechanical disassociation and other pulseless electrical activity. Although a patient cannot remain alive with these non-viable, non-shockable rhythms, applying shocks will not help convert the rhythm. The primary examples of shockable rhythms, for which the caregiver should perform defibrillation, include ventricular fibrillation, ventricular tachycardia, and ventricular flutter.
[0006] The current protocols recommended by the American Heart Association (AHA) are as follows: after using a defibrillator to apply one or more shocks to a patient who has a shockable ECG rhythm, the patient may nevertheless remain unconscious, in a shockable or non-shockable, perfusing or non-perfusing rhythm. If a non-perfusing rhythm is present, the caregiver may then resort to performing CPR for a period of time in order to provide continuing blood flow and oxygen to the patient's heart, brain and other vital organs. If a shockable rhythm continues to exist or develops during the delivery of CPR, further defibrillation attempts may be undertaken following this period of cardiopulmonary resuscitation. As long as the patient remains unconscious and without effective circulation, the caregiver can alternate between use of the defibrillator (for analyzing the electrical rhythm and possibly applying a shock) and performing cardio-pulmonary resuscitation (CPR). CPR generally involves a repeating pattern of five or fifteen chest compressions followed by a pause during which two rescue breaths are given.
[0007] Defibrillation can be performed using an AED. The American Heart Association, European Resuscitation Council, and other similar agencies provide protocols for the treatment of victims of cardiac arrest that include the use of AEDs. These protocols define a sequence of steps to be followed in accessing the victim's condition and determining the appropriate treatments to be delivered during resuscitation. Caregivers who may be required to use an AED are trained to follow these protocols.
[0008] Most automatic external defibrillators are actually semi-automatic external defibrillators (SAEDs), which require the caregiver to press a start or analyze button, after which the defibrillator analyzes the patient's ECG rhythm and advises the caregiver to provide a shock to the patient if the electrical rhythm is shockable. The caregiver is then responsible for pressing a control button to deliver the shock. Following shock delivery, the SAED may reanalyze the patient's ECG rhythm, automatically or manually, and advise additional shocks or instruct the caregiver to check the patient for signs of circulation (indicating that the defibrillation treatment was successful or that the rhythm is non-shockable) and to begin CPR if circulation has not been restored by the defibrillation attempts. Fully automatic external defibrillators, on the other hand, do not wait for user intervention before applying defibrillation shocks. As used below, automatic external defibrillators (AEDs) include semi-automatic external defibrillators (SAEDs).
[0009] Automated External Defibrillators include signal processing software that analyzes ECG signals acquired from the victim to determine when a cardiac arrhythmia such as Ventricular Fibrillation (VF) or shockable ventricular tachycardia (VT) exists. Usually, these algorithms are designed to perform ECG analyses at specific times during the rescue event. The first ECG analysis is usually initiated within a few seconds following attachment of the defibrillation electrodes to the patient. Subsequent ECG analyses may or may not be initiated based upon the results of the first analysis. Typically if the first analysis detects a shockable rhythm, the rescuer is advised to deliver a defibrillation shock. Following the shock delivery a second analysis is automatically initiated to determine whether the defibrillation treatment was successful or not (i.e. the shockable ECG rhythm has been converted to a normal or other non-shockable rhythm). If this second analysis detects the continuing presence of a shockable arrhythmia, the AED advises the user to deliver a second defibrillation treatment. A third ECG analysis may then be initiated to determine whether the second shock was or was not effective. If a shockable rhythm persists, the rescuer is then advised to deliver a third defibrillation treatment.
[0010] The typical algorithms process the ECG for measured features which will differentiate the rhythm as shockable (ventricular fibrillation (VF) and ventricular tachycardia (VT)) or non-shockable rhythms (normal sinus rhythms (NSR), abnormal rhythms (ABN), non-shockable VT's and asystole). Some of these features include R to R interval averaging, R to R interval variance, average and maximum signal amplitude, measures of baseline isoelectric time, QRS width, ECG first difference distributions, and parameters from frequency domain analysis' Analyses of annotated ECG databases establish the distribution of values for a given feature for shockable and non-shockable rhythms. Appropriate decision logic techniques can be used to combine this knowledge and produce the shock or non-shock decision.
[0011] Although AEDs have been designed for use on adults and the ECG arrhythmia logic has been developed for the adult population, there is a clear need to extend the use of AEDs to children with cardiac arrest. Recent literature have reported the accuracies of adult based AED arrhythmia algorithms on ECG databases collected from children and have concluded they are safe and effective. However, there are significant differences between adult and pediatric ECG rhythms. For example, the pediatric ECG exhibits faster normal heart rates, narrower QRS widths, and shorter PR and QT intervals as compared to adults. Shockable ventricular tachycardia occurs at much higher rates (>200 BPM) in pediatric subjects than adults (>150 BPM).
[0012] Following the third defibrillator shock or when any of the analyses described above detects a non-shockable rhythm, treatment protocols recommended by the American Heart Association and European Resuscitation Council require the rescuer to check the patient's pulse or to evaluate the patient for signs of circulation. If no pulse or signs of circulation are present, the rescuer is trained to perform CPR on the victim for a period of one or more minutes. Following this period of cardiopulmonary resuscitation (that includes rescue breathing and chest compressions) the AED reinitiates a series of up to three additional ECG analyses interspersed with appropriate defibrillation treatments as described above. The sequence of 3 ECG analyses/defibrillation shocks followed by 1-3 minutes of CPR, continues in a repetitive fashion for as long as the AED's power is turned on and the patient is connected to the AED device. Typically, the AED provides audio prompts to inform the rescuer when analyses are about to begin, what the analysis results were and when to start and stop the delivery of CPR.
[0013] The AED can be used on adult and pediatric patients. However, the American Heart Association recommends a different protocol in the rescue of pediatric victims compared to the adult rescue protocol particularly with regards to the application of CPR. Because of the heightened prominence of airway and breathing with pediatric arrest victims, the AHA recommends that prior even to calling and activating emergency medical services (EMS) system, the child's airway is first checked for obstructions, the airway is cleared, and mouth to mouth breathing is performed in order to provide what is usually the primary treatment of respiration to the child. The AHA recommends a ratio 15 chest compressions to two ventilations in the case of an adult victim and a ratio of five chest compressions to one ventilation in the case of pediatric victims. The recommended rate of compressions in both adult and pediatric victims is 100 compressions per minute. The rationale for this difference in compression to ventilation ratios is that: 1) the most common cause in pediatric (<8 years of age) arrest is respiratory; and 2) respiratory rates in pediatric (<8 years of age) population are faster than respiratory rates in adults. In addition, the recommended depth of chest compression for pediatric victims (<8 years of age) is 1 to 1.5 inches while the recommended chest compression depth for adult and pediatric (>8 years of age) is 1.5 to 2 inches.
[0014] Existing AEDs are unable to provide appropriate rescue protocol and ECG analysis for a pediatric (<8 years of age) victim that is different from an adult rescue protocol and ECG analysis. Also, a lay rescuer who is trained on pediatric resuscitation and is not aware of the AHA guidelines recommendations will not be able to provide an effective resuscitation for a pediatric victim when using these existing AEDs.
SUMMARY
[0015] In a first aspect, the invention features a device for assisting a rescuer in delivering therapy to an adult or pediatric patient, the device comprising a user interface comprising a display and/or audio speakers, the user interface being configured to deliver prompts to a rescuer to assist the rescuer in delivering therapy to a patient, a processor configured to provide prompts to the user interface and to perform an ECG analysis algorithm on ECG information detected from the patient, at least one detection element configured to determine without rescuer input via the user interface that a pediatric patient is being treated, wherein if a pediatric patient is detected, the processor modifies the ECG analysis algorithm to use an ECG analysis algorithm configured for a pediatric patient rather than for an adult patient.
[0016] In a second aspect, the invention features a device for assisting a rescuer in delivering therapy to an adult or pediatric patient, the device comprising a user interface comprising a display and/or audio speakers, the user interface being configured to deliver prompts to a rescuer to assist the rescuer in delivering therapy to a patient, a processor configured to provide prompts to the user interface and to perform an ECG analysis algorithm on ECG information detected from the patient, at least one detection element configured to determine without rescuer input via the user interface that a pediatric patient is being treated, wherein if a pediatric patient is detected, the processor modifies the prompts provided to the user interface to use prompts adapted for a pediatric patient rather than for an adult patient.
[0017] In a third aspect, the invention features a device for assisting a rescuer in delivering therapy to an adult or pediatric patient, the device comprising a user interface comprising a display and/or audio speakers, the user interface being configured to deliver prompts to a rescuer to assist the rescuer in delivering therapy to a patient, a processor configured to provide prompts to the user interface and to perform an ECG analysis algorithm on ECG information detected from the patient, at least one detection element configured to determine without rescuer input via the user interface that a pediatric patient is being treated, wherein if a pediatric patient is detected, the processor modifies the CPR protocol that governs CPR prompts provided to the user interface to use CPR prompts adapted for a pediatric patient rather than for an adult patient.
[0018] In preferred implementations, one or more of the following features may be incorporated. The invention may further comprise an automatic external defibrillator for delivering defibrillation shocks to the patient using defibrillation electrodes applied to the patient. The prompts provided via the user interface may comprise prompts as to CPR chest compression, and the CPR chest compression prompts may be changed from an adult set of prompts to a pediatric set of prompts if a pediatric patient is detected. The pediatric set of prompts may address depth and rate of CPR chest compressions. The invention may further comprise one or more sensors for measuring the rate and depth of CPR related chest compressions. The detection element may comprise circuitry for detecting whether a pediatric or an adult defibrillation electrode is in use. The detection element may comprise a force or pressure sensor located on a shoulder support element for sensing force or pressure from the weight of the patient. The energy of defibrillation shocks may be determined based in part on information as to the patient's weight obtained from the force or pressure sensor on the shoulder support. The shoulder support element may comprise a removable cover of the device. The detection element may comprise one or more sensors for determining from the separation of defibrillation electrodes placed on the patient whether the patient is a pediatric or adult patient.
[0019] In a fourth aspect, the invention features an external defibrillation device for assisting a rescuer in delivering defibrillation therapy to an adult or pediatric patient, the device comprising a user interface comprising a display or audio speakers, the user interface being configured to deliver prompts to a rescuer to assist the rescuer in delivering therapy to a patient, a processor configured to provide prompts to the user interface and to perform an ECG analysis algorithm on ECG information detected from the patient, a force or pressure sensor for detecting information pertaining to the weight of the patient, wherein the processor modifies the defibrillation energy delivered to the patient based on the information pertaining to the weight of the patient.
[0020] In preferred implementations, one or more of the following features may be incorporated. The processor may modify the ECG analysis algorithm based on the information pertaining to the weight of the patient. The force or pressure sensor may be incorporated into a shoulder support that is placed under the shoulders of the patient. The shoulder support may be a cover for the defibrillator. The cover may have an upper surface that is inclined at an angle that makes it suitable to be used to properly position the patient's airway by lifting the patient's shoulders to cause the patient's head to tilt back at an angle. The cover may be configured to be positioned under a patient's neck and shoulders to support the patient's shoulders and neck in a way that helps to maintain the patient's airway in an open position. The information from sensors in the shoulder support element may be communicated to the defibrillator by one or more of the following techniques: by a wire extending from the support to the defibrillator, or by a wireless communication connection between the support and the defibrillator.
[0021] In a fifth aspect, the invention features an external defibrillation device for assisting a rescuer in delivering defibrillation therapy to an adult or pediatric patient, the device comprising a user interface comprising a display or audio speakers, the user interface being configured to deliver prompts to a rescuer to assist the rescuer in delivering therapy to a patient, a processor configured to provide prompts to the user interface and to perform an ECG analysis algorithm on ECG information detected from the patient, a shoulder support element for placement under the shoulders of the patient to assist in keeping the airway open, sensors in the shoulder support element for determining if the patient's shoulders have been properly positioned on the element.
[0022] In preferred implementations, one or more of the following features may be incorporated. The shoulder support element may comprise a cover for the device.
[0023] In a sixth aspect, the invention features an external defibrillation device for assisting a rescuer in delivering defibrillation therapy to an adult or pediatric patient, the device comprising a user interface comprising a display or audio speakers, the user interface being configured to deliver prompts to a rescuer to assist the rescuer in delivering therapy to a patient, a processor configured to provide prompts to the user interface and to perform an ECG analysis algorithm on ECG information detected from the patient, defibrillation electrodes for placement on the chest of the patient, one or more sensors located in one or both of the defibrillation electrodes, the sensors being configured to determine a distance between the electrodes after they are placed on the patient's chest, wherein the processor can determine information pertaining to the size of the patient from the distance determined from the one or more sensors, and wherein the processor can vary the prompts, or the ECG analysis algorithm, or the energy delivered to the patient based on the information pertaining to the size of the patient.
[0024] In preferred implementations, one or more of the following features may be incorporated. The processor may estimate the circumferential girth of the patient from the information obtained from the sensors. The processor may estimate the age of the patient from the information obtained from the sensors. Modifications to the ECG analysis algorithm may include one or more of the following: heart rate criteria, QRS width criteria, VF frequency content criteria, or ECG amplitude criteria. Modifications to the prompts may include changing a sequence of prompts, a number of prompts, or a type of prompts. The prompts may include prompts on CPR compression and CPR ventilation, and the compression-ventilation ratio may be about 5:1 for pediatric patients and about 15:2 for adult patients. The prompts may include prompts on CPR compression depth, and the desired compression depth for pediatric patients may be in the range of about 1.0 to 1.5 inches, and the desired compression depth for adult patients may be in the range of about 1.0 to 2.0 inches. The prompts may include a prompt informing the rescuer as to whether the device is operating in an adult or pediatric mode. The prompts may include prompting of the CPR interval T 1 based on one or more of patient rhythm, age, or weight. The invention may further comprise one or more sensors and prompts for detecting and prompting the user to achieve a complete chest release during CPR. The prompts may include pediatric specific prompts for the compression rate R 1 . The prompts may include adult specific prompts for the compression rate R 1 .
[0025] The invention may feature a system that will alter the AED arrhythmia processing for adults or children based the automatic sensing or manual assignment of the patient type. Altering the AED arrhythmia processing for pediatric subjects based on the pediatric specific logic may achieve higher sensitivity and specificity of the shock decision that will significantly improve the safety and effective of the device.
[0026] The invention may provide an improved method for providing an appropriate rescue protocol and ECG analysis based on patient age, thoracic circumferential girth and weight in an automated fashion without the need for any user intervention. Utilizing a means of detecting a patient's age, weight or thoracic circumferential girth, the AED can automatically switch to providing the appropriate rescue protocol and optimizing performance of the ECG analysis algorithm for a specific victim age and weight. If an untrained rescuer activates the proposed AED, the protocol is tailored to instruct the user to provide one minute of CPR to the pediatric (<8 years of age) victim before activating the EMS system. The protocol is tailored to instruct the user to activate the EMS system before providing any treatment or CPR to an adult victim. Also, since the AED is capable of detecting the depth of chest compression when used with a set of defibrillation electrodes embedding a chest compression detector, it can guide the rescuer to administer appropriate chest compression-ventilation ratio and depth of compressions based on specific victim age and weight. Furthermore, the proposed AED can select a preconfigured CPR period length based on the type of rhythm when the CPR interval is entered. For example, the pre-programmed CPR period when an asystole, PEA, or normal rhythm is detected can be longer than after a ventricular fibrillation or tachycardia is detected.
[0027] The invention may provide a more comprehensive and effective system for delivering treatment to pediatric arrest victims, providing an appropriate rescue protocol and ECG analysis based on patient age, thoracic circumferential girth and weight in an automated fashion without the need for any user intervention.
[0028] The invention may feature a device for assisting a rescuer in delivering therapy to an adult or pediatric patient, the device comprising a user interface comprising a display or audio speakers, the user interface being configured to deliver prompts to a rescuer to assist the rescuer in delivering therapy to a patient; a processor configured to provide prompts to the user interface and to perform an ECG analysis algorithm on ECG information detected from the patient; at least one detection element configured to determine without rescuer input via the user interface that a pediatric patient is being treated; wherein, if a pediatric patient is detected, the processor modifies the ECG analysis algorithm or the prompts provided to the user interface to use an ECG analysis algorithm or prompts better suited to a pediatric patient than to an adult patient.
[0029] The device may incorporate an automatic external defibrillator for delivering defibrillation shocks to the patient using defibrillation electrodes applied to the patient. The prompts provided via the user interface may comprise prompts as to CPR chest compression, and the CPR chest compression prompts are changed from an adult set of prompts to a pediatric set of prompts if a pediatric patient is detected. The pediatric set of prompts may address depth and rate of CPR chest compressions. One or more sensors for measuring the rate and depth of CPR related chest compressions may be provided. The detection element may comprise circuitry for detecting whether a pediatric or an adult defibrillation electrode is in use. The detection element may comprise a force or pressure sensor located on a shoulder support element for sensing force or pressure from the weight of the patient. The energy of defibrillation shocks may be determined based in part on information as to the patient's weight obtained from the force or pressure sensor on the shoulder support. The shoulder support element may comprise a removable cover of the device. The detection element may comprise one or more sensors for determining from the separation of defibrillation electrodes placed on the patient whether the patient is a pediatric or adult patient.
[0030] The AED may include the capability of measuring the rate and depth of CPR related chest compressions and automatically switch when specific defibrillation electrode types are detected to provide appropriate rescue protocol, ECG analysis, and CPR interval length and guidance based on the victim's determined age. Based on the determined patient age, appropriate ventilation to compression ratio and compression interval length are determined, and guidance is provided to the rescuer to provide appropriate chest compressions/ventilation ratio and rate and compression depth via voice and text prompts throughout the entire rescue process.
[0031] The invention may feature an external defibrillation device for assisting a rescuer in delivering defibrillation therapy to an adult or pediatric patient. The device may comprise a user interface comprising a display or audio speakers, the user interface being configured to deliver prompts to a rescuer to assist the rescuer in delivering therapy to a patient; a processor configured to provide prompts to the user interface and to perform an ECG analysis algorithm on ECG information detected from the patient; a force or pressure sensor for detecting information pertaining to the weight of the patient; wherein the processor modifies the defibrillation energy delivered to the patient based on the information pertaining to the weight of the patient.
[0032] The processor may modify the ECG analysis algorithm based on the information pertaining to the weight of the patient. The force or pressure sensor may be incorporated into a shoulder support that is placed under the shoulders of the patient. The shoulder support may be a cover for the defibrillator. The cover may have an upper surface that is inclined at an angle that makes it suitable to be used to properly position the patient's airway by lifting the patient's shoulders to cause the patient's head to tilt back at an angle. The cover may be configured to be positioned under a patient's neck and shoulders to support the patient's shoulders and neck in a way that helps to maintain the patient's airway in an open position. The information from sensors in the shoulder support element may be communicated to the defibrillator by one or more of the following techniques: by a wire extending from the support to the defibrillator, or by a wireless communication connection between the support and the defibrillator.
[0033] Some implementations may provide an automated means for determining the age of the victim with greater specificity. Victim weight is a commonly used clinical measure for determining defibrillation energies for children. An integrated force sensor may be provided within the AED for measuring the patient's weight and the AED will then adjust the defibrillation energy and ECG analysis parameters based on the measured weight.
[0034] The force sensor may be incorporated into the cover of the AED. The cover has an upper surface that is inclined at an angle that makes it suitable to be used to properly position the patient's airway, by, for instance, lifting the patient's shoulders thereby causing the patient's head to tilt back at the proper angle. The cover is constructed to be positioned under a patient's neck and shoulders to support the patient's shoulders and neck in a way that helps to maintain his airway in an open position, i.e., maintaining the patient in the head tuck-chin lift position. When a caregiver encounters a person who appears to be suffering from cardiac arrest, the caregiver should follow recommended resuscitation procedures, such as are specified by the AHA Guidelines for Cardiopulmonary Resuscitation and Emergency Cardiovascular Care. If there is no evidence of head or neck trauma, the caregiver should clear any debris from the patient's airway. After this has been done, the caregiver should roll the patient onto his side, place cover under the patient's shoulders, and roll the patient back onto his back. The cover should be positioned so as to support the patient in the head tilt-chin lift position. The caregiver can then proceed with CPR and/or use of the defibrillator. The positions (a patient in the head lift-chin tilt position and a patient with a closed airway) are also shown in the AHA Guidelines for Cardiopulmonary Resuscitation and Emergency Cardiovascular Care, Aug. 22, 2000, p. I-32, FIGS. 7 and 8 . The cover is provided with a detection means for determining if the patient's shoulders have been properly positioned on the cover. Communication of the detection means located in the cover to the processor in the device housing can be accomplished by making the cover an integral element of the device housing, for instance via a hinge element or by providing an interconnection element such as a flat flexible cable. Communication may also be accomplished wirelessly via such technologies as Bluetooth or inductive methods. When the patient's shoulders are placed on the cover, the measured force is communicated to the AED.
[0035] The invention may feature an external defibrillation device for assisting a rescuer in delivering defibrillation therapy to an adult or pediatric patient, the device comprising a user interface comprising a display or audio speakers, the user interface being configured to deliver prompts to a rescuer to assist the rescuer in delivering therapy to a patient; a processor configured to provide prompts to the user interface and to perform an ECG analysis algorithm on ECG information detected from the patient; a shoulder support element for placement under the shoulders of the patient to assist in keeping the airway open; sensors in the shoulder support element for determining if the patient's shoulders have been properly positioned on the element.
[0036] The invention may feature an external defibrillation device for assisting a rescuer in delivering defibrillation therapy to an adult or pediatric patient, the device comprising a user interface comprising a display or audio speakers, the user interface being configured to deliver prompts to a rescuer to assist the rescuer in delivering therapy to a patient; a processor configured to provide prompts to the user interface and to perform an ECG analysis algorithm on ECG information detected from the patient; defibrillation electrodes for placement on the chest of the patient; one or more sensors located in one or both of the defibrillation electrodes, the sensors being configured to determine a distance between the electrodes after they are placed on the patient's chest; wherein the processor can determine information pertaining to the size of the patient from the distance determined from the one or more sensors, and wherein the processor can vary the prompts, or the ECG analysis algorithm, or the energy delivered to the patient based on the information pertaining to the size of the patient.
[0037] The processor may estimate the circumferential girth of the patient from the information obtained from the sensors. The processor may estimate the age of the patient from the information obtained from the sensors.
[0038] The sensor elements may be fabricated into the two defibrillation electrodes placed on the victim's chest. The electrodes may be constructed such that the relative distance between the electrodes can be determined by the AED. Based on that relative distance, the circumferential girth can be calculated by the AED and used as a means of estimating patient age as well as delivering the appropriate energy level.
[0039] Other features and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0040] FIG. 1 is a perspective view of an AED with its cover on.
[0041] FIG. 2 is a perspective view of the AED of FIG. 1 with the cover removed.
[0042] FIG. 3 is a block diagram of the AED.
[0043] FIG. 4 is a plan view of the graphical interface decal used on the cover of the AED of FIG. 1 .
[0044] FIG. 5 is a plan view of the graphical interface decal used on the device housing of the AED of FIG. 1 , as shown in FIG. 2 .
[0045] FIG. 6 a is a flow diagram for the pediatric AED resuscitation protocol.
[0046] FIG. 6 b is a flow diagram for the adult AED resuscitation protocol.
[0047] FIG. 7 shows an exploded perspective view of the cover and housing.
[0048] FIG. 8 shows a side plan view of the cover indicating angle ‘A’.
[0049] FIGS. 9 a and 9 b show the effect on the patient's airway of placing the cover beneath a patient's shoulders.
[0050] FIG. 10 shows the graphical instructions on the cover for placing the cover under a patient's shoulders.
[0051] FIG. 11 shows an integrated electrode pad.
[0052] FIG. 12 is a flow diagram of the arrhythmia processing in the AED.
[0053] FIG. 13 is a flow diagram of mode specific processing for enhancing QRS detection.
[0054] FIG. 14 is a flow diagram of mode specific processing for enhancing rhythm classification logic and shock determination.
[0055] FIG. 15 is an example AED arrhythmia logic table for an adult.
[0056] FIG. 16 is an example AED arrhythmia logic table for a child.
DETAILED DESCRIPTION
[0057] There are a great many possible implementations of the invention, too many to describe herein. Some possible implementations that are presently preferred are described below. It cannot be emphasized too strongly, however, that these are descriptions of implementations of the invention, and not descriptions of the invention, which is not limited to the detailed implementations described in this section but is described in broader terms in the claims.
[0058] The terms “caregiver”, “rescuer” and “user” are used interchangeably in the description of the invention and refer to the operator of the device providing care to the patient. “Victim” is also used interchangeably with “patient”.
[0059] Referring to FIGS. 1 and 2 , an automated external defibrillator 10 includes a removable cover 12 and a device housing 14 . The defibrillator 10 is shown with cover 12 removed in FIG. 2 . An electrode assembly 16 (or a pair of separate electrodes) is connected to the device housing 14 by a cable 18 . Electrode assembly 16 is stored under cover 12 when the defibrillator is not in use.
[0060] Referring to FIG. 3 , the invention includes a processor means 20 , a user interface 21 including such elements as a graphical 22 or text display 23 or an audio output such as a speaker 24 , and a detection means 25 for determining whether at least one of a series of steps in a protocol has been completed successfully. In the preferred embodiment, the detection means 25 also includes the ability to determine both whether a particular step has been initiated by a user and additionally whether that particular step has been successfully completed by a user. Based on usability studies in either simulated or actual use, common user errors are determined and specific detection means are provided for determining if the most prevalent errors have occurred.
[0061] Device housing 14 includes a power button 15 and a status indicator 17 . Status indicator 17 indicates to the caregiver whether the defibrillator is ready to use.
[0062] The cover 12 includes a cover decal 30 ( FIGS. 1 and 4 ) including a logo 31 and a series of graphics 32 , 34 and 36 . Logo 31 may provide information concerning the manufacturer of the device and that the device is a defibrillator (e.g., “ZOLL AED”, as shown in FIG. 1 , indicating that the device is a Semi-automatic External Defibrillator available from ZOLL Medical). Graphics 32 , 34 and 36 lead the caregiver through the initial stages of a cardiac resuscitation sequence as outlined in the AHA's AED treatment algorithm for Emergency Cardiac Care pending arrival of emergency medical personnel. (See “Guidelines 2000 for Cardiopulmonary Resuscitation and Emergency Cardiovascular Care. Supplement to Circulation,” Volume 102, Number 8, Aug. 22, 2000, pp. 1-67.) Thus, graphic 32 , showing the caregiver and patient, indicates that the caregiver should first check the patient for responsiveness, e.g., by shaking the patient gently and asking if the patient is okay. Next, graphic 34 , showing a telephone and an emergency vehicle, indicates that the caregiver should call for emergency assistance prior to administering resuscitation. Finally, graphic 36 indicates that after these steps have been performed the caregiver should remove the cover 12 of the defibrillator, remove the electrode assembly 16 stored under the lid, and turn the power on by depressing button 15 . The graphics are arranged in clockwise order, with the first step in the upper left, since this is the order most caregivers would intuitively follow. However, in this case the order in which the caregiver performs the steps is not critical, and thus for simplicity no other indication of the order of steps is provided.
[0063] The cover 12 is constructed to be positioned under a patient's neck and shoulders, as shown in FIGS. 9 a and 9 b to support the patient's shoulders and neck in a way that helps to maintain his airway in an open position, i.e., maintaining the patient in the head tuck-chin lift position. The cover is preferably formed of a relatively rigid plastic with sufficient wall thickness to provide firm support during resuscitation. Suitable plastics include, for example, ABS, polypropylene, and ABS/polypropylene blends.
[0064] Prior to administering treatment for cardiac arrest, the caregiver should make sure that the patient's airway is clear and unobstructed, to assure passage of air into the lungs. To prevent obstruction of the airway by the patient's tongue and epiglottis (e.g., as shown in FIG. 9 a ), it is desirable that the patient be put in a position in which the neck is supported in an elevated position with the head tilted back and down. Positioning the patient in this manner is referred to in the American Heart Association Guidelines for Cardiopulmonary Resuscitation and Emergency Cardiovascular Care as the “head tilt-chin lift maneuver.” The head tilt-chin lift position provides a relatively straight, open airway to the lungs through the mouth and trachea. However, it may be difficult to maintain the patient in this position during emergency treatment.
[0065] The cover 12 has an upper surface 24 that is inclined at an angle A ( FIG. 8 ) of from about 10 to 25 degrees, e.g., 15 to 20 degrees, so as to lift the patient's shoulders and thereby cause the patient's head to tilt back. The upper surface 24 is smoothly curved to facilitate positioning of the patient. A curved surface, e.g., having a radius of curvature of from about 20 to 30 inches, generally provides better positioning than a flat surface. At its highest point, the cover 12 has a height H ( FIG. 8 ) of from about 7.5 to 10 cm. To accommodate the width of most patients' shoulders, the cover 12 preferably has a width W ( FIG. 8 ) of at least 6 inches, e.g., from about 6 to 10 inches. If the cover 12 is not wide enough, the patient's neck and shoulders may move around during chest compressions, reducing the effectiveness of the device. The positions shown in FIGS. 9 a and 9 b (a patient in the head lift-chin tilt position and a patient with a closed airway) are also shown in the AHA Guidelines for Cardiopulmonary Resuscitation and Emergency Cardiovascular Care, Aug. 22, 2000, p. I-32, FIGS. 7 and 8 .
[0066] In a preferred implementation, if on power-up, the AED detects that the pediatric defibrillation pads are attached then the AED will automatically start a pediatric rescue protocol. FIG. 6 a shows the details of one instance of the pediatric protocol. The device will output voice/text prompts indicating to the rescuer to check the victim's responsiveness (i.e., “Check Responsiveness”) and allow a preprogrammed time interval (e.g., 4 seconds) to allow for checking the responsiveness before moving to the next state. The device will next output voice/text prompts instructing the rescuer to check breathing (example “Check Breathing”) and then allow a preprogrammed time interval (e.g., 7 seconds) to check the victim's breathing. The AED will next output voice/text prompts instructing the rescuer to check the victim's pulse (example “Check Pulse”) and then allow a preprogrammed time interval (e.g., 10 sec) for checking the victim's pulse. The AED will then enter a CPR state where it outputs voice/text prompts instructing the rescuer to start chest compressions (e.g., “If No Pulse, Start Chest Compressions”). While in this CPR state, the chest compression signal is received by ‘Detect & Increment Chest Compressions Counter’ function that detects chest compressions and counts them. While the number of chest compressions is less than 5, the depth of each detected compression is evaluated. If the depth of the detected compression is not higher than 1″, the rescuer is instructed to push harder on the victims chest by outputting “Push Harder” voice/text prompts and return to ‘Detect & Increment Chest Compression count’ state. Else, if the depth of the detected chest compression exceeds 1″, this depth is evaluated again. If the depth of the detected compression is less than 1.5″, a check is made for complete hand release to allow the victim's chest to recoil. If the rescuer hand is released off the victim chest after every compression, then the AED checks if the compression rate is higher than a preprogrammed R 1 rate. If the compression rate is higher than R 1 , the AED output voice/text prompts indicating effective compressions “Good Compressions”. Else, the compression rate is less than R 1 , the AED output voice/text prompts instructing the rescuer to press faster and return to ‘Detect & Increment Chest Compression count’ state.
[0067] If the rescuer is not releasing the hands off the chest after each compression, the AED instructs the user to release the hands off the victim's chest after each compression by outputting voice/text prompts “Release Hands Off Chest After Pushing”, then returns to ‘Detect & Increment Chest Compressions Count’ state. If the depth of the detected chest compression is greater than 1.5″, the AED instructs the rescuer to push on the victim chest with less force by outputting the prompt “Push With Less Force”, then returns to ‘Detect & Increment Chest Compressions Count’ state. If the number of chest compressions exceeds 5, the device instructs the rescuer to stop compressions and give the victim one breath by outputting voice/text prompts “Stop Compressions, Give One Breath”, then checks if the CPR state time interval exceeds a timer T 1 . If CPR state time interval is less than T 1 , the chest compression counter is reset and the AED returns to ‘Detect & Increment Chest Compressions Count’ state. If the CPR state time interval exceeds T 1 , the AED instructs the rescuer to activate the EMS system by calling 911 and then the AED transitions to ‘Execute 3 Shock Sequence, Set T 1 ’ state. In this state, the “Pediatric ECG Analysis Algorithm” is executed. If the first analysis detects a non-shockable rhythm, the AED transitions to the CPR state for another cycle of CPR. Else, if the first analysis detects a shockable rhythm, the rescuer is advised to deliver a defibrillation shock. Following the shock delivery a second analysis is automatically initiated to determine whether the defibrillation treatment was successful or not (i.e. the shockable ECG rhythm has been converted to a normal or other non-shockable rhythm). If this second analysis detects the continuing presence of a shockable arrhythmia, the AED advises the user to deliver a second defibrillation treatment.
[0068] A third ECG analysis is automatically initiated to determine whether the second shock was or was not effective. If a shockable rhythm persists, the rescuer is then advised to deliver a third defibrillation treatment. Following the third defibrillator shock or when any of the analyses described above detects a non-shockable rhythm, the AED transitions to the CPR state for another cycle of chest compressions and ventilation. Also In the ‘Execute 3 Shock Sequence, Set T 1 ’ state, T 1 is set to a preprogrammed value based on the type of the detected rhythm: normal, asystole, non-conductive, ventricular tachycardia or ventricular fibrillation. For instance, the asystole and non-conductive rhythms may require longer CPR periods than 1 minute in such case the ‘Execute 3 Shock Sequence, Set T 1 ’ task will set the T 1 to a preprogrammed value appropriate for pediatric asystole or non-conductive rhythms that may be longer than one minute. In the case of an arrhythmia, the required CPR time may be only 1 minute in such case the ‘Execute 3 Shock Sequence, Set T 1 ’ task will set the T 1 to a preprogrammed value appropriate for pediatric arrhythmia rhythms that may be one minute. In the case of normal rhythm, the required CPR time may be only 1 minute in such case the ‘Execute 3 Shock Sequence, Set T 1 ’ task will set the T 1 to a preprogrammed value appropriate for pediatric rhythms that may be one minute or longer.
[0069] If on the other hand, the AED detects adult defibrillation pads on power-up, the AED will automatically start an adult rescue protocol. FIG. 6 b shows the details of one instance of the adult rescue protocol. The AED will output voice/text prompts indicating to the rescuer to check the victim's responsiveness (i.e., “Check Responsiveness”) and allow a preprogrammed time interval (i.e., 4 seconds) to expire to allow for checking the responsiveness before moving to the next state. Next, the AED instructs the rescuer to activate the EMS system by calling 911 and allow a preprogrammed time interval (e.g., 4 seconds) to expire to allow someone call for help before moving to the next state. The AED will next output voice/text prompts instructing the rescuer to check breathing (e.g., “Check Breathing”) and then allow a preprogrammed time interval (example: 7 seconds) to check breathing. The device will next output voice/text prompts instructing the rescuer to check the victim's pulse (e.g., “Check Pulse”) and then allow a preprogrammed time interval (e.g., 10 seconds) for the pulse check. The AED will then transitions to ‘Execute 3 Shock Sequence, Set T 1 ’ state. In this state, the “Adult ECG Analysis Algorithm” is executed. If the first analysis detects a non-shockable rhythm, the AED will transition to the CPR state. Else, if the first analysis detects a shockable rhythm, the rescuer is advised to deliver a defibrillation shock.
[0070] Following the shock delivery a second analysis is automatically initiated to determine whether the defibrillation treatment was successful or not (i.e. the shockable ECG rhythm has been converted to a normal or other non-shockable rhythm). If this second analysis detects the continuing presence of a shockable arrhythmia, the AED advises the user to deliver a second defibrillation treatment. A third ECG analysis is automatically initiated to determine whether the second shock was or was not effective. If a shockable rhythm persists, the rescuer is then advised to deliver a third defibrillation treatment. Following the third defibrillator shock or when any of the analyses described above detects a non-shockable rhythm, the device transition to the CPR state for another cycle of CPR. Also In the ‘Execute 3 Shock Sequence, Set T 1 state, T 1 is set to a preprogrammed value based on the type of the detected rhythm: normal, asystole, non-conductive, ventricular tachycardia or ventricular fibrillation. For instance, the asystole and non-conductive rhythms may require longer CPR periods than 1 minute in such case the ‘Execute 3 Shock Sequence, Set T 1 ’ task will set the T 1 to a preprogrammed value appropriate for adult asystole or non-conductive rhythms that may be longer than one minute. In the case of an arrhythmia, the required CPR time may be only 1 minute in such case the ‘Execute 3 Shock Sequence, Set T 1 task will set the T 1 to a preprogrammed value appropriate for adult arrhythmia rhythms that may be one minute. In the case of normal rhythm, the required CPR time may be only 1 minute in such case the ‘Execute 3 Shock Sequence, Set T 1 task will set the T 1 to a preprogrammed value appropriate for adult rhythms that may be one minute or longer. Upon entering the CPR state, the AED outputs voice/text prompts instructing the rescuer to start chest compressions (example “If No Pulse, Start Chest Compressions”). While in this CPR state the chest compression signal is received by ‘Detect & Increment Chest Compressions Counter’ function that detects chest compressions and counts them. While the number of chest compressions is less than 15, the depth of each detected compression is evaluated. If the depth of the detected compression is not higher than 1.5″, the rescuer is instructed to push harder on the victims chest by outputting “Push Harder” voice/text prompts and return to ‘Detect & Increment Chest Compression count’ state. Else, if the depth of the detected chest compression exceeds 1.5″, this depth is evaluated again. If the depth of the detected compression is less than 2″, a check is made for complete hand release. If the rescuer hand is released off the victim chest after every compression to allow for complete chest recoil, then the AED checks if the compression rate is higher than a preprogrammed R 1 rate. If the compression rate is higher than R 1 , the AED output voice/text prompts indicating effective compressions “Good Compressions”. Else, the compression rate is less than R 1 , the AED output voice/text prompts instructing the rescuer to press faster and return to ‘Detect & Increment Chest Compression count’ state.
[0071] If the rescuer is not releasing the hands off the chest after each compression, the device instructs the user to release the hands off the victim's chest after each compression to provide more effective CPR by outputting voice/text prompts “Release Hands Off Chest After Pushing”, then returns to ‘Detect & Increment Chest Compressions Count’ state. If the depth of the detected chest compression is greater than 3″, the device instructs the rescuer to push on the victim chest with less force by outputting the prompt “Push With Less Force”, then checks if compression rate is higher than a preprogrammed R 1 rate. If the compression rate is higher than R 1 , the AED output voice/text prompts indicating effective compressions. Else, the compression rate is less than R 1 , the AED output voice/text prompts instructing the rescuer to press faster. If the number of chest compressions exceeds 15, the device instructs the rescuer to stop compressions and give the victim two breaths by outputting voice/text prompts “Stop Compressions, Give Two Breaths”, then checks if the CPR state time interval exceeds a selected timer T 1 .
[0072] If CPR state time interval is less than T 1 , the chest compression counter is reset and the device returns to ‘Detect & Increment Chest Compressions Count’ state. If the CPR state time interval exceeds T 1 , the AED will transition to ‘Execute 3 Shock Sequence, Set T 1 state.
[0073] FIG. 12 shows an example of a AED Arrhythmia processing flow diagram. Since the pediatric QRS is narrower and the heart faster than adult, the QRS detection system can be tailored to be more sensitive to the ECG signal. The flow diagram also shows that the arrhythmia classification logic and shock decision logic can be altered to improve the specificity and sensitivity.
[0074] In the Signal Conditioning block, the ECG signal is band passed and notch filtered to remove baseline offsets, high frequency noise, and line noise frequency noise. The noise Detection block performs baseline, motion, high frequency, muscle, and saturation noise detections and flags the ECG Signal status data accordingly.
[0075] In the QRS detection block, the processing produces a QRS detection signal by performing a QRS based matched filter on the filtered ECG data. The type of processing performed is dependant on the Processing Mode Setting (reference FIG. 13 ).
[0076] Once the location of the QRS is detected in the signal stream, the QRS Detection Block will process the signal around the QRS detection to determine specific measurements such as R-R interval, QRS width, QRS area, and other features which will support classification of the QRS complex and its underlying rhythm. The Rhythm Measurement block will perform analysis on the QRS measures and ECG signal to produce rhythm based measures required for rhythm classification. The Rhythm Determination and Shock Determination Decision Logic block will process the QRS detection and rhythm data to classify the ECG rhythm and make a shock versus no shock decision. Many beat and rhythm classification techniques are know in the art and include heuristic logic, morphological analysis, expert system analysis, and statistical clustering techniques. The outputs from the Rhythm Determination and Shock Determination Decision Logic block are used by the AED to shock the victim (fully automatic AED) or notify the user to deliver a shock (semi-automatic AED) or begin other interventions such as CPR.
[0077] FIG. 13 shows an example of the use of mode specific processing to enhance QRS detection. In the PEDI Mode selection block, the matched filter characteristics are chosen based on the Processing Mode setting (Adult or Pediatric) to produce an optimal detection signal for that class of patients. A threshold detection scheme is used to determine the location of the QRS complexes in the detection signal. A threshold system is utilized which has been optimized for use with the respective QRS matched filter. The QRS Detection Selection block determines whether to perform QRS Measurements (QRS Detected) or perform an Asystole Check (QRS Not Detected). The Asystole check will process a detection timeout, adjust detection thresholds, and notify the target system if an asystole state is present.
[0078] FIG. 14 shows an example of the use of mode specific processing to enhance the rhythm classification logic and shock decision determination. The PEDI Mode Selection block chooses which Patient Mode Rhythm Logic to process. Rhythm classification logic can be implemented in a number of ways, heuristic (if-then-else) rules, feature cluster analysis, fuzzy system analysis, neural networks, Bayesian probabilistic system analysis, etc. The Shockable Rhythm Selection block selects the appropriate process flow based on the Shock decision. The No Shock Decision block notifies the defibrillator system to take the appropriate actions such as display and audibly announce the non-shockable rhythm analysis result. A shockable decision will produce a charging of the defibrillator and a delivery of therapy (automatic defibrillator) or a prompt to the user for delivery of energy (semi-automatic defibrillator).
[0079] FIG. 15 and FIG. 16 are simple examples adult and pediatric AED arrhythmia logic tables. The rhythm classifications in column 1 are satisfied when all of the rules stated in columns 2 - 6 are met and the respective shock decision is listed in the last column. The examples show that the shockable versus non-shockable decision can come from specific adult or pediatric rhythm classification logic. The various limits, rules, or other population specific logic systems are tuned (or trained) from adult and pediatric ECG signal databases, respectively.
[0080] Referring to FIG. 7 , the cover 12 is provided with a detection means for determining if the patient's shoulders have been properly positioned on the cover 12 . Two photoelectric sensors 156 , 157 are used to determine if the cover has been placed underneath the patient's back. The sensors 156 , 157 are located along the acute edge of the cover 12 , with one facing inward and one facing outward with the cable 155 providing both power to the sensors 156 , 157 as well as detection of the sensor output. If the cover 12 is upside down, the inner sensor 156 will measure a higher light level than the outer sensor 157 ; if the cover has been placed with the acute edge facing toward the top of the patient's head, then the outer sensor 157 will measure higher than the inner sensor 156 and will also exceed a pre-specified level. In the case of a properly positioned cover, both inner 156 and outer sensor 157 outputs will be below a pre-specified level. In another embodiment, the detections means is provided by a pressure sensor 158 located underneath the cover decal. The pressure sensor 158 can be used to measure the thoracic weight of the victim. Based on the measured weight, a table lookup can be generated, determining the victim's approximate age as well as the optimal defibrillation energies to provide.
[0081] Thus, when a person collapses and a caregiver suspects that the person is in cardiac arrest, the caregiver first gets the defibrillator and turns the power on 102 . If the unit passes its internal self tests, and is ready for use, this will be indicated by indicator 17 . Next, the defibrillator prompts the caregiver with an introductory audio message, e.g., “Stay calm. Listen carefully.”
[0082] Shortly thereafter, the defibrillator will prompt the caregiver with an audio message indicating that the caregiver should check the patient for responsiveness. Simultaneously, the LED 56 adjacent graphic 42 will light up, directing the caregiver to look at this graphic. Graphic 42 will indicate to the caregiver that she should shout “are you OK?” and shake the person in order to determine whether the patient is unconscious or not.
[0083] After a suitable period of time has elapsed (e.g., 2 seconds), if the caregiver has not turned the defibrillator power off (as would occur if the patient were responsive), the defibrillator will give an audio prompt indicating that the caregiver should call for help. Simultaneously, the LED adjacent graphic 42 will turn off and the LED adjacent graphic 43 will light up, directing the caregiver's attention to graphic 43 . Graphic 43 will remind the caregiver to call emergency personnel, if the caregiver has not already done so.
[0084] After a suitable interval has been allowed for the caregiver to perform the prior step (e.g., 2 seconds) the defibrillator will give an audio prompt indicating that the caregiver should open the patient's airway and check whether the patient is breathing. The LED adjacent graphic 43 will turn off, and the LED adjacent graphic 44 will light up, directing the caregiver's attention to graphic 44 , which shows the proper procedure for opening a patient's airway. This will lead the caregiver to lift the patient's chin and tilt the patient's head back. The caregiver may also position an airway support device under the patient's neck and shoulders, if desired, as discussed below with reference to FIGS. 9 a , 9 b . The caregiver will then check to determine whether the patient is breathing.
[0085] After a suitable interval (e.g., 15 seconds), the defibrillator will give an audio prompt indicating that the caregiver should check for signs of circulation, the LED adjacent graphic 44 will turn off, and the LED adjacent graphic 45 will light up. Graphic 45 will indicate to the caregiver that the patient should be checked for a pulse or other signs of circulation as recommended by the AHA for lay rescuers.
[0086] After a suitable interval (e.g., 5 to 7 seconds), the defibrillator will give an audio prompt indicating that the caregiver should attach electrode assembly 16 to the patient, the LED adjacent graphic 45 will turn off, and the LED adjacent graphic 46 will light up. Graphic 46 will indicate to the caregiver how the electrode assembly 16 should be positioned on the patient's chest.
[0087] At this point, the LED adjacent graphic 47 will light up, and the defibrillator will give an audio prompt indicating that the patient's heart rhythm is being analyzed by the defibrillator and the caregiver should stand clear. While this LED is lit, the defibrillator will acquire ECG data from the electrode assembly, and analyze the data to determine whether the patient's heart rhythm is shockable. This analysis is conventionally performed by AEDs.
[0088] If the defibrillator determines that the patient's heart rhythm is not shockable, the defibrillator will give an audio prompt such as “No shock advised”. The LEDs next to graphics 48 and 49 will then light up, and the defibrillator will give an audio prompt indicating that the caregiver should again open the patient's airway, check for breathing and a pulse, and, if no pulse is detected by the caregiver, then commence giving CPR. Graphics 48 and 49 will remind the caregiver of the appropriate steps to perform when giving CPR.
[0089] Alternatively, if the defibrillator determines that the patient's heart rhythm is shockable, the defibrillator will give an audio prompt such as “Shock advised. Stand clear of patient. Press treatment button.” At the same time, the heart 54 and/or hand 52 will light up, indicating to the caregiver the location of the treatment button. At this point, the caregiver will stand clear (and warn others, if present, to stand clear) and will press the heart 54 , depressing the treatment button and administering a defibrillating shock (or a series of shocks, as determined by the defibrillator electronics) to the patient.
[0090] Referring to FIG. 11 , in some implementations, a means is provided of detecting the relative lateral positions of the apex electrode 255 and the sternum electrode 254 . In one implementation, magnetic Hall Effect sensors 251 are located such that when activated by the magnet 253 located within the apex electrode 255 the signal generated by the Hall effect sensor 251 indicates the relative lateral location of the electrodes. Using known anthropometrics, the thoracic girth can be estimated as well as patient age and defibrillation energy levels. The relative lateral positions of the electrodes can be determined using a linear encoder commonly used in digital calipers thus providing an accurate measurement of girth. The encoder may be an optical encoder or a magnetic based encoder.
[0091] The cover 12 of the AED may include a decal on its underside, e.g., decal 200 shown in FIG. 10 . Decal 200 illustrates the use of the cover as a passive airway support device, to keep the patient's airway open during resuscitation. Graphic 202 prompts the caregiver to roll the patient over and place cover 12 under the patient's shoulders, and graphic 204 illustrates the proper positioning of the cover 12 under the patient to ensure an open airway.
[0092] While such a graphic is not included in the decal shown in FIG. 5 , the decal 40 may include a graphic that would prompt the user to check to see if the patient is breathing. Such a graphic may include, e.g., a picture of the caregiver with his ear next to the patient's mouth. The graphic may also include lines indicating flow of air from the patient's mouth.
[0093] Many other implementations of the invention other than those described above are within the invention, which is defined by the following claims.
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A device for assisting a rescuer in delivering therapy to an adult or pediatric patient, the device including a user interface comprising a display and/or audio speakers, the user interface being configured to deliver prompts to a rescuer to assist the rescuer in delivering therapy to a patient; a processor configured to provide prompts to the user interface and to perform an ECG analysis algorithm on ECG information detected from the patient; at least one detection element configured to determine without rescuer input via the user interface that a pediatric patient is being treated; wherein, if a pediatric patient is detected, the processor modifies the ECG analysis algorithm or the prompts provided to the user interface to use an ECG analysis algorithm or prompts adapted for a pediatric patient rather than for an adult patient.
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This is a continuation of application Ser. No. 08/092,103 filed on Jul. 16, 1993, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to the oxidative coupling of methane on octahedral molecular sieves, mainly manganese oxides, equivalent to the structures of natural minerals, e.g., todorokite and hollandite.
DISCLOSURE STATEMENT
Hollandite (BaMn 8 O 16 ), cryptomelane (KMn 8 O 16 ), manjiroite (NaMn 8 O 16 ), and coronadite (PbMn 8 O 16 ) are all naturally occurring manganese minerals with a 3-dimensional framework tunnel structure. The structure consists of MnO 6 octahedra which share edges to form double chains, and the octahedra of the double chains share corners with adjacent double chains to form a 2×2 tunnel structure. The size of these tunnels is 4.6 Å×4.6 Å. Ba, K, Na and Pb ions are present in the tunnels and coordinated to the oxygens of the double chains. The identity of the tunnel cations determines the mineral species. The minerals are members of the hollandite-romanechite family which has a common double chain width, T(2×2).
Zeolites and zeolite-like materials are the well-known molecular sieves. These materials use tetrahedral coordinated species TO 4 , (T═Si, Al, P, B, Be, Ga, etc.,) as the basic structure unit. Through the secondary building units (SBU), a variety of frameworks with different pore structures are then built. Like tetrahedra, octahedra also can be used as the basic structural unit to form octahedral molecular sieves (OMS).
Herein below, we will refer to the materials with a 2×2 tunnel structure as hollandites, and identify each member by the identity of the tunnel ions. Such minerals can be characterized by the general formula:
A.sub.2-y Mn.sub.8 O.sub.16 xH.sub.2 O
where A is the counter ion (alkali or alkaline earth metal or Pb +2 ), Mn represents Mn +4 and Mn +2 and x is 6 to 10 with y varying from 0.1 to 1.3.
Because of their tunnel structure, the materials may be useful as shape selective catalysts and molecular sieves. Although K-hollandite and Ba-hollandite have reportedly been synthesized (as discussed by Parida et al, "Chemical Composition, Microstructure and other Characteristics of Some Synthetic MnO 2 of Various Crystalline Modifications", Electrochimica Acta, Vol. 26, pp. 435-43 (1981) and Strobel et al, "Thermal and Physical Properties of Hollandite-Type K 1 .3 Mn 8 O 16 and (K,H 3 O) x Mn 8 O 16 ", J. Solid State Chemistry, Vol. 55, PP. 67-73 (1984). However, these syntheses are unreliable and considerable difficulties have been experienced by practitioners in this field.
Villa et al discussed the synthesis of oxide systems containing Mn in combination with other elements in "Co--Mn--Ti--K OXIDE SYSTEMS" Applied Catalysis, Vol. 26, pp. 161-173 (1986).
Torardi et al. discussed the synthesis of a hollandite-type molybdenum compound (K 2 Mo 8 O 16 ) by hydrothermal reaction of basic K 2 MoO 4 solutions with Mo metal in "Hydrothermal Synthesis of a new molybdenum hollandite," Inorganic Chemistry, Vol. 23.
The hollandites are representative of a family of hydrous manganese oxides with tunnel structures (also described as "framework hydrates") in which Mn can be present as Mn +4 and other oxidation states, the tunnels vary in size and configuration, and various mono- or divalent cations may be present in the tunnels. Such cations may serve to form and support the tunnels in some cases. Clearfield describes various hydrous manganese oxides with tunnel structures in "Role of Ion Exchange in Solid-State Chemistry," Chemical Reviews, Vol. 88, pp. 125-131 (1988). Pyrolusite or β-MnO 2 has tunnels only one MnO 6 octahedron square (1×1), or about 2.3 Å square, while in ramsdellite, MnO 2 , these octahedra form (2×1) tunnels, about 2.73 Å×4.6 Å. Nsutite, γ-MnO2, is described as an intergrowth of pyrolusite and ramsdelite and also has (2×1) tunnels. Psilomelane, Ba 2 Mn 5 O 10 xH 2 O, and romanechite (with K +2 substituted for Ba +2 in the psilomelane formula) have (3×2) tunnels parallel to the cell b axes, about 4.6 Å×6.9 Å. Todorokites, (Na,Ca,Mn) Mn 3 O 7 xH 2 O, have (3×3) tunnels, about 6.9 Å square, and monoclinic cells. Todorokites and other species are described by Turner et al. in "Todorokites: A New Family of Naturally Occurring Manganese Oxides," Science, May 29, 1981, pp. 1024-1026, in which it is noted that since todorokites are often found in deep-sea manganese nodules containing high concentrations of copper and nickel, "it seems probable that the smaller transition elements substitute for Mn +2 in the octahedral framework." The same article suggests a new partial nomenclature scheme for such manganese oxide structures--T(m,n), in which T donates a tunnel structure and the dimensions of the tunnels are indicated by (m,n). In this notation, the common dimensions responsible for intergrowth (m) is listed first, while (n) represents a variable dimension.
D. C. Golden et al., discloses the synthesis of todorokite in SCIENCE 231.717 (1986).
U.S. Pat. No. 5,015,349 discloses a method for cracking a hydrocarbon material. The method includes introducing a stream including a hydrocarbon fluid into a reaction zone. A microwave discharge plasma is continuously maintained within the Reaction zone, and in the presence of the hydrocarbon fluid. Reaction products of the microwave discharge are collected downstream of the reaction zone.
The disclosure of U.S. Pat. No. 5,015,349 is incorporated herein by reference.
Herein below, we will refer to the (3×3) tunnel structure as OMS-1 and the (2×2) tunnel structure as OMS-2.
Many of these tunnel or framework hydrates in addition to the (2×2) hollandites and (3×3) todorokites have potential for use in separations, absorbent materials or catalyst materials. Hence, a use of the present product as a catalyst is desired.
Thus, the object of this invention is to use the materials of this invention as a catalyst to activate methane (CH 4 ) onto coupled hydrocarbons.
SUMMARY OF THE INVENTION
A method of oxidatively coupling methane (CH 4 ) onto a manganese molecular sieve comprising:
(a) passing methane through a microwave plasma activation flow (quartz) reactor onto a manganese oxide catalyst sieve, whereby polymer-free methane coupled products are produced; and
(b) recovering the polymer-free methane coupled products.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawings provided for illustration are:
FIG. 1 shows the three-dimensional framework tunnel structures of OMS-2, hollandite (2×2); and
FIG. 2 shows the three-dimensional framework tunnel structure of OMS-1, todorokite (3×3).
DETAILED DESCRIPTION OF THE INVENTION
According to the present invention, it is possible to crack or activate hydrocarbons such as methane, for example, by breaking C--H bonds using the microwave plasma without a catalyst. However, the ability to control the reaction and produce specific desired end products is generally low in the absence of a catalyst. In other words, the selectivity associated with the reaction is usually low unless a catalyst is provided. Selection of an appropriate catalyst is essential, if high selectivity of the end product and good control of the reaction is to be obtained.
The catalyst should be positioned downstream of the reaction zone. If the catalyst is placed within the plasma reaction zone there is a significant danger that the surface of the catalyst may become prematurely coked. It has been found that the best results are obtained by locating the catalyst just outside the zone in which the microwave plasma is created. The catalyst can be placed within the tubing carrying gases from the reactor outlet. Alternatively, and preferably, the catalyst may be placed within a U-tube downstream of the reactor outlet.
Selection of the catalyst is dependent somewhat on reactants and reaction conditions. Generally, a metal or metal oxide material is employed as the catalyst. If methane is used as the reactant gas, the catalyst must be a hydrogen acceptor if high selectivity towards ethane or ethylene is to be attained. For the production of olefins, it is necessary to use a catalyst that can adsorb hydrogen, such that unsaturated species will result. Typically, dehydrogenation catalysts such as nickel are used for this purpose.
Platinum catalysts are strong oxidizing catalysts. Large amounts of CO 2 are formed when Pt is used as a catalyst with the process of the present invention. At the same time, relatively large amounts of HCHO are formed. Conversely, nickel catalysts tend to minimize the formation of highly oxidized species and favor methanol production instead.
To be useful in the present invention, a catalyst should be resistant to coking under low power microwave reaction conditions, and should also be thermally and photochemically stable. Thermal stability refers to the ability of the catalyst to withstand the operating temperatures of the hydrocarbon cracking reactions carried out using the low power microwave energy conditions of the present invention.
In general, to be useful as a catalyst element in the instant process, a composition must withstand continuous long term exposure to temperatures up to about 500° C. Long term exposure refers to the intended duration of operation of the reactor vessel of the invention. It is contemplated that in commercial operation the microwave cracking process of the invention may be conducted continuously for several days, or more before the process is halted for cleaning the reaction vessel. The catalyst element of the invention should be non-volatile under operating conditions. A high catalyst surface area is desirable. A high surface area can be attained by providing the catalyst in a suitable shape or size, e.g. in finely divided powder form. In an alternative arrangement, the catalyst can take the form of a fine mesh screen or a sintered disc. In addition, the catalyst array may be disposed on one or more silica supports that are positioned in the reactant stream.
The following Examples are provided to illustrate the advantages of the present invention.
EXAMPLE I
Methane Coupling
The detailed apparatus of the microwave plasma activation can be found in the U.S. Pat. No. 5,015,349. In this example, methane was passed through a flow reactor made of quartz having an outside diameter of 12 mm with a flow rate of 60 mL/min and at a total pressure of 20 torr. A Beenaker resonance cavity was used to activate methane. A microwave generator having 60 watts power delivered by the generator was used. The hydrated todorokite catalyst was used as a powder and placed downstream of the plasma zone, about one mm outside the plasma and spread on the bottom of the quartz tube reactor. Products were collected in a cold trap and then directly injected into a gas chromatograph through a gas sampling valve. Products were identified by using known standards and comparison to measured retention times. Gas chromatography method were used to check the identification of some products. The observed conversion of methane of the catalyst was 98.5%. The product distribution included 9.9% ethylene, 17.8% ethane, 9.9% acetylene, 19.6% propane, 22.6% C4 hydrocarbons and 18.6% C5+ hydrocarbons and polymer deposit.
EXAMPLE 2
Todorokite Catalyst
The dehydrated todorokite catalyst was tested with the same procedures, except the methane flow rate was 50 mL/min and the microwave power was 40 watts. The observed conversion of methane for the catalyst was 97.8%. The product distribution included 20% ethylene, 42% ethane, 25% acetylene, 0.2% propane, 1% C4 hydrocarbons and 10% C5 hydrocarbons. No polymer deposit was observed with this catalyst.
As illustrated above, and according to U.S. Pat. No. 5,015,349 and the present invention, it is possible to activate methane using the microwave plasma technique without a catalyst. However, the ability to control the reaction and produce specific desired products is generally low in the absence of a catalyst, i.e., poor selectivity. Selection of an appropriate catalyst is essential, if high selectivity of the end products and good control of the reactions is to be obtained. Both examples have shown that associated with the microwave plasma technique, manganese oxide molecular sieves are active and selective catalysts for the oxidative coupling of methane. The conversion is extreme high (>98%) and the selectivity of C2+ products is also good. The unusual selectivity toward C4 and C5+ products shown in Example 1 should be noted. It is not possible to obtain such selectivities with metal or other metal oxide catalysts. The enhanced coupling may be due to the tunnel structure of the todorokite. The selectivities markedly change as the todorokite is hydrated and then dehydrated.
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A method of oxidatively coupling methane onto a manganese oxide molecular sieve comprising:
(a) passing methane through a microwave plasma activation flow reaction zone onto a manganese oxide molecular sieve, whereby polymer-free methane coupled products are produced; and,
(b) recovering the polymer-free methane coupled products.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to reinforcing and supporting roof, ceiling or floor systems, and more particularly to methods and apparatus for providing improved support for new and existing roof, ceiling or flooring systems to help prevent failure in the event of seismic activity, wind, water, excessive weight buildup and the like.
[0003] 2. Description of the Prior Art
[0004] Many types of buildings may be heavily damaged by seismic movement, high winds and other natural disasters. These include, but are not limited to, tilt-up buildings that have concrete walls which are formed and poured and cured flat on top of existing slabs on grade and then raised into position, masonry walls, pour-in-place concrete walls, or block walls. These varieties of walls anchor to roof systems constructed of wood usually with a series of primary beams (glued laminated beams—GLB's), secondary timber beams or purlins, joists spanning from purlin to purlin, wall mounted ledgers, or simply beams with joists spanning in between. Such buildings will simply be referred to herein as “buildings.” In these types of buildings, the plywood sheathing acts as a diaphragm which ties the roof to the wall along with assorted metal connectors such as nails, straps, bolts or other transfer mechanisms. On older buildings, the transfer mechanisms are likely to be substandard either because of design deficiencies, installation shortcomings, or both, and thus are not up to current Uniform Building Code (UBC) standards. The devices of the present invention may be used to upgrade (retrofit) the connections used in the aforementioned structures, and may also be used in new construction.
[0005] Aside from seismic and wind forces, a common roof failure results from a build-up of rain or water from pipe leakages because of clogged roof drains or snow build-up. Additionally, roof mounted equipment and/or material stored on a roof may contribute to wall separation from the roof. When this occurs, roof collapse is often the result. Another contributing factor in roof collapse is improper placement of anchor bolts that connect the walls to a ledger that is bolted to the inside of the wall at the roof level and subsequently to the roof plywood with nails. At the location where anchor bolts are positioned in line with the wood grain of the ledger, the natural grain of the wood essentially defines a fault line that is prone to splitting, which would allow the wall to separate from the roof diaphragm. Factors that exacerbate the aforementioned splitting are oversized drilling of bolt holes which, when combined with nuts that are over-tightened, may cause the (round) cut washer to bend inward at the center and exert force that causes the upper portion of the wooden ledger to separate from the lower portion. This phenomenon occurs to some degree even when stronger plate washers are used. Many older buildings have cut washers at such locations.
[0006] Another vulnerable connection is where a GLB is anchored to a column which is part of the perimeter, or where a GLB hangs onto the wall with only a metal hanger with no direct column support from below. A similar vulnerability exists where a concrete column using a prefabricated metal saddle for anchoring a GLB has been poorly installed (i.e., poor pouring, casting of the column). Ordinarily, when a connector such as a GLB beam seat is installed according to specifications, the bolts connecting the GLB to the GLB beam seat saddle pre-drilled holes are approximately two inches (plus or minus) from the bottom of the GLB. When installed on a GLB that may be 24 inches or more in height, the connection is inadequate by current building codes. In addition, when the holes drilled in the GLB for anchorage to the aforementioned GLB beam seat are oversized, this makes the edge of the drilled hole even closer to the bottom of the GLB. Also, as is often the case, when these saddle connectors are installed out of level either side to side or end for end, this already questionable installation is worsened.
[0007] Locations where one GLB is connected to another in a linear manner (abut end to end), but do not adjoin inside of a saddle that is supported by a column, usually are connected with a hinge connector that allows the two beams to stay connected, but they may separate due to the swinging action of a hinge connector. This is a system deficiency that usually occurs during a seismic event. The aforementioned movement results in loosening of the nails that are critical to the structural integrity of the roof diaphragm system.
[0008] Purlins which anchor to the wooden ledgers that bolt to the walls should have a purlin anchor strap which is embedded into the concrete when the concrete is poured. These purlin straps are usually anchored to purlins using only nails, and are not designed to provide vertical counterforce either upward or downward, even when installed properly.
[0009] It is therefore desirable to provide methods and apparatus for retrofitting existing roofing, ceiling or flooring systems, and for use in new roofing, ceiling or flooring installations, that provide improved support to help prevent failure in the event of seismic activity, wind, water, excessive weight buildup and the like. It is also desirable to provide numerous alternative methods and apparatus that may be combined, adapted and intermingled for use with various roofing system sizes, shapes and configurations.
SUMMARY OF THE INVENTION
[0010] The present invention provides a number of alternative roofing, ceiling or flooring system support structures that may be used to improve the tension and vertical strength of a wide variety of roof, ceiling or flooring systems. One set of embodiments of the present invention is made up of three elongated tension members. All three components may be shortened, lengthened or sized to accommodate individual building specifications by the engineer of record. These components, when prefabricated on-site, create a triangle shaped system having one member anchored to the side of a beam, a second member anchored to the concrete (or block or masonry) wall and forming a corner with the first member, and the remaining member connecting the ends of the first and second members forming a hypotenuse of the triangle. In alternative embodiments, another such triangular shaped system may be installed on the opposite side of the aforementioned beam in mirror image fashion.
[0011] The above-described embodiments are designed for installation under the ledger or other analogous structure in order to supply a counter force to seismic movement of the primary beam and ledger relative to the wall in the vertical plane. In addition, these systems supply a counter force to GLB movement in the horizontal plane at the GLB/wall connection through the first component that is attached to the wall, and through the second component that is attached to the beam. This aforementioned connection also provides additional vertical support to the GLB at this location. The opposite end of the first component (away from the GLB), also bolts to the wall under the ledger providing additional vertical support. The hypotenuse component acts as a brace for the wall between beams, and provides a counterforce to wall movement in two planes: lateral movement of the wall at a right angle to the roof diaphragm, and horizontal wall movement both toward the roof and outward from the roof. In some embodiments, the components of this embodiment are symmetrical at each end to the opposite end, so that the second and third components may be used on either side of the beam, and/or be installed with the angle-iron flange facing up or down. When used, the mirror image systems may be attached to each other through the beam.
[0012] A second set of embodiments of the present invention include a single welded frame that accomplishes essentially the same objectives as the first set of embodiments, but which uses the secondary beam (purlin) in place of the primary beam (GLB) as the initial anchoring roof element. In place of the duality of installed frames that may be used as part of the first set of embodiments, the second set of embodiments uses a prefabricated frame that is installed under the purlin, with two angle irons several feet apart (e.g. four feet), with the purlin intersecting the ledger in between the two aforementioned angle-irons. In most existing structures, the purlin will already be anchored to the ledger with a pre-existing purlin hanger. The two angle-irons provide vertical support for the ledger that the purlin supports. The remainder of the integrated structure is made up of two additional arms or angle straps (preferably 2″×¼″), having one end welded to each angle-iron. These arms traverse at an angle (preferably 45 degrees) inward, and the opposite ends are welded together at their junction forming a saddle that encompasses the purlin at a distance (e.g. two feet) out from the ledger. This saddle is bolted to the purlin with multiple bolts that complete the connection from wall to purlin.
[0013] The above described elements provide a counter-force to wall movement relative to the roof diaphragm element in three planes. The two angle straps provide a counter-force to lateral wall movement parallel to the length of the wall. The two angle-iron members provide vertical support at the ledger. The saddle, through the angle-iron connection, provides a counter-force to seismic forces that either push the wall into or away from the roof diaphragm system.
[0014] In one aspect of the second set of embodiments, a single welded or molded unit is provided with two sections of rigid material (e.g. angle iron) that bolt to the wall under the ledger at two locations, both locations approximately 2 feet to the side of where the purlin intersects the ledger that is bolted to the aforementioned wall. A flat rigid strap (preferably metal) is attached or welded to each section of angle iron and extends at an approximately 45 degree angle where they are attached or welded to the lower portion of a rigid (preferably steel) saddle which in turn bolts through the purlin and into the opposite side of the saddle. The two sections of angle iron that bolt to the concrete wall under the ledger provide vertical support to the ledger and consequently to the intersecting purlin where the purlin is anchored to the ledger. The lateral anchoring force provided by the two flat straps which are welded to the angle iron and the saddle transfer force along the plane of the roof diaphragm to the aforementioned wall and replace or supplement both the embedded bolts that anchor the ledger to the wall and the diaphragm perimeter nailing of the roof plywood. This system is not intended to supplement the vertical load capabilities of the purlin hanger since the purlin hanger should be adequate in the aforementioned vertical plane when these embodiments are installed and keep the purlin from separating from the wall. The two angled straps which anchor on opposite sides of the purlin exert a counter force to any seismic lateral movement of the wall relative to the roof diaphragm.
[0015] Where the purlins intersect the concrete wall at intervals of, for example, 8 feet, the only lateral connection through this 8-foot range is the nailing through the roof plywood. These embodiments add lateral support at, for example, 2-feet from the aforementioned intersection, so that in this example, the original 8 foot span is now only 4 feet.
[0016] Installation of systems of the second embodiments described above is the first step in establishing a strut connection embodiment that may extend from one end of the building to the opposite end along a series of purlins that are in line and end with similar embodiments on the opposite end of the building.
[0017] When an original ledger is installed, often the holes were oversized and/or the nuts were over-tightened which bends the cut washer into the gap created by the oversized hole and forces the ledger to split or be vulnerable to splitting when seismic or wind forces are at play. When the upper portion of the ledger rotates inward and the wall separates from the roof diaphragm, support for the purlins is compromised and the wall moves away from the building.
[0018] In another aspect of the invention, one or more retro-washer embodiments are provided to replace existing cut or plate washers that anchor the ledger to the wall. These retro-washers provide support for the full length of the washer. The retro-washers are manufactured in varying lengths to accommodate different sized ledgers. The wider part of the angle-iron is drilled with at least two holes, with one hole an inch closer to the center of the washer to allow for varying bolt locations and allow for the washer to extend closest to the bottom of the sheathing. When a retro-washer cannot be installed because the bolt is too close to the plywood then this washer may not be necessary anyway. In most embodiments, the retro-washers are provided with an outwardly extending flange. These flanges project out from the ledger and supply the strength that distributes force along the full length of the retro-washer when the original nut is replaced on the bolt. These embodiments are essentially upgraded washers that are designed to stop a ledger from splitting along the natural grain line that intersects the hole drilled for anchoring the ledger to the wall. The retro-washers are designed to replace existing cut washers or plate washers. The size and length of the retro washers will vary depending on the size of the ledger and the structural engineer specifications based on individual building conditions.
[0019] In one embodiment, a retro washer is essentially an angle iron approximately 2″×1″×11″ long that holds the upper portion of the ledger from rotating inward and also provides supplemental strength intended to keep the ledger from splitting through use of two ¼″×2½″ self tapping screws. In this embodiment, each end of the washer has one screw intended to keep the upper and lower portion of the ledger from separating.
[0020] Another set of embodiments is similar to that of the second set described above, providing structures for wall-to-wall support along the purlins. In these alternative embodiments, a bracket is provided on one or both sides of the saddle that is attached to the purlin. A transition bracket is then provided further down the purlin. This transition bracket has two welded brackets on each side of the purlin. One welded bracket is for attachment of a PT cable that traverses the length of the building through drilled holes in the primary beams (GLB's) and connects to a mirror image system on the opposite end of the building. The second transition bracket has a shrouded assembly bolted to it that connects to the angled flange on the saddle embodiment which is installed on the purlin directly adjacent to the aforementioned purlin. This may be provided on one or both sides of the purlin, thus connecting three purlins to a pair of PT cables that spans the building. These systems may be incorporated onto the adjacent set of 3 purlins, and the next set of 3, and so on, providing wall-to-wall support along these purlin sets. The purlins that run in-line with the center purlin establish a strut line through the length of the building at each purlin to GLB connection, the connection may be shimmed tight to establish the compression requirements as stated by the structural engineer. In effect, these systems are capable of anchoring 20 or more feet of wall to the roof diaphragm.
[0021] Another set of embodiments is similar to those of the first set described above. In these embodiments, a shrouded system is used in place of an angle-iron for both the tension and compression required elements required by current building codes. This system installs above the bottom of the purlin/ledger ceiling line and consequently will clear almost all ceiling mounted equipment. The shroud anchors to a stud welded to a plate which is anchored to the wall through the ledger and just below the joist system. At the wall, the rigid plate (preferably metal) that is anchored to the wall also has a stud welded on its face which is angled outward toward a purlin/GLB intersection several feet (e.g. approximately 16 feet) out from the wall. The shrouded assembly which may include an all-thread bolt and rubber spacing washers, is covered with a larger series of cylinders with threaded connections for anchorage to adjoining cylinders. This shroud assembly supplies the compression element to this system when it is tight at each end of each segment of the shroud. Each piece of the shroud has a threaded male end and female end. The required overlap length will be painted red on the male threaded portion for inspection purposes. If no red painted threads are visible, the required overlap is assured. The inner portion of the shroud assembly (which also may be all-thread) will have a similar red designated male thread coloration with the same purpose.
[0022] The threaded portion of the shroud (rod) passes through any purlin not intended for final anchorage, penetrating a drilled hole with no washer or nuts that would connect the rod to the intersecting purlin. The outer portion of the shroud will be tightened to a wedge shaped washer that installs on each side of any intersecting purlins for purpose of supplying the required compression element of current building codes. The threaded portion supplies the tension requirements when it is attached to the GLB/purlin intersection with an angle-iron that has a stud welded to it and angled toward the stud at the wall bracket.
[0023] Most components of the embodiments disclosed herein are symmetrical at each end which allows these individual components to be used on either side of a GLB or purlin or with flanges either up or down to allow the systems to clear any ceiling-mounted equipment, fire sprinkler systems, or conduit that may conflict with these systems. This means fewer parts are required to be manufactured and stocked, making installation simpler and less expensive.
[0024] The fact that these systems can be installed to clear ceiling mounted obstructions is a large advantage over other systems that must be installed completely beneath purlins and ledgers thus restricting use of the aforementioned space.
[0025] Another advantage of these systems is that it may be slightly altered to allow for use when a pitched roof or angled walls or beams require adjusted lengths to be used.
[0026] Another advantage of the systems is that they provide vertical as well as horizontal support to ledgers and beams.
[0027] Another advantage of these systems is that the wall anchorage plates have a staggered hole pattern which allows for the use of any combination of holes to be used for concrete wall anchorage. This means that if the primary hole is obstructed due to embedded steel or conduit then the next staggered hole may be used and then the next if necessary without damaging expensive drill bits or drilling into steel that has structural value and should not be damaged.
[0028] The fact that most of the wall anchoring and drilling of concrete walls required for metal plate connections installation is accomplished below the ledger means that a magnetic resonance imager can only see 7″ into the wall, or when a ledger is over the wall, only 3.5″ into the concrete after first penetrating the 3.5″ thick ledger. The result is being able to drill holes into the concrete with little or no risk of hitting obstructions.
[0029] Another advantage of these systems is the use of pre-positioned bolt holes along with the metal connecting straps that connect one angle iron to its twin on the opposite side or end, thus eliminating any location issues in positioning the holes to be drilled into wood beams or the concrete wall.
[0030] Another advantage of these inventions is that they are comprised of relatively light weight materials which should not require any special equipment to hoist them into place, but can be lifted into place using a man-lift along with the installer.
[0031] Another advantage of these inventions is that they may be prefabricated on the ground and lifted into position as a single unit. Each of the embodiments may use ¼″ predrilled holes with ¼″ self tapping screws for temporary support while holes are drilled and installed. However, the individual components may be installed separately when ceiling mounted equipment or fire-sprinklers conflict. Also, the connecting straps that connect one end angle iron to its twin may be eliminated when necessary for ease of installation.
[0032] Another advantage of these systems is that they include elements that may be readily available from a metal or other fabricating shop. This means that waiting for fabrication and delivery from a distant fabricator will not be necessary when a component is miss-fabricated or job site conditions require alterations or additional components to be fabricated.
[0033] These systems, in addition to providing a counter force to seismic or wind events caused by building/wall movement also provide vertical and horizontal support around the edges of the roof structure where water or snow build up is most likely to occur as a result of a clogged roof drain.
[0034] Other seismic retro-fit systems do not provide vertical support at purlin/wall location but only drill through ledger and wall and insert a machine bolt through the wall or anchor to the wall with epoxy cement at about mid height of the ledger. Such systems provide no vertical support for the ledger and consequently the connecting purlin which just hangs onto the ledger with a flanged hanger with usually only nailing through the top flange into the top of the ledger. The systems of the present invention attach directly to the wall, thus providing better support. Any individual components depicted in these several embodiments may be combined with any other depicted components to achieve the preferred truss required design.
[0035] Several of the embodiments may be installed substantially above the ceiling line established by the ledgers and purlins, and should not conflict with ceiling mounted equipment, fire sprinklers or conduit that may be mounted on the ceiling.
[0036] Another advantage of the wall-to-wall embodiments is that only every third purlin need be shimmed and/or bolted at purlin-GLB intersections. This eliminates approximately 66% of the usually required hardware at these locations. Each location customarily uses four welded brackets, two threaded rods, and approximately six machine bolts, not to mention the labor to install these items.
[0037] The aforementioned qualities and advantages of these inventions are not intended to be limiting factors when applying these inventions to individual buildings. Design alterations specified by a structural engineer are to be expected and should not limit the use of these inventions in any way.
[0038] Other advantages of these systems will become apparent to those skilled in the trades when installing and reviewing these systems and working with structural drawings prepared by a structural engineer for specific and individual buildings.
[0039] An object of the present invention is to provide reliable, simple and inexpensive seismic retro-fit systems to upgrade or replace existing seismic movement resistant connections on buildings with wood or metal roof, ceiling or flooring systems and concrete walls.
[0040] Another object of the invention is to provide reliable force transfer mechanisms that include both tension and compression capabilities that transfer force from the building walls to the primary beams (GLB's) and consequently to the purlins, joists and ultimately to the roof, ceiling or floor plywood diaphragm and consequently to the walls at opposite ends of the building.
[0041] Another object of the invention is to provide seismic connections of the type described that either eliminates or lessens dependence on the roof, ceiling or floor plywood diaphragm perimeter nailing into the ledger that bolts onto the concrete wall at the outside perimeter of the building at the roof line and/or at wood floor connections to concrete walls.
[0042] Another object of the invention is to provide additional vertical support as well as horizontal support for ledgers, primary beams and purlin beams.
[0043] Another object of the invention is installing a system that upgrades existing tilt-up style buildings to comply with current UBC standards.
[0044] Another object of the invention is to establish a strut line that crosses the primary beams (GLB's) and connects to 3 individual purlins to a single wall-to-wall line; essentially anchoring twenty four linear feet of concrete wall to the selected strut (purlin) which is connected to the roof plywood diaphragm and ultimately to a mirror system at the opposite end of the building.
[0045] Additional objects of the invention will be apparent from the detailed descriptions and the claims herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] FIG. 1 is a lower perspective view of one embodiment of the present invention having three main parts, illustrating those parts attached to each other.
[0047] FIG. 2 is an upper partially cut-away environmental view of a building roof support structure showing examples of the embodiments of FIG. 1 installed thereon.
[0048] FIG. 3 is a lower partially cut-away environmental view of the roof support structure with installed embodiments shown in FIG. 2 .
[0049] FIG. 4 is a cross-sectional end view along line 4 - 4 of FIG. 2 .
[0050] FIG. 5 is a cross-sectional end view along line 5 - 5 of FIG. 3 .
[0051] FIG. 6 is a cross-sectional side view along line 6 - 6 of FIG. 3 .
[0052] FIG. 6A is an illustration of an embodiment of a random hole pattern for avoiding obstructions in a wall.
[0053] FIG. 7 is a lower perspective view of another embodiment of the present invention.
[0054] FIG. 8 is an upper partially cut-away environmental view of a building roof support structure showing an example of the embodiment of FIG. 7 installed thereon.
[0055] FIG. 9 is a lower partially cut-away environmental view of the roof support structure with installed embodiment shown in FIG. 8 .
[0056] FIG. 10 is a cross-sectional end view along line 10 - 10 of FIG. 8 .
[0057] FIG. 11 is a cross-sectional side view along line 11 - 11 of FIG. 9 .
[0058] FIG. 12 is a perspective view of another embodiment of the present invention.
[0059] FIG. 13 is another perspective view of the embodiment of FIG. 12 .
[0060] FIG. 14 is an upper partially cut-away environmental view of a building roof support structure showing examples of the embodiments of FIG. 12 installed thereon.
[0061] FIG. 15 is a lower partially cut-away environmental view of the roof support structure with installed embodiments shown in FIG. 14 .
[0062] FIG. 16 is a cross-sectional side view along line 16 - 16 of FIG. 15 .
[0063] FIG. 17 is a lower perspective view of an alternative embodiment of the invention of FIG. 7 .
[0064] FIG. 18 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including the embodiment of FIG. 17 .
[0065] FIG. 19 is another perspective view of the support structure of FIG. 18 .
[0066] FIG. 20 is an upper environmental view of a building roof support structure showing examples of the embodiments of FIGS. 7 , 17 and 18 installed thereon
[0067] FIG. 21 is a lower environmental view of the roof support structure with installed embodiments shown in FIG. 20 .
[0068] FIG. 22 is a cross-sectional top view along line 22 - 22 of FIG. 21 .
[0069] FIG. 23 is a cross-sectional top view along line 23 - 23 of FIG. 21 .
[0070] FIG. 24 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including that of FIG. 1 .
[0071] FIG. 25 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including that of FIG. 1 .
[0072] FIG. 26 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including that of FIG. 1 .
[0073] FIG. 27 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including that of FIG. 1 .
[0074] FIG. 28 is an upper partially cut-away environmental view of a building roof support structure showing examples of the embodiments of FIGS. 1 and 24 - 27 , installed thereon.
[0075] FIG. 29 is a lower partially cut-away environmental view of the roof support structure with installed embodiments shown in FIG. 28 .
[0076] FIG. 30 is a cross-sectional side view along line 30 - 30 of FIG. 28 .
[0077] FIG. 31 is a cross-sectional end view along line 31 - 31 of FIG. 28 .
[0078] FIG. 32 is an upper partially cut-away environmental view of a building roof support structure showing an example of an alternative embodiment of the present invention installed thereon.
[0079] FIG. 33 is a lower partially cut-away environmental view of the roof support structure with installed embodiments shown in FIG. 32 .
[0080] FIG. 34 is a cross-sectional side view along line 34 - 34 of FIG. 32 .
[0081] FIG. 35 is a cross-sectional end view along line 35 - 35 of FIG. 32 .
[0082] FIG. 36 is a cross-sectional opposite end view along line 36 - 36 of FIG. 32 .
[0083] FIG. 37 is an upper partially cut-away environmental view of a building roof support structure showing an example of an alternative embodiment of the present invention installed thereon.
[0084] FIG. 38 is a lower partially cut-away environmental view of the roof support structure with installed embodiments shown in FIG. 37 .
[0085] FIG. 39 is a cross-sectional side view along line 39 - 39 of FIG. 37 .
[0086] FIG. 40 is a cross-sectional end view along line 40 - 40 of FIG. 37 .
[0087] FIG. 41 is an upper partially cut-away environmental view of a building roof support structure showing an example of an alternative embodiment of the present invention installed thereon.
[0088] FIG. 42 is a lower partially cut-away environmental view of the roof support structure with installed embodiments shown in FIG. 41 .
[0089] FIG. 43 is a cross-sectional side view along line 43 - 43 of FIG. 41 .
[0090] FIG. 44 is a cross-sectional end view along line 44 - 44 of FIG. 41 .
[0091] FIG. 45 is a cross-sectional end view along line 45 - 45 of FIG. 41 .
[0092] FIG. 46 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including the tubular members of FIGS. 50-52 .
[0093] FIG. 47 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including the tubular members of FIGS. 50-52 .
[0094] FIG. 48 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including the tubular members of FIGS. 50-52 .
[0095] FIG. 49 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including the tubular members of FIGS. 50-52 .
[0096] FIG. 50 is a top plan view of a building roof support structure showing an example of an alternative embodiment of the present invention installed thereon.
[0097] FIG. 51 is a cross-sectional side view along line 51 - 51 of FIG. 50 .
[0098] FIG. 52 is a lower partially cut-away environmental view of the roof support structure with installed embodiments shown in FIG. 50 .
[0099] FIG. 53 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including those of FIGS. 1 and 56 .
[0100] FIG. 54 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including those of FIGS. 1 and 56 .
[0101] FIG. 55 is a perspective view of a support structure of the present invention that may be used with several of the embodiments of the present invention including those of FIGS. 1 and 56 .
[0102] FIG. 56 is an upper partially cut-away environmental view of a building roof support structure showing an example of an alternative embodiment of the present invention installed thereon.
[0103] FIG. 57 is a cross-sectional side view along line 57 - 57 of FIG. 56 .
[0104] FIG. 58 is a cross-sectional side view along line 58 - 58 of FIG. 56 .
[0105] FIG. 59 is a cross-sectional bottom view along line 59 - 59 of FIG. 56 .
DETAILED DESCRIPTION
[0106] Referring to the drawings wherein like reference characters designate like or corresponding parts throughout the several views, and referring particularly to FIGS. 1-6 , it is seen that a first embodiment illustrated in these drawings includes three elongated rigid (preferably metallic) bracket members 70 , 80 and 90 . These members may be used independently of each other, they may be used in combination with other support members, and/or they may be attached to each other in a triangular fashion as illustrated in FIG. 1 . Some of the alternative and/or independent usages of members 70 , 80 and 90 are described and illustrated in other embodiments herein.
[0107] In the exemplary triangular embodiments illustrated in FIGS. 1-6 , and referring particularly to FIG. 3 , it is seen that a first elongated member 70 is adapted for attachment along the underside 44 of a ledger 40 of a building roof, ceiling or floor support system. In some embodiments, bracket member 70 is not attached to ledger 40 , but is inserted flush against the lower surface 44 of the ledger, and is attached directly to the concrete, masonry or block wall 140 of the building using one or more bolts 26 that are passed through holes 60 in mounting plate 170 . This location provides supplemental vertical support for the ledger 40 at both ends of bracket 70 . Bolts 26 are engaged with the concrete wall 140 using epoxy or some other suitable adhesive material for permanent attachment. Detail of this attachment is shown in FIGS. 5 and 6 .
[0108] Because the systems of the present invention may be used for retrofit purposes, structures such as the concrete wall 140 may already be in existence, and there may be metal structures, holes, or other irregularities on the surface of wall 140 where each mounting plate 170 is to be attached. Accordingly, in several embodiments of the present invention, the mounting holes 60 in plate 170 are provided in one or more different patterns in order to improve the opportunities for attaching bolts 26 to wall 140 . See FIG. 6A . It is to be appreciated that any suitable number of mounting holes may be provided in plate 170 , and that these holes may be provided in any regular, irregular, uniform or random pattern thereon. Plate 170 may be provided with a reinforcing flange or gusset 110 which transfers lateral force more evenly, and helps prevent bending of plate 170 . The number of engineer-specified holes to be used (usually no more than 2 on each side of the gusset) will leave the balance of predrilled holes unused. Elongated bracket member 70 has outwardly protruding flanges at both ends, and holes are provided in these end flanges to receive bolts or other similar devices to attach the end flanges to other support structures such as but not limited to members 80 and 90 .
[0109] In alternative embodiments, bracket member 70 may be attached directly to the lower surface 44 of the ledger 40 by using lag screws or other suitable fasteners. In these embodiments, one or more openings 68 may be provided along bracket member 70 through which such fasteners may be passed for attachment to the underside 44 of the ledger 40 . It is to be appreciated that the direct attachment to the bottom 44 of ledger 40 may be done independently or in conjunction with the previously described attachments directly to wall 140 .
[0110] In the triangular system embodiments of FIGS. 1-6 , bracket member 70 is attached and positioned such that one end is adjacent to a perpendicularly extending (roof) beam 30 . A second elongated bracket member 80 is attached along one side of the beam 30 . Bracket member 80 includes plates at both ends having openings through which bolts or other devices are used to attach bracket member 80 to beam 30 . Bracket member 80 also includes outwardly extending flanges at both ends, and holes are provided in these end flanges to receive bolts 24 or other similar devices to attach such end flanges to other support structures such as but not limited to members 70 and 90 . Bracket member 80 preferably sits over the top of bracket 70 in order to provide supplemental vertical support for the beam 30 . It is to be appreciated that in this embodiment, bracket members 70 and 80 are installed such that their orientation is perpendicular, just as beam 30 is perpendicular to ledger 40 , with one end of bracket member 70 attached to the adjacent end of bracket member 80 near where beam 30 meets ledger 40 , using one or more bolts 24 as shown in FIG. 5 . A third bracket member 90 is then installed diagonally by attachment to each of the open ends of bracket members 70 and 80 , forming the hypotenuse of the triangle made up of members 70 , 80 and 90 . Bracket member 90 exerts a counter force to any lateral wall movement either in, out or parallel to the wall at a point several feet from the beam 30 along the length of the wall. This exerted force is transferred to the roof diaphragm through the beam 30 , purlins 120 and ultimately to the plywood diaphragm system of the roof, ceiling or floor. In this context, a diaphragm is generally the structural element comprised of roof plywood nailed to joists, purlins, ledgers and GLB's.
[0111] In some embodiments, a second set of bracket members 70 , 80 and 90 is installed on the opposite side of beam 30 in a mirror image fashion to the first set of such members, as depicted in FIGS. 2 and 3 . In such embodiments, brackets 80 may be attached to both sides of beam 30 using the same bolts 29 that extend through beam 30 and protrude out from each side, as shown in FIG. 4 . However, brackets 80 may alternatively be attached separately from each other using other independent bolts 27 .
[0112] The systems of FIGS. 1-6 provide independent seismic support to beam 30 by providing apparatus and methods for direct attachment of beam 30 to wall 140 , instead of relying only on gravity. These systems prevent beam 30 from pulling away from or falling down from wall 140 in the event of seismic movement, high winds, excessive roof/ceiling/floor weight or the like.
[0113] The alternative embodiments which provide for direct attachment to the underside 44 of ledger 40 through openings 68 help prevent possible lateral movement of a metal plate that is attached to a wall 140 . These openings 68 may be provided in the straps connecting the brackets together or on the brackets themselves, or both.
[0114] Alternative support system embodiments are illustrated in FIGS. 7-11 . These embodiments are designed for use in supporting roof, ceiling or floor purlins 120 , but may also be used with support beams 30 . In these embodiments, a one-piece seismic support unit 10 is provided that is made up of an elongated cross member 51 and two diagonally oriented arms 50 , all of which may be integrated together. Attachment plates 170 having a pattern of holes 60 , as described above (uniform, irregular or random pattern), are provided at both ends of cross member 51 . In some embodiments, plates 170 may be provided with a reinforcing flange or gusset 110 which transfers lateral force more evenly, and helps prevent bending of plate 170 . One end of each of arms 50 is attached to one of the ends of cross member 51 , and the opposite ends of arms 50 meet at a junction 152 . Junction 152 is formed in the shape of a squared U, with the bottom sized so as to fit flush underneath a purlin 120 (or underneath a beam 30 ). The two opposite sides 151 of junction 152 extend upward so as to fit flush against the sides of the purlin (or beam) forming a saddle or beam pocket (i.e., metal hardware with two sides and a base that the purlins and/or beams are bolted or nailed into). An installation and fitment of the junction is illustrated, for example, in FIGS. 9 and 10 . This structure provides vertical support to the purlin (or beam). In some embodiments, the U-shaped saddle with bottom and sides 151 - 152 is a separate piece that is welded to the junction of arms 50 .
[0115] In alternative embodiments, the two metal straps 50 are welded to saddle base 152 to provide a lateral counter force from the wall to the purlin and consequently the diaphragm. The metal strap 51 that connects the two angle irons to each other is provided for ease of application purposes and to eliminate side movement of angle irons 170 attached to wall 140 . Strap 51 may be omitted when ceiling mount equipment is in conflict. If strap 51 is eliminated, angle irons 170 are attached directly to the ends of straps 51 for attachment to the wall 140 , and holes 60 in the angle iron 170 may be used to eliminate side movement.
[0116] In the integrated embodiments illustrated in FIGS. 7-11 , and referring particularly to FIG. 9 , it is seen that a cross member 51 is adapted for attachment along the underside 44 of ledger 40 of the building roof support system. In some embodiments, cross member 51 is not attached to ledger 40 , but is inserted flush against the lower surface 44 of the ledger, and is attached directly to the concrete wall 140 of the building using one or more bolts 26 that are passed through holes 60 in mounting plate 170 . This location provides supplemental vertical support for the ledger 40 at both ends of cross member 51 . Bolts 26 are engaged with the concrete wall 140 using epoxy or some other suitable adhesive material for permanent attachment. Detail of this attachment is shown in FIG. 11 .
[0117] In alternative embodiments, cross member 51 may be attached directly to the lower surface 44 of the ledger 40 by using lag screws, fasteners or the like. In these embodiments, one or more openings 68 are provided along cross member 51 through which such screws may be passed for attachment to the underside 44 of the ledger 40 . It is to be appreciated that the direct attachment to the bottom 44 of ledger 40 may be done independently or in conjunction with the previously described attachments directly to wall 140 .
[0118] Arms 50 extend from each end of cross member 51 to junction 152 underneath a purlin 120 (or beam 30 ). Anchoring bolts 29 are passed through openings 60 in flanges 151 , and through purlin 120 (or beam 30 ) to hold junction 152 against purlin 120 (or beam 30 ). This system prevents purlin 120 (or beam 30 ) from pulling away from ledger 40 or falling down from wall 140 in the event of seismic movement, high winds, excessive weight or the like.
[0119] FIGS. 12-16 illustrate other reinforcing embodiments of the present invention. These embodiments include a rigid (preferably metallic) plate 130 having an optional flange 92 that is generally orthogonally attached to it, forming a bracket having a generally L-shaped cross section. Plate 130 includes one or more openings 60 for receiving anchoring bolts 26 that are passed through openings 60 , through ledger 40 , and into concrete wall 140 as shown in FIG. 16 . One or more additional smaller openings 21 are also provided for attaching plate 130 to ledger 40 using bolts such as 22 . One or more of plates 130 may be attached to a ledger 40 in order to provide reinforced attachment to wall 140 . Flange 92 provides additional strength to plate 130 to prevent bending of plate 130 in the event that stress is placed on the ledger 40 from seismic movement, high winds, excessive roof weight or the like.
[0120] FIGS. 17-23 illustrate alternative embodiments of an integrated support unit. These alternative embodiments include an integrated triangular support structure 11 that is similar to that illustrated in FIGS. 7-11 , and previously described ( 10 ) as including a cross member 51 and a pair of arms 50 that meet at a junction 152 having a pair of opposing side walls 151 . In some embodiments, the U-shaped saddle with bottom and sides 151 - 152 is a separate piece that is welded to the junction of arms 50 . In the illustrated embodiments of structure 11 , one or both of side walls 151 includes not only openings 60 for attachment to a purlin 120 (or beam 30 ), but also a support flange 63 having an opening 69 located thereon. Flange 63 may or may not have an angled orientation. Flange 63 and opening 69 are adapted to receive one end of a support rod 23 . A bracket assembly 67 having a complementary support flange 63 ′ is also provided, with flange 63 ′ adapted to receive the opposite end of support rod 23 . Flange 63 ′ may or may not have an angled orientation. Openings 60 are provided in bracket 63 ′ for attaching bracket 67 to a beam or purlin using bolts or other suitable devices.
[0121] Detail of an embodiment of rod 23 is shown in FIGS. 22-23 . In this exemplary embodiment, rod 23 includes an inner rod 191 , an inner sleeve 196 and an outer sleeve 197 . Inner rod 191 is threaded at both ends, allowing it to be bolted to flanges 63 and 63 ′ as shown in FIGS. 22-23 . Inner rod 191 is the primary load bearing member, providing the tension required for wall anchorage. Spacers 198 aid in keeping rod 191 centered inside sleeves 196 and 197 , and also aid in keeping the whole assembly straight, which is important in terms of compression capability. Spacers 198 may be made of rubber, plastic or other suitable materials, and are preferably cut through on one edge so that they may slip over rod 191 and then return to their original shape. Sleeves 196 and 197 supplement the compression capability of the inner rod 191 . In some embodiments, the end of the inner sleeve 196 is coded red at a point that defines the necessary overlap of the inner 196 and outer 197 connection, to indicate whether the inner threaded portion of rod 191 is properly embedded into the outer sleeve 197 of the adjoining member sufficiently to meet building code requirements or engineer specifications. It is to be appreciated that in other embodiments, support rod 23 may be comprised of only inner rod 191 having threads at both ends.
[0122] In use, an integrated triangular support structure 11 having flange 63 is installed, as above, with cross member 51 attached along the underside 44 of ledger 40 (ether directly to ledger 40 through openings 68 , or to wall 140 , or both), saddle 152 underneath a purlin 120 or beam 30 , and walls 151 bolted to the sides of the purlin 120 or beam 30 . A bracket assembly 67 is installed on an adjacent purlin (or beam) downstream from junction 152 . One end of inner support rod 191 is attached to flange 63 on side wall 151 , and the other end of rod 191 is attached to flange 63 ′ on bracket 67 as shown in FIGS. 20-21 . If provided, inner sleeve 196 is rotated relative to outer sleeve 197 for snug fit against flanges 63 and 63 ′ to optimize support. It is to be appreciated that the angles of flanges 63 and 63 ′ may be varied as desired, and will establish an optimum downstream position of bracket 67 on purlin 120 for receiving the end of rod 23 . Anchoring of this assembly should preferably occur at least every 9 feet when the assembly is installed under the purlins.
[0123] The triangular support structure 11 of the present embodiment may be, and preferably is attached to a first and third purlin, and brackets 67 are attached on either side of a second intermediate purlin downstream from the triangular support structures, as shown in FIGS. 20-21 . This provides direct attachment of the downstream purlin to the concrete wall 140 . Other triangular support assemblies may also be attached to any intermediate purlins. These may be of any type described herein ( 11 ), but preferably of the type ( 10 ) illustrated in FIG. 7 or in FIG. 17 (with or without flange 67 ).
[0124] In some embodiments, an additional flange 64 is provided on bracket 67 . In other embodiments an additional flange 64 may be provided or on one or both of flanges 151 . This flange 64 is used to connect to a rod, cable or other elongated support structure 180 that may extend the length of the purlin (or beam) to the opposite side of the building. Structure 180 may be a PT cable, which is a flexible plastic encased steel cable that has tension applied to it after the installation is complete. This applied tension supplies the counter-force to any seismic wall movement. In such embodiments, a complementary bracket 67 is provided at such other end, together with complementary (mirror image) triangular support structures and rods 23 . The complementary bracket 67 (or complementary flange 151 ) has a flange 64 to receive the opposite end of rod or cable 180 , and a flange 63 ′ for receiving a rod 23 . Rod 23 is, in turn, attached to a bracket 63 on a triangular support assembly that is mounted beneath the purlin (or beam) and beneath ledger 40 . These embodiments provide a complete direct connection from the wall on one side of a building to the wall on the opposite side of the building. It is to be appreciated that multiple installations of such embodiments may be made along selected purlins (or beams) to provide additional wall-to-wall support structures along the length or width of the roof. It is also to be appreciated that support structures having dual brackets 67 (one for each of flanges 151 ) may be employed in these installations to support two rods 23 extending away from a single junction 152 . In other embodiments, one or both of flanges 151 may include a bracket 64 for direct attachment to a rod 23 .
[0125] A rod or cable 180 may be provided on each side of the purlin system that spans from one end of the building to the opposite end where it connects to another identical three-purlin system. The purlins along the rod or cable line constitute a strut at each purlin-to-beam connection, which may be approximately every 20 to 24 feet. The intersection of a strut (cabled) purlin 120 and beam 30 is shown in FIG. 22 . Such intersections may be shimmed where any gap between the purlin and beam exists, thus creating a line of compression that extends through the entire length of the building. The purlins on either side of the strut purlin need not be shimmed. This embodiment constitutes a substantial savings in labor and material over systems that require as many as four brackets and two all-thread bolts to connect purlin-to-purlin through a beam at each location.
[0126] Other embodiments of the present invention are illustrated in FIGS. 24-31 . In these embodiments, support brackets 131 , 132 , 133 and 134 are utilized in conjunction with one or more bracket members 90 to provide support to a beam 30 without the use of bracket members 70 or 80 . In particular, instead of providing a single elongated member below ledger 40 , a first L-shaped bracket 133 (such L-shaped brackets are sometimes referred to herein as angle irons) is installed by attachment to beam 30 and to concrete wall 140 below ledger 40 . A second L-shaped bracket or angle iron 131 (or 132 ) is also attached to wall 140 a distance away from beam 30 below ledger 40 . See FIG. 29 . Each of brackets 131 / 132 and 133 includes a plurality of openings 60 on a wall flange (one of the “L” surfaces of the respective bracket) through which mounting bolts 26 are passed for anchoring the bracket to the concrete wall. The pattern of openings 60 may be uniform or random, as with other bracket hole patterns described previously, in order to provide multiple opportunities for bolt attachments in case there are embedded blockages in wall 140 . One or more additional holes 60 are also provided on the remaining flange of bracket 133 allowing for attachment to beam 30 . At least one hole is provided on the remaining flange of bracket 131 or 132 for attachment to elongated bracket member 90 .
[0127] In the embodiments illustrated in FIGS. 24-31 , the first bracket 133 is preferably provided with triangular upper and/or lower flanges for improved strength. One flange of this bracket 133 is anchored to wall 140 , and the other flange is attached to the side of beam 30 , as shown in FIG. 29 . In alternative embodiments, another of brackets 133 may be installed in mirror-image fashion on the other side of beam 30 . This provides reinforcement through direct attachment of beam 30 to wall 140 . The second bracket 131 is preferably provided with a gusset 110 for improved strength. One flange of this bracket 131 is anchored to wall 140 such that the other flange has a horizontal orientation for engagement with bracket member 90 . One end of an elongated bracket member 90 is attached to bracket 131 , and the other end is extended perpendicularly from wall 140 and attached to the closest purlin 120 . A third L-shaped bracket 134 is attached to this purlin 120 where it abuts against beam 30 . One flange of the L is attached to purlin 120 , and the other flange to beam 30 . An anchoring plate may be used to further secure bracket 134 to purlin 120 or beam 30 . In alternative embodiments, another of brackets 134 may be installed in mirror-image fashion to the purlin on the other side of beam 30 ; in such embodiments, the same bolts 29 may be used which pass through both brackets 134 and beam 30 . A fourth L-shaped bracket 132 is provided for attachment to beam 30 . This bracket 132 may include a gusset 110 . One flange of bracket 132 is attached to beam 30 such that the other flange has a horizontal orientation for engagement with one end of a second bracket member 90 . Second bracket member 90 extends diagonally from bracket 131 to purlin 120 where its other end attaches to the purlin and an end of first bracket member 90 . It is to be appreciated that all of the aforementioned brackets and horizontal members are illustrated in FIG. 29 , but that not all of them may be needed in every situation, such that different combinations thereof may be used as desired by the user.
[0128] The embodiments of FIGS. 24-31 provide a direct anchoring of beam 30 to wall 140 by way of bracket(s) 133 , and provides a further anchoring of beam 30 to wall 140 through bracket members 131 , 132 and 90 . Further reinforcing and transmission of tension is provided by intermediate bracket(s) 134 . In alternative embodiments shown in FIGS. 37-40 , brackets 131 , 132 and/or 133 are used with an elongated member 90 , but bracket 134 and the other member 90 may not necessarily be used. Instead, a single elongated member 90 is provided for direct diagonal attachment between wall-mounted bracket 131 and beam-mounted bracket 132 . In many embodiments, brackets 131 and 132 may be interchanged.
[0129] The embodiments of FIGS. 24-31 and 37 - 40 may be used when the beams 30 are, for example, twenty feet apart making the un-braced section of wall slightly less than 10 feet which may be acceptable in some buildings. In these embodiments, the L-shaped brackets may, be installed with no connecting steel straps along the purlin length or the beam length. That is because, in this configuration, the length of a pre-fabricated system could make this embodiment too cumbersome to install as a single unit. The size and shape of the L-shaped brackets 131 - 134 vary from the embodiment of FIGS. 1-7 . The two members 70 , 80 that bolt together at the beam/wall intersection are replaced by one angle-iron that bolts to the beam and through the hole pattern (which may be a uniform, irregular or random pattern) in the section of the flange that bolts to the wall, thus providing a counterforce to both vertical beam collapse and transferring a counter force to seismic or other wall movement relative to the roof diaphragm. This aforementioned angle-iron may have a small gusset on top of this piece that provides vertical support for the ledger where it abuts the beam.
[0130] The embodiments of FIGS. 32-36 and 41 - 45 utilize a central threaded load bearing tension rod 175 that is positioned in parallel with the beams 30 of the roof system. Rod 175 may be surrounded by a reinforcing shaft 171 having spacers 198 such as rubber washers to center its position. One end of rod 175 is attached to a plate 172 that is anchored to wall 140 through ledger 40 using bolts 26 , as shown in FIG. 34 . In an alternative embodiment, plate 172 includes an integrated threaded shaft or welded stud 185 , and rod 175 is engaged to shaft 185 using a threaded coupler 186 or other similar engagement device (such as a turnbuckle). Rod 175 is sized such that its opposite threaded end may be passed through an adjacent purlin 120 , where it is secured on the opposite side of purlin 120 using plate 173 and at least one nut. It is to be appreciated that rod 175 may be manipulated from the opposite side of purlin 120 for engagement with turnbuckle 186 , and for securement to plate 173 . A separate L-shaped bracket 179 is provided on the near side of purlin 120 through which rod 175 passes. This bracket includes a horizontally oriented flange section 179 that included openings for receiving attachment bolts for connection to diagonally oriented members 90 .
[0131] In the embodiments illustrated in FIGS. 32-36 , members 90 are attached to wall brackets 131 that are mounted to wall 140 below ledger 40 at locations between rod 175 and beam 30 . In the embodiments illustrated in FIGS. 41-45 , members 90 are attached to corner brackets 133 that are mounted to wall 140 below ledger 40 adjacent to beams 30 . It is to be appreciated that the elements of these illustrated embodiments could be mixed, such as, for example, a first member 90 may extend from one side of flange 179 to a corner bracket 133 , and a second member 90 may extend from the other side of flange 179 to a wall bracket 131 . The angle and length of member 90 depends upon whether the member is attached to a wall bracket 131 or a corner bracket 133 , as well as the position of such bracket.
[0132] In alternative embodiments, one or more additional brackets 133 may be mounted on beams 30 where they intersect with purlins 120 , so that an elongated member 90 may be attached to extend from each such wall bracket 131 to corner bracket 133 . In other embodiments, one or more corner brackets may 133 may be mounted at the intersections of beams 30 and purlins 120 without attachment to any elongated member 90 . Each of these alternative embodiments may be used independently of the others, or in different combinations with the other embodiments, as illustrated, for example, in FIGS. 33 and 42 .
[0133] Rods 171 and 175 may be used when there is a significant span between primary beams, such as, for example, twenty-two or twenty-four feet. In such an example, the wall length between the beam and rod 171 (the center shroud lateral wall anchorage) would be approximately eleven or twelve feet. Where specifications require a lesser distance then lesser spans would be used, such as, for example, six feet between anchorage locations.
[0134] Wedge washers 178 are used when these embodiments are utilized with outer rods 171 at any intersecting purlin that the threaded rod 175 passes through, and outer shroud casing 171 abuts against. Wedge washer includes at least two holes (preferably ¼″) for holding the wedge washer 178 in position and preventing rotation. Washer 178 is drilled so that the outer shroud casing 171 will have full contact with the flat face of the washer as depicted, for example, in FIG. 43 . A nut is not required where the threaded rod 175 passes through the washers on either side of a purlin.
[0135] The embodiments of FIGS. 46-52 provide a set of versatile mounting brackets 161 , 162 , 163 and 164 which may be used in conjunction with rods 23 , 191 , 171 and/or 175 . Bracket 162 includes an angled flange thereon having an opening therein for receipt of one of the aforesaid rod members. Brackets such as 162 are designed for attachment directly to ledger 40 and may or may not also be mounted to wall 140 . Brackets 163 and 164 are triangular wedge-shaped pieces having mounting holes for attachment to a beam or purlin, and openings for receiving rod 191 or 175 . As shown in FIGS. 50-52 , a rod such as 191 or 175 is attached at one end to bracket 162 , and passes through brackets 162 and 163 , and through purlin 120 at an angle. Rod 191 or 175 then extends to and terminates at bracket 161 which is mounted at a junction between a purlin 120 and a beam 30 . Bracket 161 also includes an angled flange having an opening for receiving rod 191 or 175 . It is to be appreciated that different combinations of brackets 161 - 164 may be used with rods 23 , 191 , 171 and/or 175 of different lengths, depending on the positions selected for brackets 161 - 164 . It is to be appreciated that brackets 161 - 164 are used to support rods such as 23 , 191 , 171 and/or 175 , and that these rod-and-bracket systems may also incorporate other embodiments of the invention such as, without limitation, brackets 133 and/or 134 . It is to be appreciated that brackets 133 may be used to connect directly to a wall 140 , or between a beam 30 and purlin 120 . These embodiments install completely above the ceiling line of the purlin which means they should completely clear any ceiling mounted obstructions.
[0136] The embodiments of FIGS. 53-59 provide a set of mounting brackets 191 , 192 , 193 and 194 which may be used in conjunction with elongated bracket members 90 . Brackets 191 and 192 each include an L-shaped flange thereon having an opening therein for receipt of a bolt for attachment to an end of an elongated member 90 . Brackets 191 and 192 also include openings 60 therein for receiving mounting bolts 24 and/or 26 . Brackets such as 191 and 192 are designed for attachment directly to ledger 40 and may or may not also be mounted to wall 140 ; brackets 191 and 192 may also be attached across from each other through a beam or purlin using bolts 29 , as shown in FIG. 58 . Brackets 193 have an L-shaped cross section with a triangular cross flange having an opening thereon for receiving a bolt for attachment to an end of an elongated member 90 . As shown in FIGS. 56-59 , in one embodiment, an elongated member 90 is attached at one end to a bracket 191 or 192 at ledger 40 , and extends to a complementary bracket 191 or 192 on an adjacent purlin (or beam). In a variation of this embodiment, member 90 may extend from the ledger bracket 191 / 192 to a corner bracket 193 that is mounted at the junction of a beam or purlin. In the illustrated embodiment, another bracket 191 or 192 is provided on the other side of the purlin or beam, and a second member 90 extends away from the opposite bracket. This member 90 may terminate at another of brackets 191 / 192 , or at a corner bracket 193 (as illustrated). It is to be appreciated that different combinations of brackets 191 / 192 and/or corner brackets 193 may be used with elongated brackets 90 of different lengths, depending on the positions selected for brackets 191 , 192 and/or 193 . It is to be appreciated that these embodiments may also incorporate other embodiments of the invention such as, without limitation, brackets 133 and/or 134 . These embodiments install completely above the ceiling line of the purlin which means they should completely clear any ceiling mounted obstructions.
[0137] The embodiment depicted in FIGS. 21-22 should be installed close to or onto the bottom of the roof joists so as to be clear of any roof mounted equipment or fire sprinkler system anchored to the bottom of the ledger or purlin.
[0138] In the embodiment of FIG. 17 , the angled bracket 63 may be replaced by a square bracket 64 such as, for example, when a PT cable is required at 8 foot intervals or at every purlin.
[0139] Most embodiments of these inventions are symmetrical such that identical or mirror image components may be installed on opposite sides of the purlins or GLBs.
[0140] Most components in these inventions are fabricated in a manner that allows use with a different embodiment and/or component. In addition, some angle iron components used in the first set of embodiments may be replaced with a shrouded anchor system since both embodiments provide the required tension and compression elements. In other embodiments, the shroud assembly may also be replaced by angle iron(s).
[0141] The shrouded system described in FIGS. 22-23 provides a red marker that can be used by the installer and inspectors after installation is complete. This means that an on-site inspector is not required until the product is completely installed so that schedules are not affected and the interim inspection costs are lessened.
[0142] It is to be appreciated that all of the components of the systems disclosed herein may be shortened, lengthened, increased in size, both dimensionally and by increasing the thickness of the component parts at the discretion of the structural engineer as needed on a building by building basis. In those applications where a shroud assembly or an angle-iron has a span over 8 feet, it may be necessary to anchor either or both at a specified intervals.
[0143] It must also be appreciated that while the embodiments, components and elements of the various systems and structures of the invention(s) described herein are preferably made of metal, any of the embodiments, components and/or elements may be made of any other suitable rigid material (including without limitation plastics, acrylics, or the like) that provides an appropriate level of strength and durability.
[0144] At locations that have a wall-to-wall system connecting all beams to walls, a strut line in line with the aforementioned anchored beams along the length of the building should be established with a similar beam to wall connection on the opposite end of the building.
[0145] In some situations where the embodiment of FIG. 17 is employed, a building length strut line may be established every 24 feet, every third purlin 120 , which means only one third of the building purlins need to be shimmed for compression. The PT cables 180 that traverse the building (one on each side of the center purlin in this embodiment along with the shimmed purlin ends where they abut GLB's) supply the necessary tension and compression elements required for all three purlins at each installation. This embodiment illustrates a single system of FIG. 7 installed in the center purlin of this embodiment and two systems of FIG. 17 installed on both adjacent purlins. Both of the FIG. 17 systems connect to the angled bracket 63 ′ welded to the side of the transition bracket. The two PT cables 180 attach to two welded brackets 64 on the side of the aforementioned transition bracket and extend the length of the building where they attach to an identical FIG. 17 assembly.
[0146] It is to be appreciated that different versions of the invention may be made from different combinations of the various embodiments, elements and components described above. In particular, each of the disclosed embodiments, and any of the sub-elements thereof, may be used in combination with any of the other embodiments disclosed, or any of the sub-elements thereof. For example, and without limitation, bracket members 90 may be attached to extend between any of brackets 131 , 132 , 133 , 134 , 191 , 192 and/or 193 which brackets may be mounted in various locations on any or all of a wall 140 , ledger 40 , beam 30 and/or purlin 120 ; and/or such elements may or may not be used with other brackets such as 70 and 90 ; and/or such elements may or may not be used with other support devices such as rods 23 , 191 , 171 and/or 175 (and their respective mounting brackets 63 , 67 , 161 - 164 , 172 and/or 173 , etc.); and/or such elements may be used with brackets 10 and/or 11 ; and/or may be used with cabling systems 180 . The length and angle of members such as brackets 90 and rods 23 may be varied according to the location of the support brackets to which they are attached.
[0147] It is to be appreciated that the support systems of the present invention may be employed for use on any support structure spanning between building walls including without limitation ceilings, floors, and the like.
[0148] It is to be understood that other variations and modifications of the present invention may be made without departing from the scope thereof. It is also to be understood that the present invention is not to be limited by the specific embodiments disclosed herein, but only in accordance with the appended claims when read in light of the foregoing specification.
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The present invention includes a set of reinforcement and support devices for existing or new roof, ceiling and/or floor systems together with numerous variations that may be installed into existing buildings or new buildings to help prevent separation of wood or metal roof, ceiling and/or floor systems from the concrete, masonry or other types of walls supporting these systems in commercial, industrial and/or residential buildings. One embodiment includes a set of three brackets that are installed in a triangularly shaped arrangement along a side of a primary support beam and to the wall underneath a ledger, thus anchoring the support beam to the wall of the structure and stabilizing the roof, ceiling or floor it supports. Another embodiment includes a single integrated unit that attaches to the wall underneath the ledger and to an adjacent support board, thus anchoring the support board (and the system it supports) to the wall of the structure. Another embodiment includes an angle iron with predrilled holes that attaches through the ledger directly to the wall to reinforce the ledger and extend the area of horizontal support provided by the ledger. Other embodiments provide support structures that may be attached and arranged to provide specific structural support at designated locations, and/or to provide wall-to-wall structural support across the span of a roof, ceiling or floor. All embodiments may be adapted for use with ceilings, roofs or floors.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] A provisional patent was submitted by the investors and received by the USPO with application No. 60/556,067, filing date Mar. 25, 2004 and confirmation number 5404, with title “Real-time WaveSmooth error mitigation for global navigation satellite systems”.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0003] Not Applicable.
BACKGROUND OF INVENTION
[0004] The invention relates generally to the mitigation of errors inherent in spread-spectrum signals, and more particularly to a wavelet-based error mitigation technique directly applicable to Global Navigation Satellite Systems (GNSS) (e.g., GPS, Galileo, GLONASS, etc). Additionally, WaveSmooth™ can be integrated into GNSS software processing to improve performance. The processing can be implemented in new GNSS or existing receiver configurations. The WaveSmooth™ technique can be implemented in real-time or in a post-processing fashion.
[0005] GNSS architectures are typically multi-frequency and can be implemented by the user as a single, dual, or multi-frequency fashion to calculate the user state (i.e., position, velocity, and time). Multiple frequencies are used to help with ionosphere error mitigation as well as interference immunity. Multiple codes are implemented to provide different levels of performance/service. Modulation encodes data and codes onto the carrier frequency for transmission from the Space Vehicle (SV) to the mobile user. GNSS measurements may be modeled as the following for the code and carrier phase respectively between the user and a particular SV; the text book by Misra, P. and Enge, P., Global Position System Signals, Measurements, and Performance, Ganga-Jamuna Press, Lincoln, Mass., 2001, pp. 125-128 detail on these signal models used for GPS.
ρ q,k =r k +δt SV +b u +I q,k +T k +M q,ρ,k +ε q,ρ,k
and
φ q,k =r k +δt SV +b u −I q,k +T k +M q,φ,k +ε q,φ,k +N q,φ,k (1)
where:
ρ q,k : pseudorange measurement at frequency q, and time epoch k[m] r k : true range at frequency q, and time epoch k[m] δt SV : space vehicle clock error [m] b u : user receiver clock bias error [m] l k : ionosphere error at frequency q, and at time epoch k[m] T k : ionosphere error at time epoch k[m] M q,ρ,k : code phase multipath error at frequency q, and at time epoch k[m] ε q,ρ,k : code phase error at frequency q, and at time epoch k[m] φ q,k : carrier phase measurement at frequency q, and time epoch k[m] M q,φ,k : carrier phase multipath error at frequency q, and at time epoch k[m] ε q,φ,k : carrier phase error at frequency q, and at time epoch k[m] λ q : carrier phase wavelength at frequency q[m] N q,φ,k : carrier phase ambiguity related bias at frequency q, and at time epoch k[m] q: GNSS center frequency for signal of interest [Hz] k: time epoch [unitless]
[0021] Multi-frequency GNSS measurements can be used to remove the effects from the ionosphere. Dual-frequency GPS measurements are formed to produce ionosphere free (iono-free) code and carrier phase measurement as Equation (2), in accordance with the textbook by Misra, P. and Enge, P., Global Position System Signals, Measurements, and Performance, Ganga-Jamuna Press, Lincoln, Mass., 2001, pp. 141-142 for GPS.
ρ k * = f L 1 2 f L 1 2 - f L 2 2 ρ L 1 , k - f L 2 2 f L 1 2 - f L 2 2 ρ L 2 , k and
ϕ k * = f L 1 2 f L 1 2 - f L 2 2 ϕ L 1 , k - f L 2 2 f L 1 2 - f L 2 2 ϕ L 2 , k ( 2 )
where
f L1 : GPS L1 frequency 1575.42 MHz f L2 : GPS L2 frequency 1227.60 MHz *: iono-free η: code measurement [m] φ: carrier phase measurement [m]
[0027] Using the code and carrier phase models presented in Equation (1), a Code minus Carrier (CmC) signal can be formed for single-frequency GNSS users in accordance with Equation (3) at every time epoch k, (for each space vehicle (SV)).
CmC biased , k = ρ q , k - ϕ q , k = 2 I q , k - N ϕ , k + M q , ρ , k - M q , ϕ , k + ɛ q , ρ , k - ɛ q , ϕ , k ( 3 )
where:
CmC biased,k =biased Code minus Carrier residual at frequency q, and at time epoch k[m].
[0029] In a similar fashion the CmC is formed, using Equation (2), for dual-frequency GNSS users in accordance with Equation (4) at every time epoch k, (for each space vehicle (SV)).
CmC biased , k * = ρ k * - ϕ k * = - N ϕ , k + M ρ , k - M ϕ , k + ɛ ρ , k - ɛ ϕ , k ( 4 )
where:
CmC biased : iono-free biased Code minus Carrier residual at time epoch k[m] N φ,k : iono-free carrier phase ambiguity related bias component [m] M ρ,k : iono-free code phase multipath [m] M φ,k : iono-free carrier phase multipath [m] ε ρ,k : other iono-free code phase error terms [m] ε φ,k : other iono-free carrier phase error terms [m]
[0036] Equations (3) and (4) contain a carrier phase integer ambiguity, multipath, and receiver noise error terms associated with the code and carrier measurements. Typically, the CmC signal has been used to assess error variations in a post-processing fashion, where the mean value is subtracted from the data segment of interest.
[0037] Error mitigation techniques for GNSS can be classified into the time domain and the frequency domain. The time domain filter provides a fixed time resolution and no explicit information about frequency, while the frequency domain processing approach provides a fixed frequency resolution and no direct localization in time.
[0038] For time domain processing, the Carrier Smoothed Code (CsC) (i.e., Hatch filter), and the Kalman filter are generally utilized to smooth the code measurement and substantially reduce the high frequency noise error terms. CsC smoothing techniques have been implemented for various local area augmentation systems to reduce receiver noise, which may include relatively high rate multipath error. An example of this implementation of CsC is for the Federal Aviation Administration development of the Local Area Augmentation System, where CsC details can be found in the RTCA Minimum Aviation System Performance Standards for the Local Area Augmentation System (LAAS), DO-253A, RTCA Inc., 1998, pp. 40-41, http://www.rtca.orq. While the errors of high frequency such as receiver noise and some multipath can be mitigated through this CsC technique, low frequency errors such as ionosphere and low rate multipath can accumulate a bias at the output of this smoothing. For a single-frequency GPS user, the ionosphere divergence occurs at a typical rate of 0.018 m/s through the CsC processing, with a 100 s time constant. This typical rate is documented for the LAAS in RTCA Minimum Operational Performance Standards for GPS Local Area Augmentation System Airborne Equipment, DO-245, RTCA Inc., 2001, pp. 30, http://www.rtca.org. Higher rate divergence can occur during periods of high ionosphere activity which can affect system performance. Consequently, the 100 s smoothing time constant encompasses a trade off between high frequency error mitigation (receiver noise and some multipath mitigation) and low frequency error bias accumulation (largely, ionosphere divergence). For a typical ground based GNSS location, based on Braasch, M. S., and Van Dierendonck A. J., GPS Receiver Architectures and Measurements, Proceedings of the IEEE, Vol. 87, No 1, January 1999, pp. 48-64, a multipath model is implemented in Dickman, J., Bartone, C., Zhang, Y., and Thornburg, B., “Characterization and Performance of a Prototype Wideband Airport Pseudolite Multipath Limiting Antenna for the Local Area Augmentation System”, Institute of Navigation, National Technical Meeting, Jan. 22-24, 2003, Anaheim, Calif., pp. 783-793. The multipath model predicts that the multipath error fading frequency ranges from about zero to 0.005 Hz, and is typically less than 0.01 Hz; these multipath fading frequency rates are documented in a paper by Zhang. Y., Bartone, C. G., “Multipath Mitigation in the Frequency Domain,” Proceedings of IEEE Position Location And Navigation Symposium 2004, Sep. 9-12, 2004, Monterey, Calif., ISBN 0-7803-8417-2, © 2004 IEEE, pg. 486-495. Thus, CsC, with a 100 s time constant, cannot mitigate the majority of the multipath error, which changes at a relative slow rate, with respect to the 100 s smoothing time constant.
[0039] The frequency domain processing technique can effectively be used for multipath mitigation when the multipath fading frequency can be well predicted, as documented in a paper by Zhang. Y., Bartone, C. G., “Multipath Mitigation in the Frequency Domain,” Proceedings of IEEE Position Location And Navigation Symposium 2004, Sep. 9-12, 2004, Monterey, Calif., ISBN 0-7803-8417-2, © 2004 IEEE, pg. 486-495. This technique implements a Fast Fourier Transform (FFT) where the block size needs to be comparable to the multipath cycle targeted for removal; 20-60% real-time and 50-70% post-process multipath mitigation was achieved for FFT block sizes on the order of 256 and 512. The block size needs to be carefully select in order to leverage the tradeoff between the mitigation effect and the overlapping frequency spectrum of multipath and other measurement error components, which may not be desired for removal using the frequency domain approach. This technique is believed to be well suited for the applications where the multipath fading frequency can be well predicted which is especially true for static ground-based applications; the technique can be applied for mobile user applications where this multipath frequency estimation can occur using spectral estimation techniques on the CmC data from the code and carrier measurements.
[0040] The reduction of multipath has become an essential part of any high precise GNSS architecture. Both hardware, mainly in terms of radio frequency (RF), and software approaches have been pursued to mitigate multipath. Various RF approaches come in the form of antenna design as documented in the following papers: Thornberg, B., Thornberg, D., DiBenedetto, M, Braasch, M., van Graas, F, Bartone, C., “The LAAS Integrated Multipath Limiting Antenna (IMLA)”, NAVIGATION Journal, of The Institute of Navigation, Vol. 50, No. 2, Summer 2003, pp. 117-130; and, Brown, A., “Multipath Rejection Through Spatial Processing”, Proceedings of ION GPS-2000, September, 2000, Salt Lake City, Utah, pp. 2330-2337; and Kunysz, W., “A Novel GPS Survey Antenna”, Institute of Navigation, National Technical Meeting, Jan. 26-28, 2000, Anaheim, Calif., pp. 698-705; and Dickman, J., Bartone, C., Zhang, Y., and Thornburg, B., “Characterization and Performance of a Prototype Wideband Airport Pseudolite Multipath Limiting Antenna for the Local Area Augmentation System”, Institute of Navigation, National Technical Meeting, Jan. 22-24, 2003, Anaheim, Calif., pp. 783-793. These RF approaches attempt to minimize the net effect of the undesired multipath signal while providing sufficient gain to the desired signal of interest. Various software approaches have been pursued in the form of advanced receiver design as documented by: A. J. Van Dierendonck, Pat Fenton, and Tom Ford, Theory And Performance Of Narrow Correlator Spacing in a GPS Receiver, NAVIGATION Journal of the Institute of Navigation, Vol. 39 No. 3, 1992, pp. 265-284; and Shallberg, K., et al., “WAAS Measurement Processing, Reducing the Effects of Multipath”, Proceedings of ION GPS 2001, Sep. 11-14, 2001, Salt Lake City, Utah, pp. 2334-2340; and L. R. Weill, “High-Performance Multipath Mitigation Using the Synergy of Composite GPS Signals”, Proceedings of ION GPS 2003, Sep. 9-12, 2003, Portland, Oreg., pp. 829-840. These software approaches are at the system, receiver correlator, or post-detection point.
[0041] For ground based reference station applications, low frequency multipath can be mitigated using a RF approach by implementing advanced antenna designs where the low rate ground multipath can be mitigated with added cost and complexity; an example of this implementation can be found the paper by Thornberg, B., Thornberg, D., DiBenedetto, M, Braasch, M., van Graas, F, Bartone, C., “The LAAS Integrated Multipath Limiting Antenna (IMLA)”, NAVIGATION Journal, of The Institute of Navigation, Vol. 50, No. 2, Summer 2003, pp. 117-130. Various software multipath mitigation approaches can be classified into time domain processing and frequency domain processing techniques. A typical time domain processing technique is carrier smoothed code (CsC), i.e., Hatch filter. The CsC approach will typically limit the smoothing time (e.g., 100 s) for single frequency users, and hence has limited value to remove low rate multipath. Another time domain processing technique is the code noise and multipath (CNMP) algorithm; the paper by Shallberg, K., et al., “WAAS Measurement Processing, Reducing the Effects of Multipath”, Proceedings of ION GPS 2001, Sep. 11-14, 2001, Salt Lake City, Utah, pp. 2334-2340, provided additional detail on the CNMP. The CNMP algorithm utilizes dual frequency code and carrier phase measurements to form a multipath corrected code measurement. However, the CNMP ionosphere free measurement (with the carrier phase ambiguity bias included), turns out to be essentially the same as the conventional ionosphere free carrier phase measurement. Therefore, the CNMP algorithm is of limited value in multipath mitigation, when both code and carrier measurements are desired for use in the user solution. Another time domain processing technique is the optimum synergy of modernized GPS signal using maximum likelihood (ML) estimator as documented in the paper by L. R. Weill, “High-Performance Multipath Mitigation Using the Synergy of Composite GPS Signals”, Proceedings of ION GPS 2003, Sep. 9-12, 2003, Portland, Oreg., pp. 829-840. Significant multipath mitigation has been proved based on the Cramer-Rao bound theory. However, this technique is fairly computationally complicated and not done in real-time.
[0042] Wavelet signal processing techniques encompasses spectrogram analysis to provide a time resolution representation of the signals, and offers the ability to analyze these signals at different frequencies and to localize them in time. Additional detail on the theory of wavelet signal processing can be found in Strang G., Nguyen T., Wavelets and filter banks, Wellesley-Cambridge Press, 1996, and Albert Cohen, Robert D. Ryan, Wavelets and Multiscale Signal Processing, Chapman & Hall Press, 1995.
[0043] Wavelet based signal processing methods have been applied to GPS for error mitigation and have typically operated on either the pseudorange or double difference (DD) measurements. (DD measurements are formed in a differential GPS (DGPS) architecture between a reference and user station.) Papers by Xuan, F., Rizos, C., “The Applications of Wavelets to GPS Signal Processing”, ION GPS 1997, Sep. 16-19, 1997, pp. 697-702, and Xia, L., Liu, J., “Approach for Multipath Reduction Using Wavelet Algorithm”, ION GPS 2001, Sep. 11-14, 2001, Salt Lake City, Utah, pg 2134-2143, and Menezes de Souza E., Multipath Reduction from GPS Double Differences using Wavelets: How far can we go?, ION GNSS 2004, Sep. 21-24, 2004, pp. 2563-2571.
BRIEF SUMMARY OF THE INVENTION
[0044] In this patent, a new technique WaveSmooth™ is introduced for error mitigation in GNSS architectures. The WaveSmooth™ technique included in this patent is applicable to two main classes of GNSS architectures; 1) single-frequency error mitigation, and 2) multi-frequency error mitigation. For single-frequency GNSS architectures error mitigation comes largely in the form of pseudorange error mitigation. For multi-frequency GNSS architectures (e.g., dual-frequency GPS) error mitigation largely comes in the form of multipath mitigation. GPS is used to illustrate the WaveSmooth™ technique.
[0045] In this patent, a new WaveSmooth™ code processing technique is presented here to enable real-time smoothing of single-frequency GNSS measurements, using wavelets. The WaveSmooth™ technique effectively remove code multipath error in a real-time fashion for multi-frequency GNSS users. This WaveSmooth™ technique effectively removes the receiver noise error and major multipath error in a real-time fashion, using wavelet transforms, where n calculations are required for a given block length of n. (These calculations are less than the nlog 2 n need to perform the FFT as described in Phillips, W. J. “Wavelets and Filter Banks Course Notes”, Apr. 3, 2004, http://www.engmath.dal.ca/courses/engm6610/notes/notes.html, date visited Aug. 12, 2004.) The WaveSmooth™ technique is uniquely different from previous wavelet techniques that operate on the GPS double differences such as paper by: Xuan, F., Rizos, C., “The Applications of Wavelets to GPS Signal Processing”, ION GPS 1997, Sep. 16-19, 1997, pg 1385-1388, and Xia, L., Liu, J., “Approach for Multipath Reduction Using Wavelet Algorithm”, ION GPS 2001, Sep. 11-14, 2001, Salt Lake City, Utah, pg 2134-2143, and Menezes de Souza E., Multipath Reduction from GPS Double Differences using Wavelets: How far can we go?, ION GNSS 2004, Sep. 21-24, 2004, pp. 2563-2571. The WaveSmooth™ operates on the GNSS CmC measurement to form a real-time estimate of the error targeted for removal. This error estimate is applied to the original code phase measurement, to enhance single-frequency or dual-frequency measurements that are implemented in a standalone or differential GNSS architecture, respectively. These WaveSmooth™ techniques and enhancements have been documented for single-frequency users by Bartone, C., Zhang. Y., “A Real-Time Hybrid-Domain WaveSmooth™ Code Processing Using Wavelets”, Proceedings of ION GNSS 2004, Sep. 21-24, 2004, Long Beach, Calif., pp. 436-446, and for dual-frequency users by Zhang. Y., Bartone, C., “Real-time Multipath Mitigation with WaveSmooth™ Technique using Wavelets”, Proceedings of ION GNSS 2004, Sep. 21-24, 2004, Long Beach, Calif., pp. 1181-1194.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0046] Not Applicable.
DETAILED DESCRIPTION OF THE INVENTION
[0047] In this patent, the WaveSmooth™ technique is useful for error mitigation in various GNSS architectures. For single-frequency GNSS architectures error mitigation largely comes in the form of smoothed pseudoranges with some multipath mitigation. For multi-frequency GNSS architectures (e.g., dual-frequency GPS) error mitigation largely comes in the form of multipath mitigation with some smoothing effects. To illustrate the details of the WaveSmooth™ technique, single-frequency GPS measurements and dual-frequency (i.e., ionosphere free) GPS measurements will be used as a test case to illustrate the WaveSmooth™ technique.
[0048] The WaveSmooth™ technique utilizes spectrogram analysis to decompose the GNSS signal in time and frequency using wavelet transform, and offers the unique ability to analyze the error characteristics, including multipath at different frequencies and to localize them in time. This is because the wavelet elements are the waveforms indexed by three naturally interpreted parameters: 1) position, 2) scale in the wavelet decomposition, and 3) frequency. Therefore the wavelet transform offers advantages over its frequency domain counterpart (e.g., Fourier analysis) and time domain counterpart (e.g., CsC and Kalman filter). Consequently, WaveSmooth™ provide the option to discard the unwanted component such as multipath and receiver noise and keep the low frequency ionosphere component, which could be removed in later processing (i.e., through differential GPS (DGPS)). The technique was developed and implemented for modernized GNSS signal to provide a real-time error correction for GNSS signals.
[0049] WaveSmooth™ real-time multipath mitigation technique will now be described in three major steps where the inputs are the code and carrier phase measurements from time epoch k−τ+1 to time epoch k. The output is the real-time multipath mitigated code measurements at current time epoch k. The process can be classified into three steps.
[0050] Step 1 Unbiased CmC Residual Formation. Firstly, the ionosphere error can be not performed at this stage for a single-frequency GNSS user, or removed in a multi-frequency GNSS receiver system (e.g., by forming ionosphere free measurements using Equation (2); additionally, the ionosphere error can be removed by other techniques. (The reason not to remove the ionosphere error at this point, may be selected by the user for example, a short baseline, application.) With the CmC formed for single-frequency GNSS users as in Equation (3), or for multi-frequency GNSS users as in Equation (4) for every epoch. The bias term in the CmC (carrier integer ambiguity and initial bias errors) are removed in order to get a closer look at any dominate error that might be present. The bias term is calculated as Equation (5) in the real-time processing, which is the mean of the CmC from epoch k−τ+1 to epoch k. For a “small” smoothing window size τ, (i.e. less than a multipath cycle) the bias estimate will be less accurate. For a “large” smoothing window size τ, (i.e., comparable to a multiple multipath cycle), the average bias term in Equation (5) will represents more precisely the true constant bias.
CMC biased , k _ ❘ τ = ∑ j = k - τ + 1 k CMC biased , j τ ( 5 )
[0051] This average CmC constant bias, averaged over some smoothing window τ epochs, as expressed in Equation (5), is removed at each time epoch k from the biased CmC residual, expressed in Equation (3) or (4) to form an unbiased CmC at each time epoch k, as shown in Equation (6) for single-frequency users, and Equation (7) for multi-frequency users, respectively.
CmC unbiased , k = CmC biased , k - CmC biased , k _ ❘ τ = 2 I k + M ρ , k - M ϕ , k + ɛ ρ , k - ɛ ϕ , k + ɛ u ( 6 )
where:
ε u =additional error introduced in the unbiasing of the CmC
CmC unbiased , k = CmC biased , k - CMC biased , k _ ❘ τ = M ρ , k - M ϕ , k + ɛ ρ , k - ɛ ϕ , k + ɛ u ( 7 )
[0053] As shown in Equations (6) and (7), an additional error term (epsilon with subscript “u”) can be introduced when a small τ is used to form the unbiased CmC residual; this term represents an additional error term that is introduced in the unbiasing procedure. This term will diminish when a large τ is applied or a longer previous data are available for CmC bias estimate. This unbiased CmC signal, shown in Equation (6) or (7) will be used as the basis for the error estimation for single-frequency and multi-frequency GNSS architectures, respectively.
[0054] Step 2 Error Estimation. Wavelet analysis techniques are applied to the unbiased CmC residual, shown in Equation (3) to identify various frequency components of the error terms and localize them in time. The unbiased CmC signal is decomposed into different levels of frequency component via wavelet analysis techniques. Since the wavelet processing introduces negligible recursive delay lag, the wavelet processing time constant window (i.e., block length) can be theoretically selected relatively very long. For computation efficiency consideration, the processing window can be set at least comparable to an estimate of the multipath cycle length. The explicit notation for the time index k, where terms are calculated at every measurement epoch is now dropped for convenience. The unbiased CmC signal can be described as a sum of an “approximation” and different “detail” levels of wavelet decomposition as Equation (8). Additionally, an important factor in wavelet analysis is the decomposition level.
CmC unbiased = a l + ∑ i = 1 l d i ( 8 )
where:
CmC unbiased : unbiased CmC residual [m] a l : approximation at level l, of frequency from 0 to (1/2 l )*(f s /2)Hz l: the level of wavelet decomposition d i : detail at level i, of frequency from (1/2 i-1 )*(f s /2) to (1/2 i )*(f s /2)Hz f s =1/R s : sampling frequency of the CmC signal [Hz] R s : Data sampling interval (i.e., measurement epoch), [s].
[0061] For the single-frequency measurement set, this unbiased CmC residual has three major error components: ionosphere error, multipath error, and receiver noise. These three errors are characterized over different frequency ranges. The key of error mitigation using WaveSmooth™ is to select the appropriate detail level (frequency spectrum levels) and window size (i.e., time block), so as to isolate the ionosphere error from the multipath and receiver noise (for our single-frequency user of interest). Therefore, the multipath and receiver noise can be mitigated without introducing significant bias resulting from the ionosphere component. Of the three major error components in the unbiased CmC residual (ionosphere error, multipath error, and receiver noise), the ionosphere error typically has the lowest frequency spectrum. For the single-frequency user, the ionosphere error prediction could be make based upon the broadcast parameters, user position, local time, and SV elevation and azimuth angles. The ionosphere model for GPS can be found with the GPS Interface Control Document (ICD), ICD-GPS-200C, Navstar GPS Space Segment/Navigation User Interface, U.S. Air Force, 10 Oct. 1993, pp. 114-116 and 125-128, http://www.navcen.uscq.gov/pubs/qps/icd200/default.htm, and within the chapter by Klobuchar, John A., Ionospheric Effect on GPS, of the textbook entitled Global Positioning System: Theory and Applications, Vol. 1, B. Parkinson, J. Spilker, P. Axerald and P. Enge (Eds), American Institute of Aeronautics, 1996, pp. 485-515. An approximate rate of the ionosphere change on a daily basis can be gain by using the GPS broadcast ionosphere error model; for a typical day in 2003, this daily ionosphere error frequency spectrum had a maximum values at 5.8e-6 Hz and varies within the range from 0 to 1.2e-4 Hz, which provides an indication of the rate of this ionosphere error component.
[0062] The next major error component presented within the unbiased CmC is the multipath error. The fading frequency of the multipath error component desired for removal is estimated, for later removal. A multipath spectral estimation technique is used to provide a multipath frequency spectrum estimation, which is used to bound the frequency domain region for mitigation; either a multipath model or spectral estimation on the GNSS observable data can be accomplished. For ground-based GNSS architectures where the site is in a controlled environment, a multipath model is a good choice. For mobile user applications, a model, or spectral estimation technique can be implemented.
[0063] The wavelet analysis is applied to decompose the unbiased CmC for the purpose of error isolation for later mitigation. When receiver measurements are obtained from a single-frequency receiver, a more conservative approach is applied to preserve the ionosphere error, which may be removed in latter processing (i.e., short baseline DGPS architecture). The decomposition level should be at a sufficient level to isolate the anticipated highest rate of the multipath error targeted for removal; typically a detail level from 5 to 8 works well, again, depending on the estimated multipath frequency range. Follow Equation (8) this decomposition generates the approximation and all the details of different levels and frequency components to provide the option of preserving or discard specific frequency component (i.e., details) in a reconstruction (i.e., synthesis) of these error components for later removal.
[0064] For illustration purposes, consider a typical ground-based GNSS application. Depending upon antenna height, obstructions in the local area (i.e., the ground), and signal reception elevation angle, a single bounce multipath signal off the earth surface will have a multipath frequency spectrum associated with it. For a sampling frequency of 1 Hz, and antenna height=8.58 ft, the frequency spectral component of the multipath error ranges from about 0.003 to 0.02 Hz, depending upon the SV elevation angle as documented in a paper by Zhang. Y., Bartone, C. G., “Multipath Mitigation in the Frequency Domain,” Proceedings of IEEE Position Location And Navigation Symposium 2004, Sep. 9-12, 2004, Monterey, Calif., ISBN 0-7803-8417-2, © 2004 IEEE, pp. 486-495. When the wavelet decomposition is performed to detail level 8, the frequency rate of the ground multipath is matched to the wavelet detail levels: 5 (i.e., “d 5 ”) of frequency from 0.016 to 0.031 Hz, 6 (i.e., “d 6 ”) of frequency from 0.008 to 0.016 Hz, 7 (i.e., “d 7 ”) of frequency from 0.004 to 0.008 Hz, and 8 (i.e., “d 8 ”) of frequency from 0.002 to 0.004 Hz. This illustrates that the multipath error can be isolated, at the detail level, in the wavelet decomposition of the unbiased CmC residual. Note that the level needed to be taken (e.g., detail level 8 here) should be high enough to capture (i.e., isolate) the frequency component of the error term targeted for isolation, and no further. It should be noted that the level selection is dependent on the sampling rate, antenna height, obstruction environment, and to a limited extent, the smoothing window size.
[0065] Additionally, the processing window (time constant τ) is set to be comparable to or greater than the anticipated multipath fading cycle, so that the multipath frequency component can be effectively exposed in the wavelet decomposed details (e.g., d 5 through d 8 ). A longer processing window size (in the time-domain) is preferred for the best error mitigation; however, the window size needs to be limited for computation efficiency consideration. A good tradeoff is to set the processing window to be about one to three times the maximum anticipated multipath cycle, when multipath is the main error source targeted for mitigation. The knowledge of the multipath cycle can be retrieved from the multipath model; for ground based applications, this can be predicted as a function of the antenna height, SV elevation angle, reflection coefficient, code correlator spacing, etc.
[0066] The last major error component in the unbiased CmC is the receiver noise. Since the receiver noise spectrum is roughly Gaussian distributed, a wavelet decomposition at a detail level “l” will decompose and isolate the receiver noise, in the detail level(s), by a factor of 1-2 −l . For example a wavelet decomposition at a detail level of: 1 will represent 50% of the noise in the detail; 2 will represent 75% of the noise in the details; and 3 will represent 87.5% of the noise in the details, and so on.
[0067] With the decomposition and error isolation complete, the next step is to reconstruct (i.e., synthesize) a “smoothed error estimation” from the unbiased CmC signal, which will be targeted for removal from the code phase measurement. For single-frequency users, which choose to have the ionosphere error term largely unaffected by the WaveSmooth™ technique, this smoothed error estimation is formed in accordance with Equations (9) and (10). The reconstruction of the low frequency component shown in Equation (5) including ionosphere propagation error, from the approximation at level “l” essentially discard the multipath and receiver noise contained in the details from level d 1 to level d l .
{circumflex over (ε)} low =α l (9)
[0068] When the low frequency component, shown in Equation (9), is subtracted from the unbiased CmC signal, see Equation (10), the final WaveSmooth™ error estimation is formed for the single-frequency user.
{circumflex over (ε)} WaveSmooth =CmC unbiased −{circumflex over (ε)} low (10)
[0069] For multi-frequency GNSS users, the reconstructed “smoothed error estimation” is largely the multipath error estimation. The optimum synergy of spectrogram decomposition and the CmC provides for high fidelity multipath estimation. Specifically, the multipath estimation is the low frequency component directly from the approximation at level “l”, as shown in Equation (11).
{circumflex over (ε)} WaveSmooth ={circumflex over (ε)} low =α l (11)
[0070] Step 3 Error Mitigation. The real-time WaveSmooth™ error estimation from Equation (10) for single-frequency GNSS users, or Equation (11) for dual-frequency (i.e., iono-free) GNSS users is subtracted from to the code phase measurement to mitigate code phase measurement error as shown in Equation (12).
{circumflex over (ρ)} WaveSmooth =ρ−{circumflex over (ε)} WaveSmooth (12)
[0071] This WaveSmooth™ error mitigated pseudorange measurement can be used, along with the original carrier phase measurement for a high performance user solution. Additionally, since the WaveSmooth™ technique introduces negligible recursive delay lag, a second iteration can be conducted to achieve better smoothing result.
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WaveSmooth™ is a technique to mitigate inherent measurement error for GNSS signals. The WaveSmooth™ technique can be applied for single-frequency or multi-frequency GNSS users. For single-frequency GNSS users, WaveSmooth™ enables smoothing of GNSS measurements, in real-time using wavelets without introducing significant ionosphere divergence. For multi-frequency GNSS users, the WaveSmooth™ technique effectively mitigates multipath error in a real-time fashion. The WaveSmooth™ techniques utilizes wavelet aided methods and operate on the GNSS Code minus Carrier (CmC) signal to mitigate inherent GNSS measurement errors in a real-time fashion to improve the performance of these GNSSs. The WaveSmooth™ error mitigated pseudorange measurement can be used, along with the original carrier phase measurement for a high performance user solution.
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This application is a division of application Ser. No. 07/526,857, filed May 21, 1990, now U.S. Pat. No. 5,101,693.
BACKGROUND OF THE INVENTION
The present invention pertains to heating, ventilating and air conditioning (HVAC) systems in general, and to an air handling unit arrangement in which a direct expansion coil is utilized.
In some buildings, typically high rises, it is common to use one or more small air handling units per floor. These systems have the advantages of being inexpensive to purchase and install and a self-contained system may be provided for each tenant. For example, each floor of a high-rise building may therefore have one or more small air handling units.
Such systems are characterized by recurring problems related to equipment failure and occupant discomfort. The recurring equipment problems can be identified as being related to icing of the expansion coil and cooling compressor seizure.
The occupant discomfort problems typically are associated with wide variations in temperature due to compressor cycling and excessive removal of moisture from the air.
SUMMARY OF THE INVENTION
In accordance with the invention the foregoing and other problems associated with air handling systems are advantageously solved in an improved method and apparatus.
In accordance with one aspect of the invention, predictive algorithms are employed in a controller to avoid icing of the cooling coil, avoid compressor seizure by eliminating the possibility for certain modes of compressor operation from occurring and to maintain occupant comfort levels.
Another aspect of the invention is the control of variable air volume boxes by the controller in order to improve the comfort level in an occupied space. The controller, for small changes in space temperature requiring only a small cooling load, is programmed to change the air flow into the space, rather than cycle the compressor.
A further aspect of the present: invention is the control of cooling agent flow to the condenser by the controller. For small changes in cooling load requiring only a small portion of cooling capacity, the controller is programmed to increase the load on the compressor by restricting a valve which controls cooling agent flow from a cooling tower to the condenser.
Yet another aspect of the invention is the artificial loading of the compressor by causing warm water leaving the condenser to flow through a pre-cool coil which is upstream in the air flow from the direct expansion coil.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood from a reading of the following detailed description in conjunction with the drawing in which like reference characters designate like drawing elements and in which:
FIG. 1 is a schematic drawing of a conventional air handling system of the type to which the present invention may advantageously be applied;
FIG. 2 is a schematic drawing of the system of FIG. 1 illustrating the use of self-contained diffusers;
FIG. 3 is a schematic drawing of an improved air handling system in accordance with the present invention;
FIG. 4 illustrates in block diagram form a controller of the type which may be advantageously employed in the system of FIG. 3;
FIG. 5 is a flow diagram of cooling operation; and
FIG. 6 is a flow diagram heating and cooling operation.
DETAILED DESCRIPTION
FIG. 1 illustrates a typical prior art air handling system in which a fan 1 supplies cooled air to a distribution system 2 which may include one or more zone terminals. Each zone terminal may in turn have a variable air volume (VAV) terminal 3 with one or more diffusers 4, or it may have a self-contained diffuser 41, i.e., a diffuser with self-contained controls), as shown in FIG. 2. FIGS. 1 and 2 are identical except for the use of self-contained diffusers in place of VAV's. The following discussion applies equally to FIGS. 1 and 2. Each zone terminal regulates the flow of air into a space to control cooling level and maintain occupant comfort based upon dry bulb temperature in the space.
Air is supplied to the fan primarily by means of return air and a fixed quantity of outside air. The return air flows through return duct 5. Building codes typically require a minimum outside, i.e., fresh air supply. In the illustrative system, the minimum outside air required by building code is supplied via outside air plenum 6.
The air is cleaned by means of filter 7 and passes through a precool coil 8. Precool coil 8 is required under certain building codes for energy conservation and uses cooling water supplied from a cooling tower 9 to provide so called "free cooling" from outside ambient air without the use of a compressor. From precool coil 8, the air flows through a direct expansion coil 10 which is coupled to a compressor 11 via an expansion valve 13. Compressor 11 in turn is coupled to a water cooled condenser 12. Condenser 12 receives a cooling agent, such as cooling water from cooling tower 9.
A controller 14 measures the discharge air temperature from the direct expansion coil 10 via a temperature sensor 17 and controls the output of compressor 11 by cycling compressor 11 on or off. It should be noted that although only one compressor is shown, two or more compressors may be coupled to controller 14. Controller 14 also controls the flow of cooling water to condenser 12 and to coil 8 via three way, two position valve 15 and flow valve 16, respectively.
Condenser 12 contains an internal control valve which monitors the compressor head pressure and varies the water flow to maintain a head pressure set point. The valve opens and closes to maintain the preset compressor head pressure.
Controller 14 is typically an electromechanical controller of a type well known in the art and is of a relatively simple construction. The purpose of controller 14 is to attempt to maintain a constant discharge air temperature, typically 55° F. from the direct expansion coil 10.
In operation, the fan 1 typically runs continuously and either coil 8 or direct expansion coil 10 is used to provide cooling of air. If the cooling water temperature in the supply line from the water tower is at or less than a predetermined temperature, the controller will turn off compressor 11, operate valve 15 to divert water flow from condenser 12 to coil 8 and operate valve 16.
As pointed out briefly above, this prior art arrangement has some significant problems. These problems are icing of the direct expansion coil, compressor seizure or occupant discomfort.
Icing of the direct expansion coil 10 may occur as a result of a low load condition. A direct expansion cooling system is inherently limited in its ability to throttle cooling capacity. Because of this, cooling is limited to discrete capacity steps. As the cooling load drops below the minimum throttling capacity of the cooling stage, icing of the coil 10 occurs.
It has also been determined that loose fan belts or dirty filters can result in icing of the coil 10. In all three cases the air flow through the coil 10 is reduced and the result may be icing.
Additionally, if valves 15 and 16 stay open such that cooling water always flows to coil 8, the load on the direct expansion coil 10 is reduced. If condenser 12 cooling water valve (controlled by head pressure) sticks open, this can lead to compressor failure. This condition will cause excessive compressor cycling due to automatic safety cutouts. A stuck condenser cooling valve can result in the condenser cooled to a lower temperature than the direct expansion coil. These conditions result in oil migration from the compressor, seizure and permanent failure. Valves 15 and/or 16 commonly stick open as a result of scale or dirt build up in the valves resulting from the use of water which flows directly from cooling tower 9.
Compressor failure as evidenced by compressor seizure may result from several causes. If the compressor cycles too often in a given time period, the resulting high pressure differential in the compressor may result in seizure. A controller 14 determines the number of cycles that it will initiate in a given time period as a function of a manual setting. Very often this cycle rate will be increased by maintenance personnel to resolve occupant discomfort. The actual number of cycles may be more than the controller setting. A reason for this is if the compressor begins overheating the temperature limit switch in the compressor opens up. This limit switch cycle may repeat multiple times during a single on cycle from controller 14.
Turning now to FIG. 3, the improved system in accordance with the invention is shown. In the improved system the cooling water passes through a heat exchanger 9a. The heat exchanger protects valves 15 and 16 from dirt and scale. Controller 14 of the prior system is replaced with a programmable controller 141 which will be described in further detail below. A temperature sensor 31 is connected to measure the temperature of the cooling water from the cooling tower. A pressure sensor 32 is provided to measure the air pressure downstream of the direct expansion coil 10. Alternatively, a pressure sensor 33 may be provided downstream of fan 1. Another pressure sensor 34 is provided downstream of the coil 10. In addition, a status sensor 35 is provided at compressor 11. The status sensor may be of any conventional type which would indicate whether the compressor 11 is energized and running or not. The sensors 32, 33 and 34 may be any conventional air pressure sensor. Likewise tower water sensor 31 may be any conventional temperature sensor. Also connected into the controller but not shown is one or more temperature sensors which measure the temperature in the spaces in the building which are to be controlled.
As was noted above, one problem associated with direct expansion cooling based air handling units in the past has been icing of the direct expansion coil. In accordance with the present invention, the coil resistance to air flow is measured. The controller 141 does this by calculating the pressure differential between pressure sensors 34 and 32 or 34 and 33 and determining air flow through the DX using air flow sensor 17. The controller then determines if the DX coil is iced by looking in a look up table stored in memory at an address determined from the air flow. If the pressure drop is greater than the value stored at the selected address, the controller determines that the DX coil is iced. If as a result of that comparison it is determined that the coil is iced, the controller will turn off the compressor and deice the coil. Meanwhile, the controller will continue to measure the pressure on either side of the coil 10 by means of pressure sensors 34 and 32 or 33. When the pressure differential drops to a level which is indicative of a deiced coil, the controller then permits the compressor to be turned on again if cooling is called for.
In addition, the controller can operate to determine whether or not there is a probability that a filter 7 is dirty and needs replacement or if the belt driven fan 1 has a loose belt. In either of those situations reduced air flow occurs which may be sensed by the sensors 32, 34 and 33. Depending upon the signature of the reduced air flow it may be determined whether the air flow reduction is due to a dirty filter, icing of the coil or a loose belt. Under each of those circumstances, the time period over which the air flow reduces will be different. The controller 141 can calculate the time rate of change in the air pressure and compare that time rate of change with data stored in the controller memory to determine whether there is icing of the coil, a loose belt or a dirty filter.
Compressor seizure may occur from excessive cycling. In accordance with the invention the status of the compressor is monitored or measured by means of sensor 35. Sensor 35 can, for example, monitor the current flow to the compressor and thereby determine whether or not the compressor is running. Controller 141 monitors the number of compressor cycles and will not allow the compressor to be activated if the compressor has reached a predetermined upper limit of cycles in a given period of time, i.e., an hour. With this arrangement, should a compressor cycle too many times in an hour, due, for example, to the thermal overload switch being tripped in the compressor, then the controller will not allow a manual override to cause the compressor to be operated. Furthermore, a diagnostic message may be generated by the controller 141 to let the system or building operator know that there is a potential problem.
Controller 141 can also calculate the load imposed on the fan system by utilizing the pressure sensors to measure the air flow and by measuring the temperature differential across the system. By using predictive techniques, increasing the discharge air temperature setpoint will increase the air flow across the direct expansion coil 10. The increased air flow will prevent icing on direct expansion coil 10.
The controller 141 also may be used to maintain the condenser pressure at the lowest allowed level to not only avoid compressor seizure but to provide for energy savings.
Controller 141 also can avoid a change over from use of the precoil 8 to compressor cooling at low loads. If the water temperature as measured by sensor 31 indicates that the temperature of cooling tower water reaches a level at which cooling tower water cannot provide adequate cooling and the compressor only has a relatively low load, then the flow versus temperature difference may be used to maintain a higher level temperature in the controlled space with a higher air flow. In other words, the discharge temperature from the fan would be allowed to float and the compressor would be turned on only when the cooling load is above a predetermined threshold level (e.g. 10-15% of cooling capacity). With this arrangement an intelligent decision is made to try to maintain occupant comfort within a particular comfort band, but if it is needed to save the equipment, the controller 141 will cause the system to operate such that it operates at the higher end of the comfort band. This is of course different than prior art systems in which there was no provision for automatic override of, for example, temperature sensors.
Controller 141 also operates to prevent compressor seizure by artificially loading the compressor during low load conditions. More specifically, under low load conditions, controller 141 may energize valves 15 and 16 such that the precool coil 8 is used as a preheater to increase the load on the compressor under low load conditions. As an additional strategy, controller 141 may use the valve 15 to decrease water flow through the condenser and to increase the new pressure thereby increasing the load on the compressor.
Turning now to the aforementioned problem of occupant discomfort, the use of multiple VAV boxes 3a eliminates wide variations in temperature by maintaining the manufacturers recommended cycle rate of the compressor as discussed above and by maintaining a cooling load by changing the zone terminal air flow rate as a result of fan discharge air temperature variation. Additionally, occupant discomfort due to dehumidification is minimized by utilizing controller 141 to maintain the proper balance between air flow rate and temperature differential to maintain the smallest temperature difference across the direct expansion coil 10. Turning now to FIG. 4, a representative controller is shown. Controller 141 includes CPU 441 of a type well known in the art, a random access memory (RAM) 42 which may be any conventionally available random access memory, a read only memory (ROM) 43 which contains the various data necessary for operation of the system and an IO or input/output interface 44. The IO interface 44 provides a buffer between the CPU and the various sensors and control points of the system. As is well known, such a device will include circuitry for providing appropriate voltage and/or current interface to the various sensors and to the various control devices such as valves 15 and 16 and for control of the compressor 11. Each and every one of the elements of FIG. 4 is well known. The controller 141 may in its totality be purchased from Honeywell Inc. as Honeywell's MICROCEL system controller.
Occupant discomfort and equipment failures can be traced to the performance of the central fan direct expansion cooling system under low load conditions. The system is inherently limited in its ability to throttle cooling capacity. In addition, cooling air is limited to discrete temperature steps. Low load conditions can result in fan coil icing as the cooling load drops below the minimum throttling capacity of the first cooling stage. Coil icing may lead to compressor failure or simply starve the air flow causing occupant discomfort.
Since direct expansion cooling is a staged process, the central fan discharge air temperature will cycle under less than full load conditions. Conventional VAV zone terminal control loops are not configured to compensate for rapid changes in the cooling supply air temperature. The response of a space temperature control loop is dominated by a time constant on the order of 12 minutes. This sluggish response results in unstable control of the space temperature and occupant discomfort.
The attached control diagrams shown in FIGS. 5 and 6 describe a zone terminal control which compensates for rapid variations in the central fan supply air temperature. Conventional zone VAV controllers use a similar cascade control loop with the output of the space temperature controller directly resetting the VAV flow control set point. The proposed strategy is different because it incorporates feed forward compensation for disturbances in the cooling air temperature.
A space temperature controller determines the amount of cooling or heating energy required (Q req ) to maintain a comfortable room temperature. As the space temperature PI controller output varies from 0 to 100, this signal is converted to the space energy required Q req to maintain occupant comfort.
Q.sub.req =Q.sub.clgdsgn +(Control.sub.output * (Q.sub.htgdsgn -Q.sub.clgdsgn)/100
where ##EQU1## and Q req is the required heat transfer to the conditioned space. Control out is the output of the space temperature controller.
For zone design cooling load:
Q.sub.clgdsgn =1.1 F.sub.max (T.sub.supclg -T.sub.spacemax)
where: T supclg is the design cooling supply temperature.
T spacemax is the design cooling season space temperature.
Fmax is zone terminal design maximum air flow. For zone design heating load:
Q.sub.htgdsgn =1.1 F.sub.min ×(T.sub.suphtg -T.sub.spacemin)
where: T suphtg is the design discharge air temperature of the air VAV box reheat coil. T spacemin is the design heating season space temperature.
Fmin is zone terminal design minimum air flow. If the zone terminal is cooling only, Q htgdsgn =0
The VAV flow controller setpoint is calculated based on the required space heat transfer, current supply air temperature as well as the space temperature.
F=Q.sub.req /1.1 * (T.sub.sup -T.sub.s)
where F is the flow set point, T sup is the supply air temperature and T s is the space temperature.
Variations in the central fan supply air temperature will immediately affect the air flow distributed to the occupied space. An increase in fan supply temperature increases air flow while a decrease results in lower air flow. In all cases, the inner loop will attempt to maintain the space heat transfer dictated by the outer loop space temperature controller. Of course the VAV terminal air flow setpoint range is restricted between the minimum and maximum air flow limits.
Reheat coils located in a VAV terminal are controlled with a calculated heating discharge air temperature setpoint htg setpt .
IF Q.sub.req <0
THEN the Q.sub.htgsetpt =(Q.sub.req /1.1*F)+T
IF Q.sub.req >0
THEN heating off
Zones installed with heating convectors or radiators may use the Q req signal directly from the space temperature controller.
FIG. 5 and FIG. 6 illustrate the system and controller operation in a flow chart form. FIG. 5 illustrates the control of the VAV's boxes 3 in FIG. 3 for cooling only whereas FIG. 6 illustrates the flow control for heating and cooling with zone VAV's.
In FIG. 5, summer 505 creates an error signal as the difference between a user selected space temperature setpoint and the actual space temperature (T s ) signal produced by space temperature sensor 555. This error signal is then provided to a space temperature PI controller 510. The PI controller in turn produces a control out signal which is based on a first fraction of the error signal and a second fraction of the integral of the error signal. PI controllers are well known in the art, as are the methods of selecting the first and second fractions depending upon the control desired.
Once the Control out Q signal has been determined, the required heat transfer, Q req must be calculated, as shown in box 515. Once the Q req is calculated, the required air flow, F 1 into the space being controlled can be determined, as shown in box 520. Since F is dependent upon the space temperature T s and the supply air temperature T sup , block 520 is shown as receiving T s and T sup from space temperature sensor 555 and supply air temperature sensor 550. Once F is calculated, it is compared with actual flow (F act ) signal produced by air flow sensor 545. The difference is calculated by summer 525 and provided to terminal controller 530. Note that summers 505 and 525, PI controller 510 and blocks 515 and 520 are all parts of controller 3a.
Terminal controller 530 in turn responds to the difference signal provided to it. It also is a PI controller which operates in a manner similar to space temperature controller 510. Terminal controller produces a flow control signal which is then sent to damper 535. Damper 535 controls the amount of air flow into occupied space 540.
As we stated earlier, the system shown in FIG. 6 is basically the same as the system shown in FIG. 5, except that the system shown now includes elements so that a space can be heated as well as cooled. Block 520' now has two algorithms, one for heating and one for cooling. The heating algorithm is elected when Q req >0 and the cooling algorithms is selected when Q req <0. Note that for convenience, supply air temperature sensor 550 is shown twice although only one sensor is used.
Turning now to FIG. 6, four new parts have been added to the system of FIG. 5 so that heating may be accomplished. Block 522 creates a heating setpoint signal as a function of Q req , F act and T s ;. Summer 565 then adds T sup and heating setpoint to create a heating error signal. Both blocks 522 and summer 565 are additional blocks of controller 141 in a system which can heat as well as cool.
The heating error signal is then provided to a heating P controller. The heating P controller multiplies the error signal by a predetermined fraction to produce a heating control signal for heating coil 560. Heating coil 560 in turn heats up air passing through the damper into the occupied space.
In all other aspects, the system shown in FIG. 6 is the same as the system of FIG. 5.
The foregoing has been a description of a novel and non-obvious control system for HVAC systems. The embodiments described herein are not intended to limit the scope of the inventors property rights as defined by the appended claims.
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A system for controlling the operation of an HVAC system which includes a direct expansion coil, a condenser, a pre-cool coil, and a control system. The control system includes a controller and sensors. The controller receives signals indicative of air flow through the direct expansion coil from the sensors, compares the received signal to a stored air flow rate, and disables the compressor if the stored air flow rate is equal to or greater than the stored value. The controller is also adapted to vary air flow into an occupied space for small changes in the cooling load. In addition, the controller can artificially load the compressor during periods of small cooling load by restricting flow of a cooling agent between the cooling tower and the condenser, or by directing warm water from the condenser through the pre-coil coil.
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BACKGROUND OF THE INVENTION
SPECIFICATION
The present invention relates to the use of rubber compositions intended for the manufacture of tires as elastomeric internal filling compositions, also referred to as “cushion mixes”, in the zones of the shoulder and the crown of a tire.
Radial-carcass tires for motor vehicles bearing heavy loads at greater or lesser speeds, in particular those for heavy vehicles, have a framework formed of reinforcements or plies of metal wires coated with elastomers. Such tires comprise, in the bottom zone, one or more bead wires and carcass reinforcement extending from one bead wire to the other and, at the crown, a crown reinforcement comprising two or more crown plies. This framework is consolidated by elastomeric compositions. Radial-carcass tires, intended to be fitted on vehicles bearing heavy loads at greater or lesser speeds, in particular those for heavy vehicles, are designed to be able to be recapped several times when the tread that is in contact with the ground is worn. This involves having available recappable carcasses which have not been subject to serious damage after wear of one or more treads.
The life of the tire can be shortened due to the appearance of damage within a rubber profiled filling member, for example a break, which may then spread as far as the inner or outer surface of the tire, with the result that the tire cover must be discarded and replaced. Examples of damage are, at the level of the shoulder of the tire, a break in the rubber profiled member of triangular shape, separating the carcass ply reinforcement from the radially inner crown ply, said break resulting from an imposed deformation stress, such as an impact against a curb or an impact against the edge of a roundabout located at a cross roads, because some roundabouts are too cramped for a highway unit With trailer to be able to pass without mounting an edge, the profile of which is frequently harsh.
It is desirable for the cohesion of the rubber internal filler mixes to be as great as possible to avoid or reduce these incipient points for damage.
It is known to the person skilled in the art that elastomeric internal filler compositions undergo deformation upon each rotation of the wheel. Such deformation causes a great amount of heating which is harmful to the life of said compositions because, at operating temperatures which are frequently above 100° C., the mechanical properties and the reinforcement degrade over time by thermochemical and/or thermo-oxidizing aging, with the consequence that the compositions become less resistant to mechanical stress.
In order to eliminate or at the very least minimize as far as possible the risks of breaking of the elastomeric internal filler mixes, i.e., those devoid of reinforcements, it is desirable for these mixes to have high mechanical cohesion as well as hysteresis loss characteristics which are as low as possible at the operating temperature of the tire.
The person skilled in the art, confronted with the problem of balancing minimal heating and high cohesion at high temperature, has proposed a large number of solutions. Thus, it has been proposed to use elastomeric internal filler compositions, i.e., cushion mixes, of relatively low hysteresis, in the form of:
(i) compositions based on natural rubber, pure or in a blend with polybutadiene, the reinforcing filler being a carbon black having a specific surface area preferably less than 110 m 2 /g and used in an amount of 30 to 35 phr (parts by weight per hundred parts of elastomer);
(ii) compositions based on natural rubber, pure or in a blend with polybutadiene, reinforced with a blend of carbon black and silica, the usual amounts of carbon black being from 30 to 35 phr and those of the silica from 10 to 15 phr;
(iii) compositions based on diene rubber and syndiotactic 1,2-polybutadiene as described in Patent Application JP-A-94/092108;
(iv) compositions based on natural rubber, possibly in a blend with another diene elastomer, comprising carbon black and thermoplastic polymer fibers as described in Patent Application JP-A-95/330960.
SUMMARY OF THE INVENTION
The Applicant has discovered that it is possible to obtain a balance between heating and improved cohesion and excellent resistance to the mechanical stresses with high deformation by the use of an elastomeric internal filler composition:
(i) based on natural rubber or synthetic polyisoprene having a majority of cis-1,4 bonds, used pure or in a blend with another diene elastomer,
(ii) reinforced with:
either a carbon black filler used in an amount between 15 phr and 28 phr, and preferably between 20 phr and 25 phr,
or a clear filler selected from among precipitated or pyrogenic silicas comprising SiOH functions at the surface, precipitated aluminas comprising AlOH functions at the surface, a natural or precipitated silicoaluminate comprising at the surface both SiOH and AlOH groups, said clear filler being used in an amount from 15 phr to 40 phr and preferably from 20 phr to 35 phr,
or with a blend of carbon black and clear filler as described above, such that the total amount of filler is between about 15 phr and 50 phr, and that the amount of clear filler in phr is greater than or equal to that of the carbon black in phr minus 5phr.
DETAILED DESCRIPTION
In the case of using clear filler, it is necessary to use a coupling and/or covering agent selected from among the agents known to the person skilled in the art. Preferred coupling agents include, inter alia, sulphur-containing alkoxysilanes of the bis-(3-trialkoxysilylpropyl) polysulphide type, and among these in particular, bis-(3-triethoxysilylpropyl) tetrasulphide sold by DEGUSSA under the names Si69 for the pure liquid product and X50S for the solid product (blend 50/50 by weight with black N330). Covering agents include a fatty alcohol, an alkylalkoxysilane, such as a hexadecyltrimethoxy- or triethoxysilane sold by DEGUSSA under the names Si116 and Si216 respectively, diphenylguanidine, a polyethylene glycol, or a silicone oil possibly modified by means of OH or alkoxy functions. The covering and/or coupling agent is used in a ratio by weight relative to the filler of between 1/100 and 20/100, and preferably of between 2/100 and 15/100, when the clear filler represents the entire reinforcing filler, and between about 1/100 and 20/100 when the reinforcing filler comprises a blend of carbon black and clear filler.
The elastomeric internal filler compositions or cushion mixes according to the invention are, for example, triangular profiled members separating the carcass reinforcement from the radially inner crown ply, the profiled members located between crown reinforcement plies over their entire width and/or the profiled members separating the ends of the crown plies forming the crown reinforcement.
The diene elastomers which may be used in a blend with natural rubber or a synthetic polyisoprene having a majority of cis-1,4 bonds include a polybutadiene (BR), preferably having a majority of cis-1,4 bonds, a solution or emulsion styrene-butadiene copolymer (SBR), a butadiene-isoprene copolymer (BIR) or, alternatively, a styrene-butadiene-isoprene terpolymer (SBIR). These elastomers may be modified during polymerization or after polymerization by means of branching agents, such as divinylbenzene, or starring agents, such as carbonates, tin halides or silicon halides. Alternatively, the elastromers may be modified by means of functionalizing agents resulting in grafting of oxygenated carbonyl or carboxyl functions or, alternatively, an amine function, such as, for example, by the action of dimethyl- or diethylamino-benzophenone on the chain or at the ends of the chain. In the case of blends of natural rubber or of synthetic polyisoprene having a majority of cis-1,4 bonds with one or more of the diene elastomers referred to above, the natural rubber or the synthetic polyisoprene preferably comprises the majority of the blend, and, more preferably, comprises an amount greater than 70 phr.
When carbon black is used as the sole reinforcing filler, the required properties are obtained using a carbon black, or a blend of carbon blacks, the BET specific surface area of which is between 30 and 160 m 2 /g, preferably between 90 and 150 m 2 /g, and the DBP structure of which is between 80 and 160 ml/100 g. Preferably, the amount of black used lies within the range of the values 20 phr and 25 phr. The measurement of BET specific surface area is effected in accordance with the method of BRUNAUER, EMMET and TELLER described in “The Journal of the American Chemical Society”, vol. 60, page 309, February 1938, corresponding to Standard NFT 45007 of November 1987.
When a clear filler is used as the sole reinforcing filler, the hysteresis and cohesion properties are obtained using a precipitated or pyrogenic silica, or a precipitated alumina, or alternatively an alumosilicate of BET specific surface are of between 30 and 260 m 2 /g. Preferably an amount of filler from 20 to 35 phr is used. Non-limiting examples of this type of filler include the silicas KS404 from Akzo, Ultrasil VN2 or VN3 and BV3370GR from Degussa, Zeopol 8745 from Huber, Zeosil 175MP or Zeosil 1165MP from Rhodia, HL-SIL 2000 from PPG, etc.
In the case of a blend of carbon black with a clear filler, an amount of clear filler from 25 to 40 phr is preferably used.
Other examples of reinforcing fillers having the morphology and the SiOH and/or AlOH surface functions of the silica- and/or alumina-type materials previously described, which can be used according to the invention as partial or total replacement thereof, include carbon blacks modified either during synthesis by adding to the feed oil of the oven a compound of silicon and/or aluminum or after the synthesis by adding an acid to an aqueous suspension of carbon black in a solution of sodium silicate and/or aluminate, so as to cover the surface of the carbon black at least in part with SiOH and/or AlOH functions. As in the case of the above clear fillers, the specific surface area of the filler lies between 30 and 260 m 2 /g, and the total amount of silica- and/or alumina-type material filler is greater than or equal to 15 phr, preferably greater than 25 phr, and less than or equal to 35 phr. Non-limiting examples of this type of carbon-containing fillers, with SiOH and/or AlOH functions at the surface, include the CSDP-type fillers described in Conference No. 24 of the ACS Meeting, Rubber Division, Anaheim, Calif., May 6th-9th 1997, and of those of Patent Application EPA-0 799 854.
Additional fillers which may also be used to obtain the diene internal filler compositions having the reinforcement and hysteresis properties according to the invention, include blends of one or more carbon blacks with one or more of the other fillers already mentioned having SiOH and/or AlOH functions at the surface, the overall amount of filler being between 15 and 50 phr, preferably between 20 and 45 phr, and the amount of filler with the SiOH and/or AlOH surface functions being greater than or equal to the amount of carbon black minus five.
Finally, with the aim of improving the working and/or the cost of the compositions according to the invention, without the hysteresis and cohesion characteristics being fundamentally changed, the filler or the blends of reinforcing fillers described above may be replaced in part by a less-reinforcing filler, such as a crushed or precipitated calcium carbonate, a kaolin, etc., on the condition that x phr of reinforcing filler is replaced by x+5 parts of less-reinforcing filler, x being less than 15 phr.
The compositions according to the invention may cross-link under the action of sulphur, peroxides or bismaleimides with or without sulphur. They may also contain the other constituents usually used in rubber mixes, such as plasticizers, pigments, antioxidants, and cross-linking accelerators, such as benzothiazole derivatives, diphenylguanidine etc.
The compositions according to the invention may be prepared using known thermomechanical working processes for the constituents in one or more steps. For example, they may be obtained by thermomechanical working in one stage in an internal mixer for 3 to 7 minutes at a speed of rotation of the blades of 50 rpm or in two stages in an internal mixer for 3 to 5 minutes and 2 to 4 minutes respectively, followed by a finishing stage effected at about 80° C., during which the sulphur and the accelerator are incorporated, in the case of a sulphur-cross-linked composition.
The invention is illustrated by the following examples, which in no way constitute a limitation to the scope of the invention.
In all the examples, unless indicated otherwise, the compositions are given in parts by weight.
In these examples, which may or may not be in accordance with the invention, the properties of the compositions are evaluated as follows:
Mooney Viscosity
The Mooney viscosity ML (1+4) is measured in accordance with Standard ASTM D1646.
Rheometry
The rheometry measurements are performed by measuring the torque on a Monsanto Model 100S rheometer. They are intended to monitor the vulcanization process by determining the time To in minutes which corresponds to the vulcanization delay and the time T99 in minutes which corresponds to 99% of the maximum torque measured.
Moduli of Elongation
The moduli of elongation are measured at 100% (ME100) and at 300% (ME300) in accordance with Standard ISO 37-1977.
Scott Break Index
These indices are measured at 23° C. or 100° C. The breaking stress (BS) is determined in MPa and the elongation at break (EB) in %.
Tearability Index
These indices are measured at 100° C. The force (TBS) is determined in MPa and the elongation at break (TEB) in % on a test piece of dimensions 10×105×2.5 mm notched at the center of its length over a depth of 5 mm.
Hysteresis Losses (HL)
The hysteresis losses (HL), or hysteresis, are measured by rebound at 60° in accordance with Standard ISO R17667 and are expressed in %.
Tom surface in cm 2 After Impact of a Tire Against a Curb
The tire to be tested is first baked at 77° C. for 6 weeks in a ventilated oven to simulate aging due to travel.
A heavy vehicle equipped with the tire to be tested hits a curb at very low speed at a fixed angle of less: than 20 degrees. Five passes onto the curb are effected, after which the tire is demounted and then decorticated, and the torn surface measured.
In all the tests, the compositions according to the invention are used in the form of triangular profiled members arranged between the carcass reinforcement and the radially inner crown ply.
EXAMPLE 1
The object of this example is to compare natural rubber compositions which are reinforced with carbon black. These compositions are set forth in Table 1. They comprise, in the case of test 1, a composition according to the invention with a low amount of black N115, and, in the case of test 2, a composition according to the invention with a low amount of black N326. The compositions used in tests 3 and 4 are control compositions representing the known prior art. The composition of test 3 has an amount of 35 phr of black N330 and that of test 4 comprises an amount of 50 phr of black N347. All these compositions are sulphur-vulcanizable.
The characteristics of the constituents are as follows:
Peptized natural rubber of Mooney ML (1+4) at 100° equal to 60
Antioxidant: N-(1,3-dimethyl butyl) N′-phenyl p-phenylene diamine
Soluble sulphur
Vulcanization accelerating agents
The compositions of tests 1 to 4 are obtained by processing all the ingredients, except for the sulphur and the accelerators, by thermomechanical working in one stage in an internal mixer for about 4 minutes at a speed of rotation of the blades of 50 rpm until a dropping temperature of 170° is reached, followed by a finishing stage effected at 80° C., during which the sulphur and the vulcanization accelerators are incorporated.
TABLE 1
Test 1
Test 2
Test 3
Test 4
Composition
Invention
Invention
Control
Control
Natural Rubber
100
100
100
100
Black N115
25
—
—
—
Black N326
—
25
—
—
Black N330
—
—
35
—
Black N347
—
—
—
50
ZnO
5
5
2.10
7
Stearic acid
0.50
0.50
1.40
2
Antioxidant
1.50
1.50
0.70
1.50
Sulphur
1.60
1.60
1.75
2.50
Accelerators
0.54
0.69
1.00
0.85
The vulcanization is effected at 140° for a time sufficient to achieve 99% of the maximum torque at the rheometer.
The properties of these four compositions are compared. The results are set forth in Table 2.
It will be noted that for the control compositions 3 and 4, the surfaces torn during the test of impact against the curb are far greater than those obtained for compositions 1 and 2 according to the invention. It will also be noted that the elongation at break at 100° C. in the tearability test is far less for the control compositions.
TABLE 2
Test 1
Test 2
Test 3
Test 4
N115
N326
N330
N347
ME 100
1.0
1.0
1.7
3.2
HL
13
10.5
12
18
Break index at 100° C. EB %
780
740
630
490
Tearability index at 100° C.
400
180
80
85
TEB %
Tom surface
9
32
87
103
EXAMPLE 2
The object of this example is to compare compositions of natural rubber reinforced with silica as a majority filler compared with control compositions based on a majority of carbon black. These compositions are set forth in Table 3. They comprise, in the case of test 5, a composition based on a majority of silica and of carbon black with Si116 as the covering agent for the silica (hexadecyltrim-ethoxysilane, from Degussa); in the case of test 6, a composition based on a majority of silica and of carbon black with polydimethylsiloxane of a molecular weight close to 400 (PDMS) as covering agent for the silica; in the case of test 7, a composition based on a majority of carbon black and of silica bonded to the elastomer with the bonding agent X50S from Degussa, and in the case of test 3 a composition based on N330. Tests 7 and 3 represent known compositions serving as controls. All these compositions are sulphur-vulcanizable.
TABLE 3
Test 5
Test 6
Test 7
Test 3
Composition
Invention
Invention
Control
Control
Natural Rubber
100
100
100
100
UVN3
35
35
15
—
Black N330
5
5
—
35
Black N347
—
—
40
—
X50S
—
—
3
—
Sill6
5.00
—
—
—
PDMS
—
2.00
—
—
ZnO
7.00
7.00
7.00
2.10
Stearic acid
1.00
1.00
2.00
1.40
Antioxidant
1.50
1.50
1.50
0.70
Sulphur
1.75
1.75
1.80
1.75
Accelerators
1.50
1.51
1.25
1.00
The compositions and vulcanizations of tests 5 to 7 and 3 are obtained under the same conditions as in Example 1.
The properties of these four compositions are compared. The results are set forth in Table 4.
TABLE 4
Test 5
Test 6
Test 7
Test 3
Composition
Invention
Invention
Control
Control
Natural Rubber
100
100
100
100
UVN3
35
35
15
—
Black N330
5
5
—
35
Black N347
—
—
40
—
X50S
—
—
3
—
Sill6
5.00
—
—
—
PDMS
—
2.00
—
—
ME100
1.0
1.2
2.9
1.7
HL 60°
13.5
15
18
12
Break index at
800
780
490
630
100° C. EB %
Tearability index at
510
500
230
80
100° C. TEB %
Tom surface
8
13
83
87
It will be noted that for the control compositions 7 and 3 the surfaces torn during the test of impact against a curb are much greater than those obtained for compositions 5 and 6 according to the invention. As in the previous example, it will be noted that the elongation at break at 100° C. in the tearability test is far less for the control compositions. As in the previous example, it will be noted that the elongation at break at 100° C. in the tearability test is far lower for the control compositions.
EXAMPLE 3
The object of this example is to compare compositions reinforced with silica as majority filler by varying the nature of the bonding and covering agents. In this example, the vulcanization system is adjusted so that the moduli of elongation at 100% are sufficiently close to draw reliable conclusions as to the effects of the parameters studied. The compositions according to the invention are set forth in Table 5. They use, in the case of tests 8, 9 and 10, compositions having silica as sole filler in an amount of 30 phr with, respectively, a coupling agent X50S (test 8), a polyethylene glycol covering agent of a molecular weight of 4000 (test 9), and another polydimethylsiloxane (PDMS) covering agent (test 10). In the case of tests 11 to 15, the reinforcing filler is formed by a blend of silica and 5 phr of N330.
TABLE 5
Test
Test
Test
Test
Test
Test
Test
Test
Composition
8
9
10
11
12
13
14
15
Natural Rubber
100
100
100
100
100
100
100
100
UVN3
30
30
30
25
30
35
30
35
Black N330
—
—
—
5
5
5
5
5
ZnO
7
7
7
7
7
7
7
7
Stearic acid
1
1
1
1
1
1
1
1
Antioxidant
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
X50S
7
—
—
—
—
—
—
—
PEG4000
—
4.3
—
—
—
—
4.3
5
PDMS
—
—
1.7
1.4
1.7
2.0
—
—
Sulphur
1.75
1.75
1.75
1.75
1.75
1.75
1.75
1.75
Accelerators
1.51
2.00
1.51
1.51
1.51
1.51
2.00
2.00
The compositions and vulcanization therefor tests 8 to 15 are obtained under the same conditions as in Example 1.
The properties of these: eight compositions are compared. The results are set forth in Table 6.
TABLE 6
Test
Test
Test
Test
Test
Test
Test
Test
Composition
8
9
10
11
12
13
14
15
ME100
1.27
1.16
0.93
0.96
1.00
0.98
1.25
1.37
HL 60°
9.4
9.6
11.7
11.4
12.7
15.6
11.3
13
EB(100° C.)
733
770
855
813
856
867
762
736
TEB(100° C.)
590
371
793
538
726
685
277
307
TBS(100°)
84
38
60
51
67
62
38
38
For tests 8, 9 and 10, it will be noted that, with an amount of silica filler which is constant and in accordance with the invention, the coupling agent X50S surprisingly provides tearability results encompassed by those obtained with the covering agent PEG4000 and the covering agent PDMS.
For tests 11, 12 and 13, in the presence of the covering agent PDMS, with an amount of black of 5 phr and an amount of silica increasing from 25 to 35 phr, the best tearability results are obtained for the intermediate amount of silica of 30 phr.
By comparing the results of tests 10 and 12, on one hand, and 9 and 14, on the other hand, it will be noted that 5 phr of carbon black added to 30 phr of silica does not fundamentally change the tearability results in the presence of the covering agents PDMS or PEG4000.
Comparison of the results of tests 14 and 15 shows that passing from 30 to 35 phr of silica in the presence of 5 phr of carbon black slightly improves the results when the covering agent PEG4000 is used, whereas the reverse effect is observed with the covering agent PDMS (tests 12 and 13).
EXAMPLE 4
The object of this example is to compare compositions reinforced with silica as sole or majority filler, where the elastomeric matrix is based on natural rubber, either pure or in a blend with another diene elastomer or based on synthetic polyisoprene having a large number of cis-1,4 bonds. These compositions are set forth in Table 7. They comprise, in the case of tests 16, 17 and 18, natural rubber filled with increasing amounts of filler. In the cases of tests 19 and 20, the natural rubber of test 18 is replaced by a blend of natural rubber with another minority diene elastomer or a cis-1,4 polybutadiene (cis-1,4 BR), obtained with a titanium-based catalyst, and a solution SBR of Mooney ML (1+4) of 54, of Tg−48° C., having a 1,2 bond content of 24% and a 16.5% styrene content. In the case of test 22, the natural rubber with 30 parts of silica filler of test 21 is replaced by a synthetic polyisoprene having a large number of cis-1,4 bonds. In the case of test 23, which is not in accordance with the invention, the blend of natural rubber and cis-1,4 BR of test 19 is filled with 30 parts of N330.
TABLE 7
Test
Test
Test
Test
Test
Test
Test
Test 23
Composition
16
17
18
19
20
21
22
Control
Natural Rubber
100
100
100
60
60
100
—
60
Polyisoprene
—
—
—
—
—
—
100
—
Solution SBR
—
—
—
—
40
—
—
—
cis-1,4 BR
—
—
—
40
—
—
—
40
UVN3
15
15
30
30
30
30
30
—
N330
—
15
15
15
15
—
—
30
Si116
2
2
4
4
4
4
4
—
ZnO
5
5
5
5
5
5
5
5
Stearic acid
1
1
1
1
1
1
1
1
Antioxidant
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
Diphenylguanidine
0.2
0.2
0.4
0.4
0.4
0.4
0.4
—
Sulphur
1.6
1.6
1.6
1.6
1.6
1.6
1.6
1.6
Accelerators
1.0
0.55
0.55
0.55
0.55
1.0
1.0
0.55
The compositions and vulcanization thereof for tests 16 to 23 are obtained under the same conditions as in Example 1.
The properties of these eight compositions are compared. The result are set forth in Table 8.
TABLE 8
Test
Test
Test
Test
Test
Test
Test
Test 23
Composition
16
17
18
19
20
21
22
Control
Natural Rubber
100
100
100
60
60
100
—
60
Polyisoprene
—
—
—
—
—
—
100
—
Solution SBR
—
—
—
—
40
—
—
—
cis-1,4 BR
—
—
—
40
—
—
—
40
UVN3
15
15
30
30
30
30
30
—
N330
—
15
15
15
15
—
—
30
ME100
0.85
0.91
0.93
0.87
0.97
0.97
0.69
1.26
HL
5.4
11.0
16.5
24.4
25.2
8.2
11.5
12.8
EB(100° C.)
834
809
845
864
830
820
857
564
TEB(100° C.)
578
359
456
401
474
552
626
146
TBS(100° C.)
36
31
41
25
34
36
28
18
For the compositions according to the invention of tests 16 to 22, the characteristics of elongation at, break in the tearability test at 100° C. are far higher than those obtained with the composition not in accordance with the invention continuing 30 phr of carbon black. The natural rubber or a synthetic cis-1,4polyisoprene or a blend of natural rubber as majority with another diene elastomer make it possible to obtain high cohesion with the silica filler or blends of silica and carbon black according to the invention.
In summary, the use of the compositions of the invention either with a carbon black filler used in an amount close to 25 phr or with a white filler of the silica and/or alumina type used alone or in a majority amount of about 35 phr, independently of whether a coupling or covering agent is used, makes it possible to show that the effects of mechanical stresses of the type of deformation imposed are less damaging than to known compositions based on carbon black as the sole or majority filler. The compositions of the invention make it possible to increase the lie of the tire, even more so since said compositions are of low hysteresis, with the consequences of lower internal heating during travel and reduced thermal and/or thermo-oxidizing degradation of the carcass reinforcement.
Of course, the invention is not limited to the examples of embodiment described previously, from which other embodiments can be conceived of.
|
The subject of the present invention is the use of cohesive, low-hysteresis compositions comprising small amounts of reinforcing fillers to produce profiled filing members arranged in the zones of the shoulder and the crown of tires in order to improve the life thereof.
| 1
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FIELD OF THE INVENTION
This invention relates generally to machine components and, more particularly, to components relatively movable with respect to one another.
BACKGROUND OF THE INVENTION
Pins and pin-like cylindrical parts are frequently used in stationary mounted "in-factory" machines and in mobile machinery to secure certain machine components to one another. One type of application for such pins involves "linking" two components together in a way that one is relatively movable with respect to the other. Rotating crank arms pinned to stationary structures are but one example. A piston-type engine as in most automobiles uses a pin to connect a reciprocating piston head with a connecting rod which not only reciprocates with the head but which also rotates through a few degrees with respect to such head.
In what might be termed small scale machines (an auto engine, for example), pin retention is by a cotter key or other type of known retainer. However, with larger machines, pin retention can be and often is a substantial design problem. Nowhere is this more true than in large mobile machines such as earth-moving and earth-excavating machinery.
Such machinery is available in a wide variety of types ranging from the familiar rubber-tire mounted and crawler-mounted to the less-common dragline. A dragline is often used for removing top soil and "overburden" to expose a valuable mineral, e.g., coal, beneath but near the earth's surface.
Draglines are equipped with an angularly-extending boom from which is suspended a "bucket" having an open mouth and digging teeth, both toward the main portion of the machine. Overburden is removed by placing the bucket on the ground at a point distant from the machine and pulling it toward the machine, filling the bucket in the process. Once filled, the machine pivots about a central axis and the bucket emptied at a spoil pile somewhat away from the area being excavated.
Smaller draglines are crawler mounted (much like a military tank) and capable of movement in the same way albiet at much slower speeds. However, as draglines (and their digging buckets) increased in size, crawler mounting was found to be impractical and in the early 1900's, the "walking" dragline was developed. The walking dragline is so named because it takes short "steps" and uses a "walk leg" mechanism (which resembles a human leg) to do so. A difference is that in a walking dragline, both legs step simultaneously.
To give some perspective to the following discussion, a large walking dragline--made by Harnischfeger Industries of Milwaukee, Wisconsin, and incorporating the invention--has a main housing portion (including the machinery deck, operator's cab and the like) which is about 105 feet long, about 80 feet wide, about 40 feet high and weighs about nine million pounds. The boom extends about 300 feet and the capacity of the digging bucket is about 80 cubic yards. The walk legs of such dragline take steps about seven feet in length.
At least because of its size, weight and complexity, several problems attend draglines of earlier configuration. One is that such machines are usually used in remote sites and replacement parts are difficult to deliver and, because of their size and weight, even more difficult to install. Another is that the machine is shipped in pieces to the site and erected there. While certain types of relatively "loose tolerance" machining equipment are available to facilitate machine assembly (which can take several months), close tolerance machining equipment is not available, at least not readily so.
Wear cannot be avoided in any device having relatively moving parts but the efforts of earlier designers of draglines have not been entirely successful in reducing the effect of wear. For example, some known draglines are configured so that wear between parts involved at least one expensive, heavy, hard-to-replace part. And while such parts have been relatively durable and in many cases last for years, repair is accomplished only at great expense for the purchased part and at extended downtime. A machine like a walking dragline represents an enormous capital investment and working "uptime" must be maximized.
Yet another difficulty with earlier draglines is that they were sometimes designed and built with "loose" clearances where close or "zero clearance" construction would have been preferred. In the alternative, small clearances were used where indicated and the necessary close-tolerance machining was undertaken in the field at great expense and, on occasion, with questionable results.
As will become apparent, the invention resolves some of these difficulties in unique and imaginative ways.
OBJECTS OF THE INVENTION
It is an object of the invention to provide an improved walking dragline overcoming some of the problems and shortcomings of the prior art.
Another object of the invention is to provide an improved apparatus for handling a machine pin and apparatus and method for retaining the pin in the machine.
Yet another object of the invention is to provide, in a mechanism having a housing and a pin, means for preventing pin rotation with respect to the housing.
Another object of the invention is to provide such a mechanism in which pin movement in axial directions is limited.
Still another object of the invention is to provide a pin retention apparatus permitting certain "zero clearance" assembly while yet avoiding close tolerance machining at the factory or in the field.
Another object of the invention is to provide an improved walk leg mechanism for a walking dragline.
Still another object of the invention is to provide an improved method of assembling a dragline walk-like mechanism, shortening dragline assembly time.
How these and other objects are accomplished will become apparent from the following descriptions and the drawing.
SUMMARY OF THE INVENTION
The invention is an improvement in a machine of the type having a housing and a pin received in the housing. The improvement comprises a retainer attached to the pin and including a plurality of radially-extending retaining arms. Attachment is preferably at an exposed first pin end.
Also included is a plurality of abutment members, each of which is in contact with a retaining arm. Because of the member-arm contact, the pin is prevented from rotating with respect to the housing. Such improved arrangement is highly advantageous since the pin, a wearing part like the bushing, is intended for eventual replacement when sufficiently worn. On the other hand, the housing is very heavy, is intended to be a nonwearing part and is expensive and time-consuming to replace.
In a highly preferred embodiment, each abutment member extends between two retaining arms and contacts both retaining arms. Since each abutment member is welded to the housing along substantially the entirety of its length (and therefore provides substantial resistance to shearing forces), the arrangement provides maximum torsional resistance to pin rotation. More specifically, the abutment members are positionally located on the face of the housing during pin insertion and are thereupon welded to the housing. This eliminates any special measuring or handling of the abutment members.
Although prevented from even small incremental rotation with respect to the housing, the pin is capable of limited axial movement with respect to such housing. However, the retainer limits pin movement in a first axial direction, i.e., in a direction away from the retainer. Such movement is limited by the retainer arms bearing against the housing. When a keeper plate is mounted to extend between two abutment members, pin movement in a second axial direction, i.e., a direction toward the keeper plate, is also limited.
And unlike certain other types of pin retainers, the invention is useful with a pin mounted in a blind opening, i.e., an opening of the type preventing access to the second pin end. Irrespective of whether both pin ends are accessible, the improvement also includes structure to redundantly limit pin movement in one or both directions. This "belt and suspenders" approach is especially desirable where the pin is not readily visible to maintenance personnel or where, as in earth-moving machinery, the machine is involved in a virtually continuous, heavy duty, "hard working" application where downtime is enormously expensive.
Accordingly, in another aspect of the invention, the housing includes a bore step redundantly limiting pin movement in the first axial direction. That is, the bore step is redundant as to the retainer which also limits pin movement in such direction.
A keeper plate mounted to extend between two abutment members limits pin movement in a second axial direction or, in the alternative, a retaining collar limits pin movement in such direction. Yet another way to limit pin movement in both axial directions is to attach first and second retainers to the first and second ends, respectively, of the pin. That is, the second retainer is redundant as to the keeper plate or as to the collar.
In another aspect of the invention, the retainer includes at least three retaining arms and to maximize the length of the weld between each abutment member and the housing, the number of abutment members is equal to the number of retaining arms. In a highly preferred embodiment, the retainer includes four retaining arms and is cruciform-shaped.
A method of assembling machine components such as a housing and a pin includes the steps of providing a pin retainer having a plurality of arms and attaching the retainer to the pin, preferable by several bolts inserted through the retainer and threaded to the pin. The pin is then inserted in an opening in the housing. With large pins, the pin-inserting step may also include positioning the pin at least in part by attaching a lifting device to the retainer. Steps also include mounting a plurality of abutment members on the housing so that each abutment member is in contact with at least one arm.
Mounting is by positioning each abutment member to contact an arm and thereupon welding the abutment member to the housing. There is then substantially "zero clearance" between each abutment member and an arm and the pin is prevented from rotating with respect to the housing. And it is to be appreciated that such zero clearance mounting prevents even small increments of rotational movement of the pin in the housing and accomplishes that result without resorting to close-tolerance machining in the field.
As briefly mentioned above, a highly preferred method includes the step of mounting a plurality of keeper plates, each plate extending between a pair of abutment members. The keeper plates are mounted by bolts and the plates and abutment members are pre-drilled with bolt holes prior to mounting. The importance of predrilling and the reason it is possible will become more apparent from the detailed description. However, one point is immediately apparent--drilling need not be done under usually-difficult field conditions.
Merely by way of example, the invention is disclosed in connection with a dragline of the type which is self-propelled over a limited range by a walk-like mechanism often referred to as a "walk leg" because of its resemblance, in shape and motion, to the human leg. The mechanism has a housing and a pin received in the housing and coupled to a "knee link," either directly or by using a bushing (which may or may not be replaceable) interposed between the link and the pin. The knee link may also be replaceable but at greater expense than a bushing.
Very large, heavy machines such as walking draglines are shipped to the field work site in pieces and assembled there. Finish boring and facing equipment is assumed to be available at the site for final boring of the hole in the housing through which the pin is inserted and for "facing off" the external portion of the housing adjacent to the hole. However, no equipment is available for close-tolerance machining and fitting of parts.
In an exemplary large dragline, the pin is nearly two feet in diameter, more than two and one-half feet in length and weighs about 2,400 pounds. And in one specific embodiment, the cruciform-shaped retainer weighs about 240 pounds. Clearly, it is very difficult for workers to mount the retainer after pin placement and impossible to manually place the pin into position in the housing. In an aspect of the invention, the retainer is attached to the pin before the pin is inserted and insertion includes positioning the pin at least in part by attaching a lifting device, e.g., a crane sling, to the retainer. In the vernacular, the retainer provides a "handle" for the pin.
Other aspects of the invention are set forth in the following detailed description and the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a representative side elevation view of a walking dragline.
FIG. 2 is a top plan view, in phantom, of the main housing portion of the dragline of FIG. 1, taken along the viewing plane 2--2 thereof and with parts broken away.
FIGS. 3A-3G show a sequence of operation of one of the walk legs of the dragline of FIG. 1.
FIG. 4 is an isometric view of the dragline walk leg shown with related supporting structure.
FIG. 5 is an elevation view of a portion of the walk leg housing (part of which is broken away) and the pin and retainer taken along the viewing axis VA5 of FIG. 4.
FIG. 6 is an elevation view, partly in cross-section, of the structure of FIG. 5. Abutment members are omitted for clarity
FIG. 7 is an elevation view, partly in cross-section, of a portion of the structure of FIG. 6.
FIG. 8A is an elevation view, partly in cross-section, of a structure similar to that of FIG. 6 but involving a pin in a "blind" opening having a bore step limiting pin axial movement.
FIG. 8B is an elevation view generally like that of FIG. 8A except that the pin is in an opening of uniform diameter.
FIG. 9 is an elevation view of another embodiment of the retainer and abutment member.
FIG. 10 is an elevation view of yet another embodiment of the retainer and other embodiments of the abutment member.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Before describing the preferred embodiments, it should be appreciated (and persons of ordinary skill will appreciate) that the improved apparatus 10 and method are applicable to stationary mounted "in-factory" machines and to mobile machinery to secure certain machine components to one another. The invention has special appeal in applications where pins "link" two components together in a way that one is relatively movable with respect to the other. The invention clearly offers convenience in machines of moderate size and becomes more compelling as the size of the machine increases. To help "dramatize" and emphasize this fact, the invention is disclosed in connection with one of the largest types of machines in the world, a walking dragline 11.
Referring first to FIGS. 1 and 2, an exemplary walking dragline 11 includes a main housing portion 13 having a boom 15 extending therefrom to support and manipulate a digging bucket 17. Within the housing portion 13 are mounted the bucket hoist, bucket drag and swing systems 19, 21 and 23, respectively. The drive 25 for the "walking" system is also mounted therein. When digging, the dragline 11 sits on and pivots about a generally circular "tub" or platform 27 which rests on the earth's surface 29.
The dragline 11 also includes a pair of pads or "shoes" 31 which, when moved in unison as described below, lift the platform 27 and move the dragline 11 rearward away from the bucket 17. Movement in the exemplary dragline 11 is in "steps" of about seven feet in length and along the long axis 33 of the main housing portion 13.
Referring additionally to FIGS. 3A-3G and FIG. 4, a walk-like mechanism 35 typically includes a walk leg structure 37, a driven eccentric 39 and a knee link 41. The knee link 41 has its upper end 43 coupled to the walk leg housing 45 by a pin 47 to permit relative rotation of a few degrees between the link 41 and the housing 45. The lower end 49 of the knee link 41 is similarly coupled to the nearby main housing structure 37. As a rough analogy, the coupling at the upper end 43 of the link 4 is analogous to the human knee and the eccentric 39 is analogous to the human hip joint. While pin 47 is shown to be hollow, it could be a solid pin 47. In FIG. 4, numeral 39 indicates the location of the eccentric shown in FIGS. 3C and 3F.
As the eccentric 39 is driven counterclockwise (in FIG. 4 and in the right-side sequence of FIGS. 3A-3G) through one revolution, the shoe 31 is lowered to ground contact and the dragline 11 lifted and moved rearward. The shoe 31 is then raised until the platform 27 again rests on the surface 29.
Since the bucket 17 is drawn toward the dragline 11, removal of overburden 51 progresses toward the dragline 11 until the edge 53 of the pit becomes relatively near to the dragline 11. Therefore, the dragline 11 must occasionally be moved rearward a few feet to expose additional overburden 51 for digging.
Detailed aspects of the inventive apparatus 10 will now be described with reference to FIG. 5 and, particularly, to FIG. 6. The housing 45 includes outer and inner walls 55 and 57, respectively, each having a flat, annular face 59. Each face 59 is concentric with the long axis 61 of the pin 47, defines a plane normal to the pin 47 and also has an edge 63 which defines an opening 65 in the housing wall 55 and 57, respectively. The pin 47 connects the upper end 43 of the knee link 4 with the housing 45 and in a highly preferred, more-readily-repairable arrangement, includes a bushing 67 press-fitted into the end 43 and interposed between the end 43 and the pin 47. The knee link 41 (if devoid of a bushing) and the pin 47 are both considered expendable parts, the bushing 67 may be expendable and all three parts are replaced rather readily (but at varying cost) when sufficiently worn.
As is apparent from FIG. 6 and as the knee link 41 "swings", relative motion can and does occur between the bushing 67 and the pin 47. Unless prevented, relative motion could also occur between the pin 47 and the housing 45. Such motion prevention is important since, unlike the pin 47, bushing 67 and, possibly, the knee link 41, the housing 45 is a very heavy, expensive component which is difficult to replace in the field.
Referring particularly to FIG. 5, a retainer 69 has a plurality of arms 71 extending radially outward. Preferably, each arm 71 is of generally uniform width along its length, the arms are of generally uniform width one to the other and the retainer 69 is of uniform thickness.
The retainer 69 is attached to the outer end 72 of the pin 47 by a plurality of bolts 73 extending through each retainer arm 71 and threaded into appropriate holes in the pin end 72. In a highly preferred arrangement, slots 75 are milled in the first end 72 of the pin 47 to receive the retainer 69. In that way, the bolts 73 are isolated from shear forces. The retainer 69, weighing about 220 pounds in a specific embodiment, is very sturdy and limits pin movement in the first or inward axial direction, i.e., to the left in FIG. 6.
The pin 47 and openings 65 in the housing walls 55, 57 are cooperatively sized so that the pin 47 is received in the housing 45 with very slight clearance. Because of its weight as described in the exemplary dragline 11, it is highly advantageous to attach the retainer 69 to the pin prior to inserting the pin 47 in the openings 65. This is particularly true where the pin 47 is to be inserted into an opening 65 having a stepped bore as shown in FIG. 8A where external lifting devices are not readily adaptable. The inventive arrangement readily permits such "pre-attachment." Another advantage of this arrangement is that the retainer 69 can be used (with appropriate lifting equipment) to help lift the pin 47 and facilitate pin insertion.
Depending upon the specific machine configuration, the first pin end 72 or both the first and second pin ends 72, 77 may be exposed for attachment of retainers 69 or retaining devices. Later in the specification, there is explanation of ways to provide redundant pin retention in "through" or "blind" openings.
After the pin 47 is inserted through the openings 65, abutment members 79 are placed against each face 59 and positioned so that each end of each abutment member 79 is in contact with a retainer arm 71. Once positioned, each abutment member 79 is welded to the face 59 along the inner and outer member edges 81 and 83, respectively. It will be observed that each abutment member 79 is relatively long and, referred to the pin axis 61, spans an arc of about 80° or so in the preferred embodiment. However, intersecting lines extending from the ends 85 of each member 79 defines an angle of 90°. Since welding is preferably along both edges 81, 83 there is substantial strength and resistance to the torsional loads that may be applied to the abutment members 79 by the pin 47 through the arms 71.
lt should be appreciated that instead of using milled slots 75, the retainer 69 can be doweled to the pin 47 to absorb shear forces. Similarly, the abutment members 79 can be doweled and/or bolted to the face 59 rather than being welded thereto. But these are more complex approaches than that described above.
Without the abutment members 79, it is apparent from FIG. 5 that the pin 47 would have a tendency to undesirably rotate incrementally in the housing 45. And it is to be appreciated that each abutment member 79 is brought to and secured in a "zero clearance" position with respect to the arms 71 with which it is in contact. Essentially no rotational movement of the pin 47 occurs and such result is achieved without close tolerance machining, either at the factory or in the field.
For reasons explained below and as shown in FIG. 7, the abutment members 79 are selected to have a thickness slightly greater than the thickness of the retainer 69 and arms 71. A relatively light weight keeper plate 87 spans each pair of abutment members 79 and is secured by bolts 89 threaded into the abutment members 79. Because of the disparity in thickness between the members 79 and the arms 71, a slight clearance 91 is provided between the keeper plate 87 and the arm 71.
For the reasons mentioned above, it may be important to provide redundant retention of pins 47 to prevent excessive axial movement. And such retention should be available for either "through" openings (where both ends 72, 77 of the pin 47 are accessible) or "blind" openings where only one end 72 is accessible.
Referring again to FIG. 6, the housing has a through opening 65 and pin movement in the second axial direction (to the right in the FIGURE) is limited by a split retaining collar 93 as well as by the keeper plates 87. It should be appreciated that a second retainer 69 or another type of retaining device could be attached to the pin second end 77 to provide redundancy.
Referring additionally to FIG. 8A, the housing 45 has a blind opening which includes a bore "step" or shoulder 95 limiting movement of the pin 47 in the first or leftward axial direction. Such shoulder 95 is redundant as to the retainer 69 which likewise limits such movement.
As shown in FIG. 5, a highly preferred retainer 69 is cruciform is shape and has four retaining arms extending radially outward and spaced about 90° apart. And other variations are possible. For example, FIG. 9 shows a retainer 69 having three retaining arms 71 spaced about 120° apart while FIG. 10 shows a bar-like retainer 69 having two arms 71 spaced about 180° apart. In each instance, each corresponding abutment member 79 has a length selected to span the distance between two adjacent arms 71. And in all embodiments, the number of one-piece abutment members 79 is equal to the number of arms 71.
After appreciating the foregoing, one of ordinary skill will understand that as shown in FIG. 9, short arc-shaped blocks could be used as abutment members 79. However, the preferred embodiments are selected to optimize resistance to torsional loading and simplicity of assembly, the latter by minimizing the number of pieces.
But that is not all. There is another, highly advantageous aspect to the inventive apparatus 10. Referring again to FIGS. 6 and 9, it will be recalled that each retainer arm 71 is of generally uniform width along its length and that the arms 71 are of generally uniform width one to the other. The spacing 98 between each pair of bolts 89 holding a keeper plate 87 and between each pair of abutment member holes 101 in which the bolts 89 are received is a function of arm width but, importantly, not of the relative position of the abutment members 79 with respect to the arm center 99. And the foregoing is true even if the arms 71 are tapered somewhat on each side rather than being of uniform width.
Using the three-legged retainer 69 of FIG. 9 as an example, an abutment member 79 can be at a position shown in solid outline or a shorter member 79 at a position shown in dashed outline (or anywhere in between) and the bolt hole spacing 98 does not change. The functional result is that all bolt holes 101 can be drilled and, where necessary, tapped at the factory prior to shipment. No close tolerance drilling need be done in the field and this fact is of substantial importance with larger, field erected machines.
While the invention has been shown and described in connection with a few preferred embodiments and in connection with a specific machine, a walking dragline 11, it should be clearly understood that such embodiments are exemplary and not intended to be limiting.
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The invention is an improvement in a machine having a housing and a pin received in the housing and coupled to a link-like movable part, either directly or with a bushing interposed between the part and the pin. The improvement comprises a retainer, preferably of cruciform-shape, which is attached to one end of the pin and has a plurality of radially-extending retaining arms. The improvement also includes a plurality of arc-shaped abutment members, each of which extends between and is in torque-absorbing contact with a pair of arms. The pin, a wearing component like the movable part or the bushing, is intended for eventual replacement when sufficiently worn. The pin is prevented from rotating with respect to the housing which is a non-wearing part expensive to replace or repair. The invention also includes a method for assembling machine components including a housing and a pin so that there is substantially zero clearance between each abutment member and a retainer arm. Relative pin-housing rotational or axial movement is prevented without the necessity of resorting to close-tolerance machining at the field erection site.
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TECHNICAL FIELD
[0001] The present invention relates to a hair regrowth promoter and use thereof. The present invention also relates to a method for promoting hair regrowth.
BACKGROUND ART
[0002] Many people are concerned about alopecia caused by aging, genetic predisposition, social stress or other reasons. Under such circumstances, various products have been developed, including hair growers for promotion of hair growth and anti-alopecia agents for prevention of hair loss.
[0003] A known example is an anti-alopecia agent containing a soybean protein-derived peptide with a specific sequence as an active ingredient (Patent Literature 1).
[0004] The inventors have conducted studies on the functions of egg-yolk protein hydrolysates, and found that egg-yolk protein hydrolysates have antioxidant effect (Patent Literature 2), bone strengthening effect (Patent Literature 3), chondrocyte growth-promoting effect (Patent Literature 4), and other effects. However, no report has been made on hair regrowth-promoting effect of egg-yolk protein hydrolysates, which effect has no correlation with antioxidant effect, bone strengthening effect, or chondrocyte growth-promoting effect.
CITATION LIST
Patent Literature
[0005] Patent Literature 1: JP 2008-247874 A
[0006] Patent Literature 2: JP 2001-328919 A
[0007] Patent Literature 3: WO 2006/075558
[0008] Patent Literature 4: WO 2014/007318
SUMMARY OF INVENTION
Technical Problem
[0009] An object of the present invention is to provide a novel use of an egg-yolk protein hydrolysate.
Solution to Problem
[0010] The present invention was made to solve the above problem and includes the following.
(1) A hair regrowth promoter comprising an egg-yolk protein hydrolysate as an active ingredient. (2) The promoter according to the above (1), which has a promoting effect on the production of a growth factor in hair follicle dermal papilla cells. (3) The promoter according to the above (2), wherein the growth factor is one or more selected from the group consisting of vascular endothelial growth factor (VEGF), fibroblast growth factor-7 (FGF-7) and insulin-like growth factor-1 (IGF-1). (4) The promoter according to any one of the above (1) to (3), which is in a form of an oral preparation. (5) A hair regrowth-promoting medicament comprising the promoter according to any one of the above (1) to (3). (6) A hair regrowth-promoting dietary supplement comprising the promoter according to any one of the above (1) to (3). (7) A hair regrowth-promoting food additive comprising the promoter according to any one of the above (1) to (3). (8) Use of an egg-yolk protein hydrolysate for production of a hair regrowth promoter. (9) A non-therapeutic method for promoting hair regrowth, the method comprising orally administering an egg-yolk protein hydrolysate to a human in need of promotion of hair regrowth.
[0020] The present invention further includes the following.
(10) A method for promoting hair regrowth, the method comprising administering an effective amount of the promoter according to any one of the above (1) to (3) to an animal in need of promotion of hair regrowth. (11) Use of the promoter according to any one of the above (1) to (3) for promotion of hair regrowth. (12) The promoter according to any one of the above (1) to (3) for use in promotion of hair regrowth. (13) A food for specified health use, a dietary supplement, a supplemental food, or a functional food, comprising the promoter according to any one of the above (1) to (3) and bearing a statement indicating hair regrowth-promoting effect.
Advantageous Effects of Invention
[0025] The present invention provides a hair regrowth promoter comprising an egg-yolk protein hydrolysate as an active ingredient. The egg-yolk protein hydrolysate is a safe ingredient produced from a natural source, and therefore can be widely used in daily consumable products, such as food and drink products, medicaments, animal feeds, and dietary supplements, or as a food additive, etc. The promoter etc. of the present invention can be orally administered and is thus very advantageous.
BRIEF DESCRIPTION OF DRAWINGS
[0026] FIG. 1 is a graph showing the results of molecular weight analysis of an egg-yolk protein hydrolysate of Example 1 by gel filtration chromatography.
[0027] FIG. 2 is a graph showing the areas of dorsal regions covered with new hair in mice on Day 17 of feeding with a feed mixed with an egg-yolk protein hydrolysate.
[0028] FIG. 3 is photographs showing the comparison of the appearance of dorsal regions covered with new hair in mice fed with a regular feed and in mice fed with a feed mixed with an egg-yolk protein hydrolysate on day 17 of feeding.
[0029] FIG. 4 is a graph showing the VEGF production-promoting effect of an egg-yolk protein hydrolysate on hair follicle dermal papilla cells.
[0030] FIG. 5 is a graph showing the FGF-7 mRNA expression-enhancing effect of an egg-yolk protein hydrolysate on hair follicle dermal papilla cells.
[0031] FIG. 6 is a graph showing the IGF-1 mRNA expression-enhancing effect of an egg-yolk protein hydrolysate on hair follicle dermal papilla cells.
[0032] FIG. 7 is photographs showing the comparison of the appearance of dorsal regions covered with new hair in telogen-induced mice fed with a regular feed and in telogen-induced mice fed with a feed mixed with an egg-yolk protein hydrolysate on day 14 of feeding.
DESCRIPTION OF EMBODIMENTS
[0033] The present invention provides a hair regrowth promoter comprising an egg-yolk protein hydrolysate as an active ingredient.
[0034] The egg-yolk protein hydrolysate may be any egg-yolk protein hydrolysate as long as it is obtained by hydrolysis of an egg yolk protein. The egg yolk used as a raw material of the egg-yolk protein hydrolysate may be an egg yolk of chicken, duck, quail, etc., but an egg yolk of chicken is preferred to achieve high productivity. The egg yolk used herein may be in the form of an egg yolk liquid, an egg yolk powder, a defatted egg yolk powder, etc., but preferred is an egg yolk powder or a defatted egg yolk powder. For effective use of resources and high cost performance, preferred is a defatted egg yolk that is obtained as a by-product of a production process of an egg yolk oil or an egg yolk lecithin from an egg yolk. Defatting of an egg yolk is preferably performed by treating the egg yolk with an organic solvent usable for food processing (for example, at least one selected from ethanol, isopropanol, hexane, etc.). Typically, defatting of an egg yolk is carried out by adding such a solvent to an egg yolk, stirring the mixture, and collecting the resulting solids. This procedure may be repeated more than once. Ethanol is preferred to achieve convenience and safety.
[0035] The hydrolysis of an egg yolk protein is performed with the aid of an enzyme. The enzyme is not particularly limited, but preferred is an enzyme that has protease or carboxypeptidase activity and is usable for food production. Examples of the enzyme include pepsin (EC.3.4.23.1), trypsin (EC.3.4.21.4), renin (EC.3.4.23.15), rennet, which contains renin and is used for cheese making, carboxypeptidase A (EC. 3.4.17.1), proteases from Bacillus bacteria (trade name “Alcalase” produced by Novozymes A/S, trade name “Orientase 22BF” produced by HBI Enzymes Inc., trade name “Nukureishin” produced by HBI Enzymes Inc., trade name “Protease S ‘Amano’ G” produced by Amano Enzyme, Inc., trade name “THERMOASE PC10” produced by Daiwa Fine Chemicals Co., Ltd., etc.), proteases from Aspergillus fungi (trade name “Orientase ONS” produced by HBI Enzymes Inc., trade name “Orientase 20A” produced by HBI Enzymes Inc., trade name “Protease P ‘Amano’ 3G” produced by Amano Enzyme, Inc., trade name “Flavourzyme” produced by Novozymes A/S, etc.), etc. These enzymes for hydrolysis of an egg yolk protein may be used alone or in combination of two or more types. Preferred are a protease from Bacillus bacteria, pepsin, and a combination thereof.
[0036] The concentration of the enzyme for hydrolysis of an egg yolk protein is appropriately adjusted depending on the raw material egg yolk and the enzyme to be used. When a defatted egg yolk is used as the raw material, the mass ratio of the enzyme to the defatted egg yolk is preferably in the range between about 1:20 and about 1:1000. The enzyme reaction temperature and the reaction time also vary depending on the raw material egg yolk and the enzyme to be used. Preferably, the hydrolysis is performed at about 25 to 75° C. for about 1 to 24 hours.
[0037] The thus prepared egg-yolk protein hydrolysate may be desalted as needed and directly used. Alternatively, the egg-yolk protein hydrolysate obtained as above may be used after purification and/or fractionation by ultrafiltration, gel filtration, various column chromatographic techniques, membrane filter filtration, methods using an isoelectric point, etc. The hair regrowth-promoting effect of the egg-yolk protein hydrolysate after purification and/or fractionation can be assessed by, for example, the methods described in Examples 2 and 3.
[0038] The molecular weight distribution of the egg-yolk protein hydrolysate as determined by gel filtration chromatography is preferably such that the peak area percentage for a molecular weight range of about 100 to about 20,000 is about 65% or more of the total area of all the peaks of proteins, peptides and amino acids. More preferably, the peak area percentage is about 75% or more, further more preferably about 85% or more, further more preferably about 90% or more, of the total area.
[0039] A more preferred egg-yolk protein hydrolysate is one obtained through fractionation using an ultrafiltration membrane with a molecular weight cut-off of 1,000, wherein the molecular weight distribution of the hydrolysate as determined by gel filtration chromatography is such that the peak area percentage for a molecular weight range of about 500 to about 20,000 is about 85% or more, preferably about 90% or more, of the total area of all the peaks of proteins, peptides and amino acids.
[0040] The egg-yolk protein hydrolysate prepared as above has hair regrowth-promoting effect, hair growth-promoting effect, hair nourishing effect, anti-alopecia effect, etc. The egg-yolk protein hydrolysate is thus suitable as an active ingredient of hair regrowth promoters, hair growth promoters, hair nourishers, anti-alopecia agents, etc. Thus, the hair regrowth promoter of the present invention may also be referred to as a hair growth promoter, a hair nourisher, or an anti-alopecia agent.
[0041] The amount of the egg-yolk protein hydrolysate contained in the hair regrowth promoter of the present invention is not particularly limited, but is preferably about 0.05 to about 50% by mass, more preferably about 0.1 to about 25% by mass. The daily dose of the egg-yolk protein hydrolysate varies depending on the subject, but in cases where the subject is, for example, a human adult, the daily dose is typically about 0.05 to about 2000 mg/day, and is preferably about 0.1 to about 1000 mg/day.
[0042] The hair regrowth promoter of the present invention promotes the production of a growth factor in hair follicle dermal papilla cells. The growth factor is not particularly limited, and examples thereof include vascular endothelial growth factor (VEGF), fibroblast growth factor-7 (FGF-7), insulin-like growth factor-1 (IGF-1), etc. Preferably, the growth factor is one or more selected from the group consisting of VEGF, FGF-7, and IGF-1, and is more preferably VEGF, FGF-7, and IGF-1. The hair regrowth promoter of the present invention may also be referred to as a promoter for the production of a growth factor in hair follicle dermal papilla cells, a promoter for the production of vascular endothelial growth factor (VEGF) in hair follicle dermal papilla cells, a promoter for the production of fibroblast growth factor-7 (FGF-7) in hair follicle dermal papilla cells, or a promoter for the production of insulin-like growth factor-1 (IGF-1) in hair follicle dermal papilla cells.
[0043] The hair regrowth promoter of the present invention can be administered to a mammal via an oral or parenteral route. Examples of oral preparations include granules, powders, tablets (including sugar-coated tablets), pills, capsules, syrups, emulsions, suspensions, etc. Examples of parenteral preparations include injections (e.g., subcutaneous, intravenous, intramuscular, and intraperitoneal injections), intravenous infusions, external preparations for skin (e.g., transnasal preparations, transdermal preparations, and ointments), suppositories (for example, rectal suppositories, and vaginal suppositories), etc. These preparations can be formulated with a pharmaceutically acceptable carrier in accordance with the usual pharmaceutical practice. Examples of the pharmaceutically acceptable carrier include excipients, binders, diluents, additives, fragrances, buffering agents, thickeners, colorants, stabilizers, emulsifiers, dispersants, suspending agents, preservatives, etc. Specific examples of the carrier include magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethyl cellulose, low melting wax, cacao butter, etc.
[0044] Preferably, the oral solid preparations (tablets, pills, capsules, powders, granules, etc.) are produced by mixing the active ingredient with an additive, such as an excipient (lactose, mannitol, glucose, microcrystalline cellulose, starch, etc.), a binder (hydroxypropyl cellulose, polyvinylpyrrolidone, magnesium aluminometasilicate, etc.), a disintegrant (calcium carboxymethyl cellulose etc.), a lubricant (magnesium stearate etc.), a stabilizer, a solubilizer (glutamic acid, aspartic acid, etc.) and/or the like, and processing the mixture into the dosage form of interest in the usual manner. If needed, the oral solid preparations may be covered with a coating material (sucrose, gelatin, hydroxypropyl cellulose, hydroxypropyl methylcellulose phthalate, etc.), or alternatively, the oral solid preparations may be covered with two or more coating layers.
[0045] The oral liquid preparations (solutions, suspensions, emulsions, syrups, elixirs, etc.) can be produced by dissolving, suspending or emulsifying the active ingredient in a commonly used diluent (purified water, ethanol, a mixture of them, etc.). The oral liquid preparations may further comprise a wetting agent, a suspending agent, an emulsifier, a sweetener, a flavoring agent, a fragrance, a preservative, a buffering agent and/or the like.
[0046] The parenteral preparations are, for example, external preparations for skin. The external preparations for skin can be in the form of solutions, creams, ointments, gels, aerosols, etc., but the dosage forms are not limited thereto. Other dosage forms suitable for external use may also be employed.
[0047] The external preparations for skin can comprise, as needed, water, a lower alcohol, a solubilizer, a surfactant, an emulsion stabilizer, a gelatinizing agent, an adhesive and/or other ingredients, as well as a commonly used base appropriate for the desired dosage form. The external preparations for skin may further comprise, as appropriate, a vasodilator, a corticosteroid, a moisturizer, a microbicide, a cooling agent, a vitamin, a fragrance, a pigment and/or the like in accordance with the intended use unless the additives impair the effects of the present invention.
[0048] Other examples of the parenteral preparations include injections. The injections include solutions, suspensions, emulsions, and solid injectable preparations that are intended to be dissolved or suspended in a solvent at the time of use. The injections can be produced by dissolving, suspending or emulsifying the active ingredient in a solvent. Examples of the solvent include distilled water for injection, physiological saline, vegetable oils, alcohols such as propylene glycol, polyethylene glycols and ethanol, and a combination thereof. The injections may further comprise a stabilizer, a solubilizer (glutamic acid, aspartic acid, polysorbate 80 (registered trademark), etc.), a suspending agent, an emulsifier, a soothing agent, a buffering agent, a preservative, and/or the like. The injections are sterilized in the final step of the production process or produced in an aseptic manner. Alternatively, sterile solid preparations, for example, lyophilized preparations may be produced for use as injections. Such sterile solid preparations are intended to be dissolved in a sterilized or aseptic distilled water for injection or another solvent at the time of use.
[0049] The present invention provides a medicament for promoting hair regrowth. The medicament of the present invention may be any type of medicament as long as it comprises the above hair regrowth promoter of the present invention. The medicament of the present invention may be in the form of an oral solid preparation (a tablet, a pill, a capsule, a powder, granules, etc.), an oral liquid preparation, etc. These preparations can be formulated in the same manner as above.
[0050] The present invention provides a dietary supplement for promoting hair regrowth. The dietary supplement of the present invention may be any type of dietary supplement as long as it comprises the above hair regrowth promoter of the present invention. The dietary supplement of the present invention may be in the form of an oral solid preparation (a tablet, a pill, a capsule, a powder, granules, etc.), an oral liquid preparation, etc. These preparations can be formulated in the same manner as above.
[0051] The present invention is intended to provide not a food or drink itself but a food or drink product to which the egg-yolk protein hydrolysate for promoting hair regrowth has been added or which has an increased content of the egg-yolk protein hydrolysate. The food or drink product of the present invention may be any type of food or drink product as long as it comprises the above hair regrowth promoter of the present invention. Examples of the food or drink product include health foods, functional foods, foods for specified health use, and foods for the sick. The form of the food or drink product is not particularly limited, and the food or drink product may be in the form of a processed food or drink, such as a liquid diet, a low residue diet, and an elemental diet, or an energy drink. Examples of the food or drink product include drinks such as tea drink, soft drink, carbonated drink, nutritional drink, fruit juice and lactic drink; noodles such as buckwheat noodle, wheat noodle, Chinese noodle and instant noodle; sweets and bakery such as hard candy, candy, chewing gum, chocolate, snack, biscuit, jelly, jam, cream, baked sweets and bread; processed fishery and livestock products such as fish cake, ham and sausage; dairy products such as processed milk and fermented milk; fats, oils and processed fat and oil products such as vegetable oil, tempura oil, margarine, mayonnaise, shortening, whipped cream and dressing; seasonings such as sauce and dipping sauce; retort pouch food products such as curry, stew, rice bowl, rice porridge and rice soup; and frozen desserts such as ice cream, sherbet and shaved ice. The food or drink product of the present invention includes a food for specified health use, a dietary supplement, a supplemental food, and a functional food, each bearing a statement indicating hair regrowth-promoting effect. The food or drink product of the present invention may comprise a pharmaceutical excipient, such as lactose, starch, crystalline cellulose, and sodium phosphate.
[0052] The present invention is intended to provide not a food or drink itself but a food additive for promoting hair regrowth. The food additive of the present invention may be any type of food additive as long as it comprises the above hair regrowth promoter of the present invention. The form of the food additive of the present invention is not particularly limited, and may be, for example, a liquid, a paste, a powder, flakes, granules, etc. The food additive of the present invention includes an additive for drinks. The food additive of the present invention can be produced in accordance with a conventional production process for food additives.
[0053] The present invention provides an animal feed for promoting hair regrowth. The animal feed of the present invention may be any type of animal feed as long as it comprises the above hair regrowth promoter of the present invention. Examples of the animal feed include feeds for domestic animals, such as cattle, horses, pigs, sheep, goats, llamas, alpacas, camels, rabbits, minks, foxes, chinchillas, geese, and ducks; feeds for companion animals, such as dogs and cats; etc. The animal feed of the present invention can be produced with the addition of the hair regrowth promoter of the present invention etc., in accordance with a conventional production process for animal feeds.
[0054] The egg-yolk protein hydrolysate as an active ingredient of the hair regrowth promoter of the present invention is a substance present in an egg yolk, which already has a long history as a food. The egg-yolk protein hydrolysate is therefore highly safe and has mild effects, and hence can be administered or used for a long period of time. The egg-yolk protein hydrolysate as an active ingredient is a multifunctional substance with various effects. A combination use of the egg-yolk protein hydrolysate with another active ingredient for promoting hair regrowth is expected to achieve additive effect or synergistic effect. Examples of the additional active ingredient for promoting hair regrowth include minoxidil and finasteride.
[0055] The present invention also includes a method for promoting hair regrowth, the method comprising administering an effective amount of the egg-yolk protein hydrolysate to a human in need of promotion of hair regrowth. The present invention further includes a non-therapeutic method for promoting hair regrowth, the method comprising orally administering the egg-yolk protein hydrolysate to a human in need of promotion of hair regrowth.
[0056] The term “non-therapeutic” refers to any means other than medical practice, i.e., other than therapeutic treatments to human or animal bodies.
[0057] The present invention also includes a method for promoting hair regrowth, the method comprising administering an effective amount of the hair regrowth promoter of the present invention to an animal in need of promotion of hair regrowth. The animal is not particularly limited, and may be, for example, a human, a non-human mammal, etc. Examples of the non-human mammal include, but are not limited to, cattle, horses, pigs, sheep, goats, llamas, alpacas, camels, rabbits, minks, foxes, chinchillas, geese, ducks, etc.
[0058] The present invention also includes use of the hair regrowth promoter of the present invention for promotion of hair regrowth.
[0059] The present invention further includes the hair regrowth promoter of the present invention for use in promotion of hair regrowth.
EXAMPLES
[0060] The present invention will be described in more detail below with reference to Examples, but the present invention is not limited thereto.
Example 1
Production of Egg-Yolk Protein Hydrolysate
(1) Preparation of Defatted Egg Yolk
[0061] To 1 kg of egg-yolk powder was added 5 L of ethanol, the mixture was stirred with a blender for 30 minutes, and the resulting solids were collected. This procedure was repeated three times for fat removal from the egg yolk. The collected solids were air-dried to give 568 g of defatted egg yolk powder.
(2) Preparation of Egg-Yolk Protein Hydrolysate
[0062] To 500 g of the defatted egg yolk powder prepared in the above (1) were added 2.5 kg of water and 25 g of Alcalase (trade name) (protease from Bacillus licheniformis ) produced by Novozymes A/S. The pH of the mixture was adjusted to 7, and the enzyme reaction was allowed to proceed at 55° C. for 3 hours. The reaction mixture was heated at 80° C. for 15 minutes to inactivate the enzyme, and centrifuged at 3000×g for 20 minutes to remove insoluble matter. After filtration, the filtrate was spray-dried to give about 140 g of egg-yolk protein hydrolysate.
[0063] The molecular weight analysis of the egg-yolk protein hydrolysate was performed by gel filtration chromatography under the following conditions.
[0064] Column: Diol 60 (trade name) (6.0×300 mm) (YMC Co., Ltd.)
[0065] Eluent: 0.2 M potassium phosphate buffer, 0.2 M NaCl (pH 6.9)/acetonitrile (70:30)
[0066] Flow rate: 0.7 mL/min
[0067] Detection wavelength: 280 nm
[0068] The results of the molecular weight analysis are shown in FIG. 1 . As shown in FIG. 1 , the molecular weight distribution of the egg-yolk protein hydrolysate of Example 1 was such that the peak area percentage for a molecular weight range of 100 to 20,000 was about 90% of the total area of all the peaks of proteins, peptides and amino acids.
Example 2
Animal Testing (Assessment of Hair Growth-Promoting Effect in C3H Mice)
[0069] SPF C3H/HeN Slc (male) mice available from Japan SLC, Inc. were used for the test. The animals were randomly divided into test groups so that the mean body weight was approximately equal between groups. The mice were housed five per cage at room temperature (25° C.) under a 12-hour light-dark cycle.
[0070] The mice at six weeks old purchased from the vendor were preliminarily bred for one week for acclimation to the test environment. The dorsal region of the mice at an age of seven weeks old was shaved with a safety razor to remove the hair.
[0071] Until the start of the test, the mice were fed with free access to a solid CRF-1 feed (Oriental Yeast Co., Ltd.) and tap water as drinking water.
[0072] The test conditions are shown in Table 1.
[0000]
TABLE 1
Dose
Number of
Type of feed
Test group
(mg/kg)
animals
Negative control
Regular feed (CRF-1)
0
10
Test sample
Feed mixed with egg-yolk
10
10
protein hydrolysate (low dose)
Feed mixed with egg-yolk
100
10
protein hydrolysate (medium
dose)
Feed mixed with egg-yolk
1000
10
protein hydrolysate (high dose)
[0073] The test was started three days after shaving. Specifically, the mice in the test sample administration groups were fed with a mixed feed of the regular feed (CRF-1) and the egg-yolk protein hydrolysate in the dose indicated in Table 1, whereas the mice in the negative control group were fed with the regular feed (CRF-1).
[0074] On the final observation day (Day 17), the mice in the test and control groups were anesthetized and euthanized. The mice were fixed on a photography table and the shaved region was photographed. The region covered with new hair was quantified from the photographs using an image analysis software to determine whether the test sample had hair regrowth-promoting effect.
[0075] FIG. 2 shows the areas of the dorsal regions covered with new hair in the mice on Day 17 of feeding with the feed mixed with the egg-yolk protein hydrolysate. FIG. 3 shows the comparison of the appearance of the dorsal regions covered with new hair in the mice fed with the regular feed and in the mice fed with the feed mixed with the egg-yolk protein hydrolysate on day 17 of feeding. Hair regrowth in the groups fed with the egg-yolk protein hydrolysate was promoted in a manner dependent on the amount of intake of the egg-yolk protein hydrolysate. A significant difference was observed at a dose of 100 mg/kg or more.
Example 3
Cell Test (Measurement of Growth Factors in Hair Follicle Dermal Papilla Cells)
(1) Measurement of the Production Levels of Vascular Endothelial Growth Factor (VEGF)
[0076] Human hair follicle dermal papilla cells (HFDPCs) (Cell Applications, Inc.) in the logarithmic growth phase were suspended at 3×10 4 cells/mL in hair follicle dermal papilla cell growth medium (PCGM) (Cell Applications, Inc.). One milliliter of the suspension was seeded in a 24-well (collagen-coated) plate and the cells were precultured.
[0077] After the growth of the cells was observed under a microscope, all the medium was replaced with a fresh medium.
[0078] Test samples were separately added to the medium and incubation was started. Specifically, the test samples were prepared by dissolving the egg-yolk protein hydrolysate in PBS (−) at 100 mg/mL and 500 mg/mL, and added to the medium at 1% of the total volume of the medium (final concentration: 1 mg/mL and 5 mg/mL, respectively). As a model drug for promotion of the production of VEGF, minoxidil (Sigma-Aldrich Co. LLC.) was used. Minoxidil was dissolved in ethanol at 3 mM and added to the medium at 1% of the total volume of the medium (final concentration: 30 μM).
[0079] After two days' incubation, the VEGF concentration in the medium was measured using Human VEGF ELISA kit (R&D Systems).
[0080] The results are shown in FIG. 4 . The amounts of VEGF secreted from the hair follicle dermal papilla cells into the medium increased in a manner dependent on the concentration of the egg-yolk protein hydrolysate added.
[0000] (2) Measurement of the mRNA Expression Levels of Fibroblast Growth Factor-7 (FGF-7)
[0081] Human hair follicle dermal papilla cells in the logarithmic growth phase were suspended at 3×10 4 cells/mL in DMEM medium (containing 10% serum). One milliliter of the suspension was seeded in a 24-well (collagen-coated) plate and the cells were precultured.
[0082] All the medium was removed and serum-free DMEM medium was added. Immediately after that, a test sample was added to the medium, and the cells were incubated in a CO 2 incubator for 2 hours. Specifically, the test sample was prepared by dissolving the egg-yolk protein hydrolysate in PBS (−) at 100 mg/mL, and added to the medium at 1% of the total volume of the medium (final concentration: 1 mg/mL). As an inducer of the expression of FGF-7, adenosine (Wako Pure Chemical Industries, Ltd.) was used. Adenosine was dissolved in DMSO at 10 mM and added to the medium at 1% of the total volume of the medium (final concentration: 100 μM).
[0083] After the incubation, all the medium was removed, and immediately after that, the cells were lysed in 1 mL of ISOGEN II (NIPPON GENE), and total RNA was extracted following the manufacturer's recommended protocol. cDNA was synthesized using the total RNA as a template with PrimeScript RT reagent Kit (Takara) following the manufacturer's recommended protocol. Real-time PCR was performed using the reaction mixture as a template with SYBR Premix EX Taq (Takara) and LightCycler 480 (Roche) following the manufacturer's recommended protocols. The nucleotide sequences of the primers used in the PCR are shown in Table 2.
[0000]
TABLE 2
Forward
Reverse
FGF-7
TCTGTCGAACACAGTGGTACCTG
AGTACCTTTAGTCCTGTCAC
AG (SEQ ID NO: 1)
CG (SEQ ID NO: 2)
GAPDH
GCACCGTCAAGGCTGAGAAC
ATGGTGGTGAAGACGCCAGT
(SEQ ID NO: 3)
(SEQ ID NO: 4)
[0084] The results are shown in FIG. 5 . The addition of the egg-yolk protein hydrolysate to the medium increased the mRNA levels of FGF-7.
[0000] (3) Measurement of the mRNA Expression Levels of Insulin—Like Growth Factor (IGF-1)
[0085] Human hair follicle dermal papilla cells in the logarithmic growth phase were suspended at 3×10 4 cells/mL in DMEM medium (containing 10% serum). One milliliter of the suspension was seeded in a 24-well (collagen-coated) plate and the cells were precultured.
[0086] All the medium was removed and serum-free DMEM medium was added. Immediately after that, a test sample was added to the medium, and the cells were incubated in a CO 2 incubator for 4 hours. Specifically, the test sample was prepared by dissolving the egg-yolk protein hydrolysate in PBS (−) at 100 mg/mL, and added to the medium at 1% of the total volume of the medium (final concentration: 1 mg/mL). As an inducer of the expression of IGF-1, adenosine was used. Adenosine was dissolved in DMSO at 10 mM and added to the medium at 1% of the total volume of the medium (final concentration: 100 μM).
[0087] After the incubation, all the medium was removed, and immediately after that, the cells were lysed in 1 mL of ISOGEN II (NIPPON GENE), and total RNA was extracted following the manufacturer's recommended protocol. cDNA was synthesized using the total RNA as a template with PrimeScript RT reagent Kit (Takara) following the manufacturer's recommended protocol. Real-time PCR was performed using the reaction mixture as a template with SYBR Premix EX Taq (Takara) and LightCycler 480 (Roche) following the manufacturer's recommended protocols. The nucleotide sequences of the primers used in the PCR are shown in Table 3.
[0000]
TABLE 3
Forward
Reverse
IGF-1
TTTCAAGCCACCCATTGACC
GCGGGTACAAGATAAATATC
(SEQ ID NO: 5)
CAAAC (SEQ ID NO: 6)
GAPDH
GCACCGTCAAGGCTGAGAAC
ATGGTGGTGAAGACGCCAGT
(SEQ ID NO: 3)
(SEQ ID NO: 4)
[0088] The results are shown in FIG. 6 . The addition of the egg-yolk protein hydrolysate to the medium increased the mRNA levels of IGF-1.
Example 4
Animal Testing (Assessment of Anagen Induction Effect in C57BL/6 Mice)
[0089] C57BL/6 (female) mice available from Charles River Laboratories Japan, Inc. were used for the test. The animals were randomly divided into test groups so that the mean body weight was approximately equal between groups. The mice were housed five per cage at room temperature (25° C.) under a 12-hour light-dark cycle.
[0090] The mice at six weeks old purchased from the vendor were preliminarily bred for one week for acclimation to the test environment. A commercially available hair removal cream was applied to the dorsal region of the mice at an age of seven weeks old to remove the hair.
[0091] Until the start of the test, the mice were fed with free access to a solid CRF-1 feed (Oriental Yeast Co., Ltd.) and tap water as drinking water.
[0092] The test conditions are shown in Table 4.
[0000]
TABLE 4
Dose
Number of
Type of feed
Test group
(mg/kg)
animals
Negative control
Feed mixed with casein
100
5
Test sample
Feed mixed with egg-yolk
100
5
protein hydrolysate
[0093] The hair of the 7-week-old C57BL/6 mice was in the telogen phase of the hair cycle, but due to the stimulation of hair removal, the hair gradually entered into the anagen phase. The test was started three days after the hair removal. Specifically, the mice in the test sample administration group were fed with a mixed feed of the regular feed (CRF-1) and the egg-yolk protein hydrolysate in the dose indicated in Table 4, whereas the mice in the negative control group were fed with the regular feed (CRF-1) mixed with casein.
[0094] On the final observation day (Day 9 of administration), the mice in the test and control groups were anesthetized and euthanized. The dorsal skin was shaved with an electric shaver to remove the hair, and the skin on each side of the median line was harvested (from the base of the ears towards the rump). The harvested skin was fixed in 10% neutral buffered formalin solution and paraffin-embedded. The specimens were sectioned parallel to the body axis into 4-μm slices, and were HE stained. On the stained sections, 500 hair follicles were examined for each group, and the frequency of anagen VI hair follicles was determined.
[0095] The group with oral administration of the egg-yolk protein hydrolysate showed a higher frequency of anagen VI hair follicles than the group with oral administration of casein. The results indicated that oral administration of the egg-yolk protein hydrolysate induced the maturation of anagen hair follicles, thereby promoting hair regrowth.
Example 5
Animal Testing (Assessment of Hair Growth-Promoting Effect on Androgen-Induced Telogen)
[0096] C57BL/6 (female) mice available from Charles River Laboratories Japan, Inc. were used for the test. The animals were randomly divided into test groups so that the mean body weight was approximately equal between groups. The mice were housed three per cage at room temperature (25° C.) under a 12-hour light-dark cycle.
[0097] The mice at six weeks old purchased from the vendor were preliminarily bred for one week for acclimation to the test environment. A commercially available hair removal cream was applied to the dorsal region of the mice at an age of seven weeks old to remove the hair.
[0098] Until the start of the test, the mice were fed with free access to a solid CRF-1 feed (Oriental Yeast Co., Ltd.) and tap water as drinking water.
[0099] The hair of the 7-week-old C57BL/6 mice was in the telogen phase of the hair cycle, but due to the stimulation of hair removal, the hair gradually entered into the anagen phase. This transition in the hair cycle was hampered by administration of an androgen after the hair removal. Specifically, dihydrotestosterone (DHT) was dissolved at 2 mg/mL in phosphate buffered saline containing 20% by mass of ethanol, and 100 μL of the solution was subcutaneously injected into the hair removal region every other day. From two days after the hair removal, the mixed feeds indicated in Table 5 were given with free access thereto.
[0000]
TABLE 5
DHT
Number of
administration
Test group
Mixing ratio
animals
No
Feed mixed with casein
2% by mass
3
Yes
Feed mixed with casein
2% by mass
3
Yes
Feed mixed with egg-yolk
2% by mass
3
protein hydrolysate
[0100] On the final observation day (Day 14 of administration), the mice in the test and control groups were anesthetized and fixed on a photography table, and the hair removal region was photographed. As shown in FIG. 7 , the dorsal skin of the mice in the casein-containing feed group with no DHT administration appeared to be blackened, and hair regrowth was confirmed. However, the blackening of the dorsal skin was inhibited by DHT administration. In contrast to the casein-containing feed group with DHT administration, the blackened region of the skin increased in the egg-yolk protein hydrolysate-containing feed group, and hair regrowth was confirmed. The results indicated that oral administration of the egg-yolk protein hydrolysate induced the transition from telogen to anagen, thereby promoting hair regrowth.
[0101] The present invention is not limited to each of the embodiments and Examples described above, and various modifications are possible within the scope of the claims. Embodiments obtainable by appropriately combining the technical means disclosed in the different embodiments of the present invention are also included in the technical scope of the present invention.
INDUSTRIAL APPLICABILITY
[0102] The present invention is useful as a hair regrowth promoter.
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The present invention provides a hair regrowth promoter comprising an egg-yolk protein hydrolysate as an active ingredient. The egg-yolk protein hydrolysate is a safe ingredient produced from a natural source, and therefore can be widely used in daily consumable products, such as food and drink products, medicaments, animal feeds, and dietary supplements, or as a food additive, etc. The promoter etc. of the present invention can be orally administered and is thus very advantageous.
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[0001] This application is based on application No. 2001-318625 filed in Japan, the content of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a mobile telephone that includes a function for suppressing transmission of radio waves.
[0004] 2. Description of the Related Art
[0005] Use of mobile telephones is prohibited in places such as hospitals and crowded trains because of the detrimental effect of radio waves transmitted by mobile telephones on medical devices and the like. It is necessary for people who have a mobile telephone (hereinafter “user(s)”) to turn their mobile telephone off in such places.
[0006] However, in addition to call functions and electronic mail (hereinafter simply referred to as “mail”) functions, modern mobile telephones perform various functions such as telephone book management, schedule management, reproduction of downloaded music, images and the like, games, and photography. Many of these functions do not require transmission of radio waves.
SUMMARY OF THE INVENTION
[0007] The object of the present invention is to provide a mobile telephone in which functions such as viewing received mail and transmitted mail, schedule management, and games can be used while a radio wave transmission function of the mobile telephone is suspended, even in a place where transmission of radio waves is prohibited.
[0008] In order to achieve the stated object, the mobile telephone of the present invention is a mobile telephone that communicates with use of radio waves, including: a radio wave flag setting unit for setting a radio wave flag that shows either ON or OFF, ON showing that transmission of radio waves is permitted, and OFF showing that transmission of radio waves is suppressed; and radio wave suppression unit for suppressing transmission of radio waves while the radio wave flag is set to OFF.
[0009] According to the stated construction, when the radio wave flag is set to OFF, the mobile telephone does not transmit radio waves, therefore while the mobile telephone is on, functions that do not require radio waves to be transmitted can be used even in a place where radio wave transmission is prohibited.
[0010] Here, the mobile telephone may further include: automatic power-on unit for, on occurrence of a predetermined event while power supply to main components is suspended, supplying power to the main components; and suppression flag setting unit for, on the automatic power on means supplying power to the main components, setting a suppression flag that shows whether transmission of radio waves is being suppressed, wherein the radio wave flag setting unit sets the radio wave flag to OFF when the predetermined event occurs and the suppression flag shows that transmission of radio waves is suppressed.
[0011] According to the stated construction, when the mobile telephone that is off is then turned on according to an auto-power-on function even in a place where use of mobile telephones is prohibited, the radio wave flag is set to OFF regardless of the stored radio wave flag. Therefore, radio wave transmission can be suppressed even if the user does not notice that the mobile telephone has turned on.
[0012] Here, when a power-on operation and a predetermined operation are performed simultaneously by the user, the radio wave flag setting unit may set the radio wave flag to OFF and power may be supplied to main components.
[0013] According to the stated construction, the radio wave flag is set to OFF when the user presses the power button. Therefore, even in a place where use of mobile telephones is prohibited, radio wave transmission can be suppressed after the power has been turned on until the user sets the radio wave mode to OFF.
[0014] Here, when a power-on operation and a predetermined operation are performed simultaneously by the user, the flag setting unit may set the radio wave flag to OFF and power may be supplied to main components.
[0015] According to the stated construction, when the power of the mobile telephone is off and the radio wave flag is set to OFF, the radio wave flag can be set to ON simultaneous to the power being turned on. Therefore, in an emergency radio waves can be transmitted as soon as the power is turned on.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other objects, advantages and features of the invention will become apparent from the following description thereof taken in conjunction with the accompanying drawings which illustrate a specific embodiment of the invention.
[0017] In the drawings:
[0018] [0018]FIG. 1 is a block diagram showing the structure of a mobile telephone 10 ;
[0019] [0019]FIG. 2 is a flowchart, which continues in FIG. 3, showing operations of the mobile telephone 10 ;
[0020] [0020]FIG. 3 is a flowchart, which continues from and returns to in FIG. 2, showing operations of the mobile telephone 10 ;
[0021] [0021]FIG. 4 is a flowchart showing operations of the mobile telephone 10 at “auto-power-on”;
[0022] [0022]FIG. 5A is a diagram of a screen 201 that is displayed by a display unit 103 when a “ 0 ” button is pressed together with a power button;
[0023] [0023]FIG. 5B is a diagram of a screen 202 that is displayed by a display unit 103 when a “ 1 ” button is pressed together with a power button;
[0024] [0024]FIG. 6A is a diagram of a screen 301 that is a function setting screen that is displayed by the display unit 103 of the mobile telephone 10 in which the radio wave mode is set to ON;
[0025] [0025]FIG. 6B is a diagram of a screen 302 that is displayed by the display unit 103 , and that is used for setting the radio wave mode to ON and OFF;
[0026] [0026]FIG. 6C is a diagram of a screen 303 that is displayed by the display unit 103 , and that is for the user to confirm the set radio wave mode;
[0027] [0027]FIG. 6D is a diagram of a screen 304 that is a function setting screen that is displayed by the display unit 103 of the mobile telephone 10 whose radio wave mode is set to OFF;
[0028] [0028]FIG. 7A is a diagram of a screen 401 displayed by the display unit 103 when input to make a call is received while the radio wave mode of the mobile telephone 10 is set to OFF;
[0029] [0029]FIG. 7B is a diagram of a screen 402 displayed by the display unit 103 when input to transmit mail or connect to the Internet is received while the radio wave mode of the mobile telephone 10 is set to OFF;
[0030] [0030]FIG. 8A is a diagram of a main menu screen 501 displayed by the display unit 103 ;
[0031] [0031]FIG. 8B is a diagram of a screen 502 displayed by the display unit 103 ; and
[0032] [0032]FIG. 8C is a diagram of a screen 503 displayed by the display unit 103 at “auto-power-on”, that shows that the radio wave mode is set to OFF.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] The following describes the mobile telephone 10 as an embodiment of the present invention, with reference to the drawings.
[0034] 1. Structure of the Mobile Telephone 10
[0035] [0035]FIG. 1 is a block diagram showing the structure of the mobile telephone 10 .
[0036] As shown in FIG. 1, the mobile telephone 10 is composed of a transmission/reception unit 101 , a control unit 102 , a display unit 103 and an input unit 104 .
[0037] The mobile telephone 10 is a portable telephone that communicates with use of radio waves. Specifically, the mobile telephone 10 is a computer system that includes a microprocessor, a ROM (read only memory), a RAM (Random access memory), an LCD (liquid crystal display) unit, a key operation unit, a communication unit and an antenna.
[0038] The transmission/reception unit 101 performs communication such as transmission and reception of mail and connection to the Internet.
[0039] The control unit 102 stores a control program, and controls functions of the mobile telephone 10 such as calls, transmission and reception of mail, connection to the Internet, telephone book management, schedule management, multimedia content, and games. This control is performed according to the microprocessor executing the control program.
[0040] The control unit 102 further stores a radio wave mode. The radio wave mode is set to either ON or OFF. ON shows that transmission of radio waves is permitted, and OFF shows that transmission of radio waves is prohibited. The control unit 102 sets the radio wave mode in the following way.
[0041] The control unit 102 internally pre-stores the radio wave mode set to either ON or OFF. The control unit 102 receives input of the radio wave mode from the user via the input unit 104 . When the received radio wave mode differs to the pre-stored radio wave mode, the control unit 102 stores the newly received radio wave mode instead of the pre-stored radio wave mode.
[0042] On receiving an input to initiate a call, transmit mail, or connect to the Internet from the user via the input unit 104 , the control unit 102 reads the internally-stored radio wave mode, and when the radio wave mode is OFF, outputs an instruction to the transmission/reception unit 101 to suspend transmission of radio waves. On receiving an instruction from the control unit 102 to recommence transmission of radio waves, the transmission/reception unit 101 recommences transmitting radio waves.
[0043] The display unit 103 , which includes the LCD, displays screens that are generated by the control unit 102 . When each screen is being displayed, the display unit 103 further displays screens whose content corresponds to operations received from the user via the input unit 104 .
[0044] The input unit 104 includes a plurality of buttons such as numeric keys, an up arrow, a down arrow, an “OK” button, and a power button. These buttons are provided on an operation surface of the mobile telephone 10 . While the display unit 103 displays each screen, the input unit 104 receives operations from the user and outputs corresponding operation signals to the control unit 102 .
[0045] The following describes power-on state and the power-off state of the mobile telephone 10 .
[0046] “Power off” denotes a state is which power is supplied only to a monitoring unit in the mobile telephone 10 . The monitoring unit denotes a clock function and the power button. The clock function operates to manage an alarm. The power button receives inputs by being pressed by the user.
[0047] The power being on denotes a state in which power is supplied to the main components of the mobile telephone 10 . The main components include all the composite elements for achieving ordinary functions of the mobile telephone 10 , such as communication and display functions.
[0048] 2. Operations of the Mobile Telephone 10
[0049] The following describes the operations of the mobile telephone 10 with reference to the flowcharts in FIGS. 2 to 4 , and FIGS. 5 to 8 .
[0050] <Turning the Power on According to a Press of the Power Button>
[0051] The following describes operations of the mobile telephone 10 when power is supplied to the main components of the mobile telephone 10 according to the user pressing the power button.
[0052] The input unit 104 of the mobile telephone 10 receives an input to turn the power on (step S 101 ), and judges which button the user has pressed simultaneously with the power button (step S 102 ).
[0053] When the “1” button has been pressed simultaneously (step S 102 , “1”), the control unit 102 sets the radio wave mode to ON, and stores the set radio wave mode internally (step S 103 ). An example of the screen displayed by the display unit 103 at this time is a screen 202 shown in FIG. 5B. The screen 202 is the ordinary stand-by screen. Here “pressed simultaneously” denotes detection of input by the power button while the “1” button is being pressed.
[0054] When the “0” button has been pressed simultaneously (step S 102 , “0”), the control unit 102 sets the radio wave mode to OFF, and stores the set radio wave mode internally (step S 104 ). An example of the screen displayed by the display unit 103 at this time is a screen 201 shown in FIG. 5A. An antenna bar display area in the screen displays “OFF”. Here “pressed simultaneously” denotes detection of input by the power button while the “0” button is being pressed.
[0055] Next, the control unit 102 judges the type of operation signal shown by the button that received the input (step S 105 ).
[0056] When the operation signal shown by the button that received the input is “radio wave mode” (step S 105 , “radio wave mode”), the control unit 102 receives and input of radio wave mode via the input unit 104 (step S 106 ), and rewrites the internally pre-stored radio wave mode to the received mode (step S 107 ). The control unit 102 then returns to step S 105 to continue processing.
[0057] Examples of the screens displayed by the display unit 103 at this time are shown in FIGS. 6A to 6 D. A screen 301 shown in FIG. 6A is for setting various functions, and is displayed when selecting the radio wave mode setting. Antenna bars are displayed in the antenna bar display area. This shows that the radio wave mode of the mobile telephone is ON. A screen 302 shown in FIG. 6B is displayed when selecting to set the radio wave mode either ON or OFF. A screen 303 shown in FIG. 6C is for the user to confirm the newly-set radio wave mode OFF. A screen 304 in FIG. 6D is displayed after the radio wave mode has been set. Here, “OFF” displayed in the antenna bar display area shows that radio wave mode is OFF.
[0058] When the operation signal shown by the button that received the input is “end” (step S 105 , “end”), the control unit 102 measures the length of time that the “END” button is held down by the user (step S 108 ), and judges whether the measured length of time is at least three seconds (step S 109 ). If the measured length of time is at least three seconds (step S 109 , YES), the control unit 102 stops the supply of power to the main components, and turns the power off (step S 110 ). If the measured length of time is less than three seconds (step 109 , NO), the control unit 102 returns to step S 105 to continue processing.
[0059] When the operation signal shown by the button that received the input is “view mail” (step S 105 , “view mail”), the control unit 102 reads internally-stored received mail, transmitted mail, and so on, displays the read screens on the display 103 , and performs processing for viewing (step S 121 ). The control unit 102 then returns to step S 105 to continue processing.
[0060] When the operation signal shown by the button that received the input is “reproduce” (step S 105 , “reproduce”), the control unit 102 reads internally-stored, pre-downloaded multimedia content such as a game, animation, music or the like, performs reproduction processing by outputting to the display unit 103 and a speaker as appropriate (step S 122 ). The control unit 102 then returns to step S 105 to continue processing.
[0061] When the operation signal shown by the button that received the input is one of “call initiation”, “mail transmission” and “Internet connection” (step S 105 , “call initiation”, “mail transmission”, or “Internet connection”), the control unit 102 ditinguishes the internally-stored radio wave mode (step S 123 ).
[0062] When the radio wave mode is ON (step S 123 , ON), the control unit 102 performs processing for initiating a call, transmitting mail or connecting to the Internet according to the type of operation signal (step S 124 ). The control unit 102 then returns to step S 105 to continue processing.
[0063] When the radio wave mode is set to OFF (step S 123 , OFF), the control unit 102 returns to step S 105 to continue processing. Examples of screens displayed by the display unit 103 at this time are shown in FIGS. 7A and 7B. A screen 401 shown in FIG. 7A is displayed when the operation signal is “call initiation”. A screen 402 shown in FIG. 7B is displayed when the operation signal is “mail transmission” or “Internet connection”.
[0064] When the operation signal shown by the button that received the input is different to those described above (step S 105 , “other”), the control unit 102 performs processing according to the operation signal (step S 125 ), and then returns to step S 105 to continue processing.
[0065] <Auto-Power-On Function>
[0066] The following describes operations by the mobile telephone 10 for when power is supplied to the main components of the mobile telephone 10 according to the auto-power-on function or the alarm-power-on function.
[0067] The auto-power-on function turns on the mobile telephone 10 , which has been turned off, at a specific pre-set time. At the specific time, the control unit 102 instructs a power supply unit to supply power to the main components. The alarm-power-on function turns the mobile telephone 10 on at a specific time and has an alarm sound output via the speaker when it turns the mobile telephone 10 on.
[0068] The following describes with use of FIGS. 8A to 8 C the method for turning the mobile telephone 10 on by either the auto-power-on function or the alarm-power-on function and setting the radio wave mode to “OFF”.
[0069] The auto-power-on function or the alarm-power-on function is pre-set in the mobile telephone 10 . On the input unit 104 detecting a long press of the power button while the display unit 103 displays a screen 501 shown in FIG. 8A, the mobile telephone 10 is turned on by the auto-power-on function or the alarm-power-on function. On the mobile telephone 10 being turned on, the control unit 102 sets a suppression flag to show that the radio wave mode is set to OFF, and stores the set suppression flag internally.
[0070] The display unit 103 then displays a screen 502 shown in FIG. 8B, to show the user that the power of the mobile telephone 10 is to be turned off. Next, when the mobile telephone 10 is turned on at the pre-set time according to auto-power-on or alarm-power-on, the display unit 103 displays a screen 503 shown in FIG. 8C showing that the radio wave mode has been set to OFF. Then the control unit 102 turns the mobile telephone 10 off.
[0071] The following describes with use of the flowchart in FIG. 4 operations of the mobile telephone 10 when the auto-power-on function or the alarm-power-on function and the suppression flag have been set.
[0072] The control unit 102 judges whether the present time is the pre-set time (step S 151 ), and if the present time is the pre-set time (step S 151 , YES), the control unit 102 has the mobile telephone 10 turned on, by outputting an instruction to the power supply unit to supply power to the main components, and by the power supply unit supplying power to the main components (step S 152 ). Next, the control unit 102 reads the internally-stored radio wave mode, and if the radio wave mode is set to OFF, continues processing. If the radio wave mode is set to ON, the control unit 102 stores ON instead of OFF as the radio wave mode (step S 153 ).
[0073] At step S 151 , when the present time is not the pre-set specified time (step S 151 , NO), the control unit 102 repeats step S 151 .
[0074] 3. Conclusion
[0075] As has been described, according to the present invention the control unit 102 of the mobile telephone 10 has a function of setting a radio wave mode showing whether radio wave transmission is ON or OFF, and storing the setting. On receiving an operation instruction for initiating a call, transmitting mail, or the like, the control unit 102 reads the internally-stored radio wave mode, and, when the radio wave mode is OFF, suppresses the radio wave transmission function of the transmission/reception unit 101 .
[0076] Note that the present invention is not limited to the above-described embodiment. The following cases are also included in the present invention.
[0077] (1) The method for setting the radio wave mode is not limited to the above-described method in which the control unit 102 receives an input of the radio wave setting via the input unit 104 while a function setting screen is displayed by the display unit 103 . For example, the input unit 104 may include a “radio wave button” that is similar to a conventional “manner button”, and the radio wave mode may be switched on and off by the user pressing the radio wave button.
[0078] (2) The method of setting the radio wave mode is not limited to setting the radio wave mode to OFF while the power is on by a simultaneous long press of the power button and the “0” button, and setting the radio wave to ON while the while the power is on by a simultaneous long press of the power button and the “1” button. The button pressed simultaneously with the power button in each case may be instead be any button besides “0” and “1 respectively.
[0079] (3) The method for setting the radio wave mode to be OFF when the power is turned on according to the auto-power-on function is not limited to a long press of the power button in a menu screen. For example, the radio wave mode may be set to be OFF in a screen for setting the auto-power-on time.
[0080] (4) The control unit 102 may have a structure in which, when the radio wave mode is set to OFF, it switches the radio wave mode to ON and performs call initiation processing when the input unit receives input for initiating a call to a predetermined emergency services number.
[0081] (5) The present invention may be methods shown by the above. Furthermore, the methods may be a computer program realized by a computer, and may be a digital signal of the computer program.
[0082] Furthermore, the present invention may be a computer-readable recording medium apparatus such as a flexible disk, a hard disk, a CD-ROM (compact disk-read only memory), and MO (magneto-optical), a DVD-ROM (digital versatile disk-read only memory), a DVD-RAM (digital versatile disk random access memory), or a semiconductor memory, that stores the computer program or the digital signal. Furthermore, the present invention may be the computer program or the digital signal recorded on any of the aforementioned recording medium apparatuses. Furthermore, the present invention may be the computer program or the digital signal transmitted on a electric communication line, a wireless or wired communication line, or a network of which the Internet is representative.
[0083] Furthermore, the present invention may be a computer system that includes a microprocessor and a memory, the memory storing the computer program, and the microprocessor operating according to the computer program.
[0084] Furthermore, by transferring the program or the digital signal to the recording medium apparatus, or by transferring the program or the digital signal via a network or the like, the program or the digital signal may be executed by another independent computer system.
[0085] (6) The present invention may be any combination of the above-described embodiments and modifications.
[0086] Although the present invention has been fully described by way of examples with reference to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art. Therefore, unless otherwise such changes and modifications depart from the scope of the present invention, they should be construed as being included therein.
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A control unit 102 of a mobile telephone 10 sets a radio wave mode to ON or OFF, and stores the setting of the radio wave mode internally. ON shows that radio wave transmission is permitted, and OFF shows that radio wave transmission is prohibited. When the stored radio wave mode setting is OFF, radio wave transmission is suppressed even if input such as that for mail transmission is received. By setting the radio wave mode to OFF, functions that do not require radio wave transmission can be used, even in places where radio wave transmission is prohibited.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part application of application Ser. No. 08/126,184, filed Sep. 24, 1993, entitled "Mold for Stepping Stones, now abandoned."
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention applies to the field of ground covering, such as molds, for casting ground-covering, such as stones, from cement, or similar material, and the ground-covering stepping stones produce by casting such materials in generally planar shaped molding cavities.
2. Description of the Prior Art
There are two principal commercial applications for such molds: The first is the use of the molds by do-it-yourself craftsmen for home improvements. The second is in commercial manufacturing, wherein such molds am employed to manufacture decorative stepping stones for sale to others. The molds and products therefrom disclosed are appropriate for both applications.
There have been a number of prior art molds patented or otherwise known and/or manufactured as decorative patterns. However, these prior art molds and patterns have limited flexibility in use, being capable of producing only rectilinear patterns. Thus, they are incapable of producing oblique, curved or circular patterns.
Of course, most of the actual decorative patterns in use every old, some dating back centuries to the practice of fitting ships ballast stones into reputed decorative patterns to make cobblestone streets at loading ports. Other typical prior art patterns are ancient and traditional Japanese designs, such as that based or evolved therefrom and marketed under the pattern name "Royal Rock," by Color Tile, Inc., having stores throughout the United States.
One prior art mold and ground covering is taught in U.S. Pat. No. 4,354,773 (Noak) for a ground-coveting element.
Additional prior art is shown in U.S. Pat. No. 4,773,790 (Hagenaugh) also for a ground covering element.
A prior art mold pattern is shown in U.S. Design Patent No. D-432,528 (Hupp). This pattern has been marketed under the phrase "Walkmaker", remarkably similar to the above-referenced "Royal Rock" Japanese design.
All of the above prior art devices represent generally rectangular patterns having "zig-zag" sides comprising projections and recesses of approximately equal obtuse angles included between approximately equal line segment lengths.
All of these prior art devices lack the capability to create the variety of straight walks, curves and circular patterns desired by both home-owners and commercial manufacturers. None of the foregoing molds have the capability of selectively casting concrete simulated ground-coveting patterns less than the full pattern enclosed by the perimeter of the molds, and hence, they are limited to rectilinear patterns.
Another prior art mold pattern is shown in the advertisement for the mold, ROCK'N'MOLD®, manufactured by the assignee of the present invention. This product has the capability of being partially filled to produce separate simulated stones in triangular partial patterns within the overall mold to produce various ground-covering configurations. However, this product does not have the capability to monolithically cast adjacent stones.
The ROCK'N'MOLD® II or New ROCK'N'MOLD® is a generally hexagonal mold manufactured and recently marketed by the assignee of the present invention. This product has the capability of casting an overall monolithic pattern of stones filling the entire mold, but lacks the ability of the assignee's previously-marketed ROCK'N'MOLD® to produce simulated stones in partial patterns.
Prior art devices which cast a number of small separate stones have safety problems, as small stones are prone to being moved or tipped in use. Also, small stones require the site to be prepared very flat and well compacted, in order to stay in place in a common plane in use. The average consumer normally does not have the tools and equipment to accomplish such site preparation, nor the case and patience obviously required.
It is a purpose of the present invention to overcome the limitations of all the prior art devices by producing a more versatile mold and ground-covering stone pattern, in which selected portions of the mold may be filled to produce various ground-covering configurations, and also in which those selected portions can produce patterns of monolithically-cast stones.
It is a purpose of the present invention to provide a casting mold that can produce repeated patterns in the form of linear and rectilinear transverse areas, as well as oblique, arcuate and even circular shapes in a single, inexpensive mold.
It is another purpose of the present invention to employ a mold into which separate, nesting, groups of interconnected stones cast and divided by partial dividers, with actual dividers separating the groups of interconnected stones in a nesting relationship.
It is another purpose of the present invention to provide a mold for casting concrete ground-covering elements by which the user can manufacture straight walk-ways, large areas such as patios, oblique patterns, curved walk-ways and even circular patterns, by filling selected portions of the mold.
It is yet another purpose of the present invention to provide a mold for casting safer concrete ground-covering elements in which small stones may be cast, but which are interconnected monolithically with adjacent stones to preclude moving or tipping in use, and to minimize site preparation.
A feature of the present invention is the ability to use any partial dividing wall to produce either an isolated edge for any stones or to produce the monolithic connection between two adjacent stones.
In addition to a square perimeter, other preferred embodiments include additional nesting polygonal, or generally polygonal, configurations including rectangles, triangles, trapezoids and hexagons.
SUMMARY OF THE INVENTION
The foregoing purposes are achieved by the present invention in which a mold for casting a plurality of ground-covering stones comprises a generally square concrete molding frame having top and bottom surfaces in a parallel plane. The frame has first and second corners connected by a first perimeter wall, second and third corners connected by a second perimeter wall, third and fourth corners connected by a third perimeter wall and fourth and first corners connected by a fourth perimeter wall. Each wall has a plan shape of contiguous straight-line segments connected at obtuse angles.
A first diagonal wall extends approximately from the first corner to the third corner, dividing the square frame into two generally triangular portions. A second diagonal wall extends approximately from the second corner to the fourth corner, dividing the square frame into two alternative triangular portions. The first perimeter wall is geometrically congruent with the third perimeter wall and the second perimeter wall is geometrically congruent with the fourth perimeter wall. The diagonal walls are geometrically congruent with the second and fourth perimeter walls.
Individual ground-covering stepping stone patterns are produced by dividing walls extending from the top planar surface of the frame to a plane intermediate of the bottom planar surface, whereby the individual stone patterns are monolithic in the generally triangular portions. In use, the generally square perimeters of repetitive castings nest to form linear, transverse or rectilinear patterns; and the triangular portions mutually nest or nest with sides of the square perimeters to form arcuate or circular repetitively cast patterns.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top-side perspective view of a first preferred embodiment of a mold according to the present Invention;
FIG. 2 is a bottom-side perspective view of the mold of FIG. 1;
FIG. 3 is a bottom plan view of the mold of FIG. 1;
FIG. 4 is a top plan view of the mold of FIG. 1;
FIG. 5 is an enlarged cross-sectional view of a perimeter side wall of the mold of FIG. 1, taken along section line 5--5;
FIG. 5A is a full-size cross-sectional view of the perimeter of a ground-covering element as molded by the portion of the mold of FIG. 5;
FIG. 6 is an full-size cross-sectional view of a diagonal wall of the mold of FIG. 1, taken along section line 6--6;
FIG. 6A is a cross-sectional view of a diagonal portion of a section of a ground-covering element molded by the portion of the mold of FIG. 6;
FIG. 7 is an approximately full-size cross-sectional view of a partial dividing wall of the mold of FIG. 1, taken along section line 7--7;
FIG. 7A is a full-size cross-sectional view of a portion of a ground-covering element as molded by the portion of mold of FIG. 7 in which adjacent mold openings have been simultaneously filled, producing stones that are cast monolithically joined;
FIG. 7B is a full-size cross-sectional view of a portion of a ground-covering element as molded by the partial dividing wall filling only one side of the portion of the mold of FIG. , producing the edge of a stone pattern selected within the perimeter of the mold;
FIG. 8 is a schematic representation showing how either of two triangular portions divided by line A-A' of the mold of FIG. 1 may be filled to produce two different triangular patterns of cast stones;
FIG. 9 is a schematic representation of showing how either of two other triangular portions divided by line B-B' of the mold of FIG. 1 may be filled to produce another triangular pattern of cast stones;
FIG. 10 is a top-side perspective view of a second preferred embodiment of a mold according to the present invention, including partial diagonal walls and partial dividing walls supported on columns; FIG. 11 is a bottom-side perspective view of the mold of FIG. 10;
FIG. 12 is a full-size cross-sectional view of a perimeter side wall of the mold of FIG. 10, taken along section line 12--12;
FIG. 12A is a full-size cross-sectional view of a perimeter of a ground-covering element as molded by the portion of mold of FIG. 12;
FIG. 13 is an enlarged cross-sectional view of a diagonal wall of the mold of FIG. 11, taken along section line 13--13;
FIG. 13A is a full-size cross-sectional view of a portion of the central section of a ground-covering element as molded by the diagonal wall portion of mold of FIG. 13, in which adjacent stones are being monolithically cast;
FIG. 14 is a full-size cross-sectional view of a partial dividing wall of the mold of FIG. 10, taken along section line 14--14;
FIG. 14A is a full-size cross-sectional view of a portion of a ground-covering element as molded by a partial dividing wall of FIG. 4, in which adjacent stones are monolithically cast;
FIG. 15 shows how a plurality of rectangular castings of the mold of FIG. 1 or FIG. 10 may be filled to produce a rectilinear area ground-covering configuration;
FIG. 16 shows how a plurality of rectangular castings of the mold of FIG. 1 or FIG. 10 may be filled to produce a rectilinear area ground-covering configuration In a staggered orientation;
FIG. 17 shows how a plurality of rectangular castings of the mold of FIG. 1 or FIG. 10 may be filled to produce a straight walk ground-covering configuration;
FIG. 18 shows how triangular portions of the mold of FIG. 1 or FIG. 10 may be filled to produce curved walk portions;
FIG. 19 shows how triangular portions of the mold of FIG. 1 or FIG. 10 may be filled to produce circular walk configurations;
FIG. 20 shows how generally trapezoidal portions of a mold may be filled to produce an irregular polygonal pattern.
FIG. 21 shows how a plurality of trapezoidal castings of the mold of FIG. 41 may be filled to produce a linear area ground-covering configuration having oblique-direction capability;
FIG. 22 shows how a plurality of trapezoidal castings of the mold of FIG. 41 may be filled to produce a rectilinear ground-covering configuration;
FIG. 23 shows how trapezoidal portions of the mold of FIG. 41 may be filled to produce circular walk configurations;
FIG. 24 shows how right-triangle portions of a mold may be filled to produce an isosceles triangle pattern;
FIG. 25 shows how right-triangle and isosceles triangle portions of a mold may be filled to produce a square pattern;
FIG. 26 shows how a plurality of square and triangular castings of the mold of FIG. 24 or FIG. 25 may be filled to produce a linear area ground-covering configuration having oblique-direction capability;
FIG. 27 shows how a plurality of castings of the mold of FIG. 24 or FIG. 25 may be filled to produce a rectilinear ground-covering configuration;
FIG. 28 shows how triangular castings of the mold of FIG. 24 or portions of the mold of FIG. 25 may be filled to produce circular walk configurations;
FIG. 29 shows how trapezoidal portions of a mold may be filled to produce a hexagonal pattern;
FIG. 30 shows how a plurality of trapezoidal and hexagonal castings of the mold of FIG. 29 may be filled to produce a linear area ground-covering configuration having oblique-direction capability;
FIG. 31 shows how a plurality of castings of the mold of FIG. 29 may be filled to produce a rectilinear ground-coveting configuration; and
FIG. 32 shows how a plurality of castings of the mold of FIG. 29 may be filled to produce a circular walk configurations.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a top perspective view, and in FIG. 2, a bottom perspective view, a mold 1 for casting stepping stones according to a preferred embodiment of the invention is shown having a generally square perimeter wall 2 having a planar top surface 3, and a spaced parallel planar bottom surface 4. A first diagonal wall DW1 along centerline 23A extends from A to A'; and a second diagonal wall DW2 along centerline 23B extends from B to B' intersect perimeter wall 2 proximate the corners of the perimeter, separating the square into triangular areas. A plurality of partial dividing walls 5 intersect diagonal walls and perimeter walls to divide the triangular area into irregular shapes 6 simulating stone patterns.
In FIG. 3, a bottom plan view of the mold 1 of FIG. 1, and in FIG. 4, a top plan view of the mold of FIG. 1, the invention is shown having a generally square perimeter 2 having a first corner C1 and second corner C2 connected by a first perimeter wall side S 1, second corner C2 and third corner C3 connected by a second perimeter wall side S2, third corner C3 and fourth corner C4 connected by a third perimeter wall side S2 and fourth corner C4 and first corner C1 connected by a fourth perimeter wall side S4, each said perimeter wall having a plan shape comprising a series of contiguous, generally-straight line segments 20 of successive unequal lengths, connected at obtuse angles forming alternating projections 21 and recesses 22.
A first diagonal separating wall DW1 extends along line A-A' from perimeter wall junction J4 proximate fourth corner C4, to perimeter wall junction J2 proximate second corner C2 and comprising a common wall separating the generally square perimeter into a first generally triangular portion J4-C1-J2 and a second generally triangular portion J2-C3-J4.
A second diagonal separating wall DW2 extends along line B-B' from perimeter wall junction J3 proximate the third corner C3, to perimeter wall junction J1 proximate the first corner C1 and comprising a common wall separating the generally square perimeter into a third generally triangular portion J3-C4-J1 and a fourth generally triangular portion J1-C2-J3. First perimeter wall side S1 is geometrically complementary to the third perimeter wall side S3, and the second perimeter wall side S2 is geometrically complementary to fourth perimeter wall side S4.
First diagonal wall DW1 is geometrically complementary to second perimeter wall side S2 and fourth perimeter wall side S4.
In FIG. 5, a cross-section of a portion of the perimeter wall 2 of FIG. 4 is shown taken along section line 5--5, in which perimeter wall 2 is in the general configuration of an inverted "L" having a vertical exterior portion 8 extending between the plane of top surface 3 and the plane of bottom surface 4. The angular interior surface 13 of perimeter wall 2 causes perimeter wall 2 to have the cross-sectional shape of an asymmetric "V" in which the top of each side of the V has a radius tapering to an edge 19.
In FIG. 5A, the molded side wall of the casting of simulated stone pattern element 6 by perimeter wall 2 is shown as 6C (element 6 casting), having an angular cast surface 13C replicating wall 13 and a radius tapering to edge 19C in top surface 3.
In FIG. 6 a cross-section of a portion of a diagonal wall DW1 or DW2 of FIG. 4 is shown taken along section line 6--6, in which diagonal wall DW1 or DW2 has a cross-sectional shape of a "T" having a v-shaped angular vertical surfaces 14 and 15 extending from plane of bottom surface 4 and curving out to opposed top surface edges 19 at top surface 3.
In FIG. 6A, the cast angular walls 14C and 15C are shown as simulated stone pattern cements 6C cast by replicating the surfaces of walls 14 and 15 of the typical diagonal wall of FIG. 6, the cast walls 14C and 15C curving outwards and terminating at cast ledges 19C.
In FIG. 7, a cross-section of a portion of a partial dividing wall 5 of FIG. 4 is shown taken along section line 7--7, in which partial dividing wall 5 has a cross-sectional shape of a "T" having a v-shaped angular vertical surfaces 16 and 17 extending from a truncated intermediate-plane bottom surface 4a, curving out to opposed top surface edges 19 at planar top surface 3.
In FIG. 7A, the cast angular walls 16C and 17C are shown as simulated stone pattern elements 6C cast by replicating the surfaces of walls 16 and 17 of the typical dividing wall of FIG. 6, the cast walls 16C and 17C curving outwards and terminating at cast ledges 19C. The truncated bottom surface 4A produces a cast monolithic connection 4AC between adjacent cast cements 6C.
In FIG. 7B, it is shown that any dividing wall 5 may also separate a cast stone segment 6C from an empty mold segment 6. The intermediate plane 4A of a dividing wall 5 has a distance "D" from bottom surface 4, such that the larger gravel of a typical concrete aggregate will jam up and not flow through the gap. Thus, distance D of between 5/8-inch and 3/4-inch forms a concrete dam between an untilled pattern element 6 and a filled, cast element 6C, as shown in FIG. 7B. However, when adjacent mold elements 6 are filled to produce adjacent cast stones 6C, the thickness of distance D is sufficiently strong to provide monolithic integrity in the finished pattern. If distance D was made larger, freshly-poured concrete would flow into the mold clement that is planned to be empty. Conversely, if distance D was made smaller, there may be a gap under the wall, whereby the monolithic structural integrity is lost, or the connection may be too thin to resist breaking in use, and small stones might become loose.
FIG. 8 shows how two triangular portions J2-C1-J4 and J4-C3-J2 of a generally square molded stone pattern 30 are cast. The triangular portions, divided by line (23A, 23B) in the top planar surface of the mold of FIGS. 1-4, are filled to produce a first triangular pattern of cast stones 31 and a second triangular pattern of cast stones 32.
FIG. 9 shows how the two other triangular portions J1 C4-J3 and J3-C2-J1, of the same molded pattern 30 as in FIG. 8 are cast. The triangular portions divided by line B--B of the mold of FIGS. 1-4, are filled to produce a third triangular pattern of cast stones 33 and a fourth triangular pattern of cast stones 34.
In FIG. 10, a top perspective view and in FIG. 11, a bottom perspective view, another preferred embodiment mold 24 of the present invention is shown. The entire configuration of the mold may be used to cast a monolithic pattern of stones. In this embodiment, as in mold 1 of FIG. 1-4, the perimeter 2 extends from the top planar surface 3 to the bottom planar surface 4. However, the diagonal walls DW3 and DW4 of the illustrated mold 24, along with the dividing walls 5, extend from the top planar surface 3 only as far as an intermediate plane 4A. Thus, in use, the bottoms of all of the walls excepting the perimeter wall 2 are raised off the ground. In order to provide support for the elevated walls, a plurality of vertical columns 25 are integrally molded as parts of the walls. This permits adequate clearance of the diagonal walls and dividing walls to permit the flow of cement under and between the walls to cast a monolithic pattern of stones.
FIG. 12 shows a cross-sectional view, taken along section line 12--12, which is identical to cross-section 6--6 of FIG. 4 and FIG. 6, and in which the perimeter wall 2 casts the simulated stone 6C.
FIG. 13 shows a cross-sectional view, taken along section line 13--13, which is different from the cross-section 6--6 of FIG. 4 and FIG. 5. In mold 24 of FIGS. 10 and 11 the diagonal wall DW3 and DW4 extend downward only to the intermediate plane 4A, which is spaced above the bottom plane 4 a distance "D". This spacing permits any adjacent cast stones to be joined together as a single monolithic casting as shown in FIG. 13A.
FIG. 14 shows a cross-sectional view, taken along section line 14--14, which is similar to that shown in the cross-section 7--7 of FIG. 4. This produces the joined stones as shown in FIG. 7A, or the partial cast pattern as shown in FIG. 7B. Thus, due to the optimum distance D, any wall extending between top surface 3 and the intermediate plane 4A, within any perimeter wall configuration extending between top planar surface 3 to bottom planar surface 4, may optionally terminate the stone pattern of the mold. This provides the pattern versatility to produce a wide variety of pattern configurations for a multitude of uses described below.
FIG. 15 shows a plurality of generally square molded stone patterns 30, as shown in FIG. 8 and FIG. 9, arranged in a rectilinear configuration 35. The dimensions of the patterns are limited only by the desired size of the finished area.
FIG. 16 shows a plurality of generally square molded stone patterns 30, arranged in a staggered rectilinear configuration 36. Again, the dimensions of the patterns are limited only by the desired size of the finished area.
FIG. 17 shows a plurality of generally square molded stone patterns 30, arranged in a straight linear configuration 37.
FIG. 18 shows a plurality of generally square molded stone patterns 30, arranged in a curved linear configuration 38, in which a right turn curve is produced by the casting of two triangular portions 33. A straight walk section is then produced by a number of square patterns 30 and the left turn curve is produced by casting additional triangular portions 34. The direction of the curve is determined by the triangle selected, and the angle of the turn is determined by the number of successive triangles used.
FIG. 19 shows a plurality of generally triangular portions 33, which are successively cast around a complete circle. Other triangular portions may be selected to alter the radius of the circle, permitting circles of different sizes, ellipses, and the like, and with the insertion of square patterns between the triangles, modified circles, such as ovals, may be produced.
FIG. 20 shows a generally-hexagonal polygon pattern 41, which is divided by a diagonal wall DW5 into a pair of identical, generally trapezoidal shapes 42 having complementary sides and diagonals, and having partial dividing walls 43 defining individual stone shapes. The desired size of the mold will determine whether the mold is made in one piece 41 or one or two smaller molds 42.
FIG. 21 shows a plurality of generally hexagonal molded stone patterns 41 and 42, arranged in a linear configuration 46, in which a left turn curve is produced by the casting of two trapezoidal portions 41. The direction of the curve is determined by the angle on pattern 41 selected.
FIG. 22 shows a plurality of molded stone patterns 41 and/or 42, arranged in a rectilinear configuration 45. The dimensions of the patterns are limited only by the desired size of the finished area.
FIG. 23 shows a trapezoidal mold 42, or half the hexagonal mold 42, which is successively cast to form a complete circle.
FIG. 24 shows a pattern of triangular stones in an isosceles triangular pattern mold 51, which is bisected by a diagonal wall DW6 extending from a first corner C1 to bisect a side S2 between the second corner C2 and the third corner C3, and which has a stone pattern defined by partial dividing walls 55.
FIG. 25 shows a pattern of triangular stones, including an isosceles triangular pattern mold 51 having two aides comprising diagonal walls DW6, along with adjacent right-triangle portions to form a square mold 52.
FIG. 26 shows a plurality of square molded stone patterns 52, arranged in a straight and curved linear configuration 56, in which left and right turns are produced by the casting of two triangular portions 51.
FIG. 27 shows a plurality of square molded stone patterns 52, as shown in FIG. 25, arranged in a rectilinear configuration 57. The dimensions of the patterns are limited only by the desired size of the finished area.
FIG. 28 shows a plurality of triangular portions 51, which are successively cast around a complete circle. The insertion of square patterns between the triangles, modified circles, such as ovals or rounded squares, may be produced.
FIG. 29 shows a pattern of two trapezoidal patterns 62, having a diagonal wall DW6 and forming portions of a hexagonal mold 61.
FIG. 30 shows a plurality of hexagonal molded stone patterns 61 and trapezoidal patterns 62, arranged in a straight and angular linear configuration 66, in which a left turn (shown) or right turn (not shown) may be produced by the casting of hexagons 62 and a triangular portion 63.
FIG. 31 shows a plurality of hexagonal 61 and trapezoidal sections 62, arranged in a rectilinear configuration 67. The dimensions of the patterns are limited only by the desired size of the finished area.
FIG. 32 shows a plurality of hexagonal portions 61, which are successively cast around a complete circle. The insertion of trapezoidal patterns 62 between the hexagons, modified circles, such as ovals or rounded squares, may be produced.
Although the invention has been described in terms of special embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
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A mold for casting ground covering, such as a plurality of stepping stones, has a generally polygon concrete molding frame having top and bottom surfaces in parallel planes and divided into openings. The frame is generally square and may include nesting polygonal configurations. Each wall has a plan shape of contiguous line segments connected at obtuse angles. A first diagonal wall extends approximately from the first corner to the third corner, and a second diagonal wall extends approximately from the second corner to the fourth corner. The first perimeter wall is geometrically congruent with the third perimeter wall and the second perimeter wall is geometrically congruent with the fourth perimeter wall. The diagonal walls are geometrically congruent with the second and fourth perimeter walls.
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This application is a Divisional Application of U.S. patent application Ser. No. 09/958,092, filed Nov. 16, 2001, now abandoned which is a National Stage Application of PCT Application No. PCT/FR00/01007 filed Apr. 18, 2000, published in a non-English language, which in turn claims priority to French Application 99/04,875 filed Apr. 19, 1999, the entire contents of all of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to a novel peptide extract which has antimetalloprotease activity, in particular anticollagenase and antigelatinase activity. It also relates to the pharmaceutical, cosmetic or nutraceutical compositions comprising such an extract, in particular to a pharmaceutical composition intended to treat inflammatory diseases, such as arthrosis, parodontosis or ulcers, or to the cosmetic compositions intended to combat aging, which may or may not be actinic aging, or aging accelerated by outside attacks (tobacco, pollution, etc.).
The pharmaceutical, cosmetic or nutraceutical composition is also intended to treat neoangiogenesis (vessel proliferation) which is pathological or unsightly (psoriasis, tumors, erythosis, acne erythematosa, rosacea, local treatment with irritants such as retanoic acid), cicatrization deficiencies, burns or the attack of dental enamel (Ch. M. Lapiere, Cours de biologie de la peau [Skin biology course]—COBIP INSERM U 346, Lyon 1999).
Metalloproteases are a family of zinc- and calcium-dependent endopeptidases which have the combined property of degrading the diverse components of connective tissue matrices (thesis by S. Charvat—Métalloprotéinases et épiderme [Metalloproteinases and epidermis], pages 101–113 No. 248–98, 1998, Lyon I).
They are classified according to the nature of their substrate: collagenase (fibrillar collagen: ex. MMP-1, -13, -8); gelatinase (denaturated collagen, gelatin: ex. MMP-2, MMP-9); stromelysins (fibronectin, proteoglycin: ex. MMP-3, MMP-10). They are used in the physiological remodeling (low expression) or pathological remodeling of the extracellular matrix (strong induction).
Metalloproteases are in particular involved in the cicatrization process, eliminating the damaged tissues.
MMPs may act anarchically and cause significant lesions if their activity is not controlled.
Moreover, it is known that metalloproteases are involved in certain biological disorders, such as inflammatory diseases, in particular arthrosis and parodontosis (H. BIRKEDAL-HANSEN et al., Critical Reviews in Oral Biology and Medicine, 4(2): 197: 250 (1993)), in the processes of aging, in particular linked to the action of solar radiation (MARTIN RIEGER; Allured's Cosmetics & Toiletries®, Vol. 114, No. 1/January 1999 or G. J. FISHER et al., The New England Journal of Medicine , Vol. 337, No. 20 pp. 1419–1428 , “Pathophysiology of premature skin aging induced by ultraviolet light ” and G. J. FISHER et al., the Society for Investigative Dermatology , Inc. 1998, pp. 61–68 “Molecular mechanisms of photoaging and its prevention by retinoic acid: ultraviolet irradiation induces MAP kinase signal transduction cascades that induce A -1- regulated matrix metalloproteinases that degrade human skin in vivo ”) or in acute and chronic inflammations (XIE et al.; J. Biol. Chem. 273: pp. 11576–11582; 1998) and blistering diseases (toxic epidermal necrolysis), pathologies with cellular hyperproliferation during inflammation or irritation, bedsores, burns and ulcers.
The same is true for the proliferation of neoangiogenesis endothelial cells which, in their proliferative phase during inflammatory or pathological processes (psoriasis, tumors) need MPPs to destroy the connective tissue, in order to migrate toward other regions and to form microtubules and capillaries ( Controlling the vasculature: angiogenesis, anti-angiogenesis and vascular targeting of gene therapy —T. P. D. FAN, R. JAGGAR and R. BICKNELL, TiPS—February 1995, Vol. 16 ; Natural Products as angiogenesis inhibitors , D. H. PAPER, Planta Medical 64 (1998) pp. 686–695 ; Membrane - type matrix metalloproteinases in human dermal microvascular endothelial cells: expression and morphogenetic correlation —V. T. CHAN et al., J.I.D. 111, pp. 1153–1159, 1998 ; Matrix metalloproteinases in blood vessel development in human fetal skin and in cutaneous tumors —T. V. KARELINA et al. J.I.D.; 105, 411–417, 1995 ; Vascular profiferation and angiogenic factors in psoriasis , J. D. CREAMER and J. N. W. N. BARKER, Clinical and Experimental Dermatology, 1995, 20, pp. 6–9).
The role of inhibitors of metalloproteases, in particular of collagenases, gelatinases and of stromelysins, in certain treatments for the abovementioned diseases is also known.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a novel broad-spectrum inhibitor of metalloproteases of the collagenase or gelatinase type, which allows the treatment of humans or of mammals suffering from a condition or a disease linked to excess or pathological degradation of collagen or of another extracellular support macroprotein, or any other diseases linked to excessive expression of these proteolytic enzymes.
A subject of the invention is a peptide extract of lupin (lupinus), characterized in that it has activity for inhibiting metalloproteases, in particular collagenases or gelatinases. As a variety of lupin, mention is made in particular of the sweet white lupin genus ( lupinus albus ), such as the Ares variety which has a low alkaloid content.
A subject of the invention is in particular a novel peptide extract of lupin (lupinus), characterized in that it has an activity for inhibiting purified Clostridium histolycum collagenase on DQ-gelatin, which is in particular greater than 50% at 24 hours, for a concentration of equal to or greater than 0.1% (w/v).
According to one variant, this peptide extract of lupin is lipid-depleted.
It advantageously comprises at least 50%, preferably at least 70%, preferably at least 80% of peptide.
These peptides are obtained by hydrolysis of the protein fraction of lupin.
The hydrolysis may be carried out by any suitable means, in particular enzymatic hydrolysis.
A process for preparing such a peptide extract of lupin comprises the following steps:
preparing a lipid-free, ground lupin meal or a micronized lupin flour (containing lipid), extracting the soluble protein and saccharide fractions or precipitating with acid pH (4 or 5) depending on the isoelectric point, optionally separating the protein fraction, hydrolyzing the protein fraction and recovering, optionally after filtration, the protein extract.
The invention also relates to the protein extract which can be obtained using the abovementioned process.
In general, the invention comprises the lipid-containing lupin flours and the peptide extracts also comprising the sugars.
Preferably, the protein extract has the following amino acid composition (percentage by weight relative to the total weight of amino acids).
Amino acids
%/total AAs
ASP
11.3
GLU
23.2
SER
5.1
HIS
1.7
GLY
3.4
THR
3.2
ALA
2.8
ARG
10.3
TYR
6.1
CYS-CYS
2.4
VAL
3.8
MET
0.2
PHE
7.0
ILE
3.3
LEU
7.9
LYS
3.7
PRO
4.4
A subject of the invention is also a pharmaceutical, cosmetic or nutraceutical composition comprising a peptide extract as described above and, optionally, a suitable physiologically acceptable inert vehicle.
Such a pharmaceutical or dermocosmetic and nutraceutical composition is intended in particular for treating humans or mammals suffering from a condition or disease linked to excessive destruction of collagen and/or excessive destruction of support tissues. Such a composition may be used by way of prevention or cure.
Among these conditions or diseases, mention is made, for example, of arthrosis, periodontal diseases, diseases linked to skin lesions, inflammatory diseases, tumor-related or pathological neoangiogenesis (erythrosis, acne erythematosa, telangiectasia, rosacea, psoriasis, etc.), cicatrization deficiency, ulcers, burns, blistering diseases and the attack of dental enamel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents the kinetics of inhibition of the aspecific collagenase—influence of the concentration of peptide extract. The y-axis represents gelatinolytic activity (%), the x-axis represents incubation time (h).
DETAILED DESCRIPTION OF THE INVENTION
The invention also relates to cosmetic compositions for treating skin lesions due to aging, such as lesions caused by the action of solar radiation (photoaging), the intrinsic deleterious effects of the skin or the deleterious effects of tobacco.
The pharmaceutical, dermocosmetic or cosmetic compositions are, according to one variant, in the form of a formulation for topical application. A subject of the invention is therefore a method for cosmetic treatment, comprising applying such a composition on the surface of the skin of an individual.
The peptide extract according to the invention may also be incorporated into or formulated in a polymeric vehicle or a delivery system, for topical or local use, such as in the case of treating a periodontal disease, so as to be delivered directly into the periodontal pocket.
According to another variant, the pharmaceutical compositions are in the form of a formulation for oral administration.
These compositions may, in general, be formulated in the form of tablets, of capsules or of ointment.
In the case of nutraceutical compositions or food compositions, the forms conventionally used may be employed.
The invention is now illustrated using the examples of implementation described hereinafter, by way of illustration.
I—Preparation of peptide extracts of lupin I.1.—Extract A
Extraction and Purification of Lupin Proteins
This step comprises aqueous solubilization of the fraction soluble at alkaline pH, followed by separation from the insoluble components:
Using the lipid-free ground lupin meal, the proteins are extracted at pH 9.0 (pH adjusted by adding sodium hydroxide) with a flour/water ratio equal to 1/10 (w/w). The solution is incubated with stirring at room temperature for one hour. The insoluble portion of the meal is then separated from the soluble portion by spin-drying. The cake obtained is washed. The soluble fraction containing the soluble sugars and proteins is diafiltered on an ultrafiltration module with a cutoff threshold of 10 000 Daltons, in order to separate the proteins (retentate) from the soluble sugars (ultrafiltrate).
Production and purification of peptides by enzymatic hydrolysis:
The ultrafiltration retentate containing the proteins is adjusted to the concentration of 100 g/l and then hydrolyzed at pH 8.0 in the presence of Alcalase® (NOVO NORDISK) at 55° C. for approximately 3 h. After hydrolysis, the enzyme is denatured by hydrolysis for 15 min at 85° C. As soon as the solution has cooled down, it is neutralized by adding hydrochloric acid. The peptides obtained are purified by diafiltration on an ultrafiltration module with a cutoff threshold of 10 000 Daltons. The solution obtained is then nanofiltered in order to desalify (eliminate the sodium chloride) and concentrate the peptide fraction. The peptide solution is finally decolorized using 3% active charcoal (1 hour at 50° C.), the charcoal being removed by filtration.
Sterilization and packaging of the peptide fraction:
Before packaging, the solution is microfiltered (0.2 μm) sterilely and then distributed into sterile containers at the concentration of 10%, in the presence of preserving agents.
I.2—Extract B
The peptide extract B is obtained according to the described method implemented for obtaining extract A, except that the decolorization step is deleted.
I.3—Extract C
The peptide extract of lupin C is obtained according to the described method implemented for obtaining extract A, except that the purification, ultrafiltration and decolorizing steps are deleted.
II—Analysis of peptide extract A
The dry extract is then analyzed.
Presentation:
Appearance:
nonhygroscopic homogeneous powder
Color:
off-white
Amount:
5 g
Chemical composition:
Total of sugar content (test
<1%
using anthrone):
Chloride content (SIGMA kit
6%
ref: 955-30):
Water content (100° C., 4 h):
8% maximum
Peptide content:
85%
Characterization
pH (solution at 20 g/l):
7.06
Solubility (osmozed water):
>100 g/l
TABLE 1
Amino acid composition of the hydrolysate
Amino
M.W.
Conc. in
Conc. in
% in
%/total
acids
A.A.
mM
mg/l
powder
AAs
ASP
133.1
2.078
276.582
9.9
11.3
GLU
147.1
3.858
567.438
20.3
23.2
SER
105.1
1.196
125.647
4.5
5.1
HIS
155.2
0.270
41.904
1.5
1.7
GLY
75.1
1.114
83.624
3.0
3.4
THR
119.1
0.664
79.023
2.8
3.2
ALA
89.1
0.763
67.983
2.4
2.8
ARG
174.2
1.447
251.980
9.0
10.3
TYR
181.2
0.829
150.215
5.4
6.1
CYS-CYS
240.3
0.247
59.234
2.1
2.4
VAL
117.1
0.792
92.743
3.3
3.8
MET
149.2
0.029
4.327
0.2
0.2
PHE
165.2
1.044
172.469
6.2
7.0
ILE
131.2
0.621
81.410
2.9
3.3
LEU
131.2
1.481
194.307
6.9
7.9
LYS
146.2
0.626
91.448
3.3
3.7
PRO
115.1
0.935
107.619
3.8
4.4
Total
2447.952
87.4%
III—Anticollagenase and antigelatinolytic activity of the lupin peptides—extract A, in vitro
The anticollagenase activity was measured in vitro in a biochemical model of the screening type, based on the use of a purified collagenase and of the substrate for the latter, gelatin conjugated to fluorescein (EnzChek™ gelatinase/collagenase kit, MOLECULAR PROBES). The collagenase purified from Clostridium histolyticum was supplied in the EnzChek™ gelatinase/collagenase kit (MOLECULAR PROBES). This enzymes has a double functionality on collagen IV (epidermis/dermis basal membrane) and gelatin.
The DQ-gelatin purified from porcine skin and conjugated to fluorescein was supplied in the EnzChek™ gelatinase/collagenase kit (MOLECULAR PROBES).
The reaction buffer, consisting of 0.05 M of Tris-HCl, 0.15 M NaCl, 5 mM of CaCl 2 , and 0.2 mM of sodium azide (pH 7.6) was supplied in the EnzChek™ gelatinase/collagenase kit (MOLECULAR PROBES).
The peptide extract was solubilized in the reaction buffer. It was tested at 0.004; 0.02; 0.04; 0.2 and 0.4% (w/v).
The dilutions of the test extracts were incubated with DQ-gelatin at 1 mg/ml and collagenase at 0.2 Ru/ml for 1 hour, 2 hours and 24 hours at room temperature.
A control, corresponding to the “collagenase+DQ-gelatin” mixture, was incubated in parallel.
For each experimental condition, samples, subsequently named “samples without enzyme”, were incubated in the presence of DQ-gelatin and in the absence of collagenase.
Each experimental condition was performed in triplicate.
After 1 hour, 2 hours and 24 hours, the signal corresponding to the degradation of the DQ-gelatin was measured by fluorimetry (excitation: 485 nm and emission: 595 nm). For each sample, the value obtained for the “samples without enzyme” was attracted.
The results were expressed as fluorescence units per sample and as percentage variation relative to the control group.
The groups of data (control group and treated groups) were compared by factor analysis of variance (ANOVA 1, p<0.05), followed by a Dunnett's test. The effect of the extracts was thus compared to that obtained in the control group.
The peptide extract tested from 0.004 to 0.2% (w/v) had a dose-dependent anticollagenase and antigelatinolytic activity. The effect was maximal at the 24 hour time point, as indicated in Table 2 below.
TABLE 2
Control
0.004
0.02
0.04
0.2
0.4
Incubation time = 1 hour
16237
14161
11890
11205
11249
9434
14329
13561
11161
10863
9840
7544
15636
13965
11757
11344
11387
8878
15401
13896*
11603*
11137*
10825*
8619*
+/−
+/−
+/−
+/−
+/−
+/−
976
306
388
248
856
971
100%
89
75
73
73
57
Incubation time = 2 hours
24776
20526
13689
11000
7617
6853
22516
19597
6710
10406
6072
4933
23779
20144
13148
11349
7824
6467
23690
20089*
11182*
10918*
7171*
6084*
+/−
+/−
+/−
+/−
+/−
+/−
1133
467
3883
477
957
1016
100%
85
55
48
33
27
Incubation time = 24 hours
31653
12655
2583
2378
524
1154
29536
11531
1487
1442
484
467
29745
13008
2657
2713
693
927
30311
12398*
2242*
2178*
567*
849*
+/−
+/−
+/−
+/−
+/−
+/−
1167
771
655
659
111
350
100%
41
7
7
2
3
The results are expressed as fluorescence units/sample.
In bold: mean and standard deviation
*mean significantly different from the control group (p < 0.05).
In conclusion, under the experimental conditions selected, the protein extract tested between 0.004 and 0.4% (w/v) had a dose-dependent antigelatinase/collagenase activity. An excellent effect/dose/time ratio for the lupin peptides compared to the aspecific collagenase is in particular noted: at 24 hours, for example, 0.04% inhibits 93% of the gelatinolytic activity of the clostridium collagenase, at 2 hours: 52%.
Other tests with the same peptide extract were carried out at concentrations of 0.01; 0.05; 0.1; 0.5 and 1% (w/v) and the results are given in table 3 below and also in the attached FIG. 1 . This figure represents the kinetics of inhibition of the aspecific collagenase—influence of the concentration of peptide extract. The y-axis represents gelatinolytic activity (%), the x-axis represents incubation time (h).
TABLE 3
Concentration of extract A (% w/v)/
Incubation
gelatinolytic activity as (%)
time (h)
0.01
0.05
0.1
0.5
1
1
89
75
73
73
57
2
85
55
48
33
27
4
79
38
29
14
12
6
69
27
21
8
9
24
41
7
7
2
3
Under the experimental conditions selected, the peptide extract tested between 0.01 and 0.5% (w/v) has a dose-dependent and time-dependent antigelatinase/collagenase activity.
The aspecific inhibitor 1,10-phenanthroline was used in all the tests as a reference anti-MMP product. The results obtained were in accordance with those expected and validated the tests.
IV—Specific anticollagenase activity of the lupin peptides—extract A, on a human organotypic model
Skin aging is characterized, inter alia, by a modification of the cutaneous mechanical properties of the skin, subsequent to degradation of the collagen fibers of the dermis and of other macroproteins. This degradation involves endogenous collagenases (Grymes, R. A., Kronberger A. and Bauer E. A.— Collagenases in disease— in “Connective Tissue Diseases of the skin ” Eds. Lapière C. M. and Krieg T., 1993, 69–85; G. Fischer and J. Voorhees “ Pathiophysiology of premature skin aging induced by ultraviolet light ” and “ Molecular mechanisms of photoaging and its prevention by retinoic acid: ultraviolet irradiation induces MAP kinase signal transduction cascades that induce A -1- regulated matrix metalloproteinases that degrade human skin in vivo ”).
Products which have anticollagenase activity can be envisaged for combating the signs of skin aging.
The anticollagenase activity of a test product can be studied in vitro in an organotypic model of human skin. The principle of the test is as follows: application of purified collagenase to sections is accompanied by degradation of the endogenous collagen fibers. The collagen fibers are then stained with Masson trichrome. The digestion of the endogenous collagen fibers by the purified collagenase is evaluated qualitatively by morphological observation and quantitatively by image analysis. A product which has anticollagenase activity will partially or totally preserve the integrity of the collagen fibers placed in the presence of the enzyme.
The test products were stored at +4° C. until they were used.
Three dilutions were tested: 0.01; 0.1 and 1% (v/v).
Phosphoramidon, used as a reference product, came from SIGMA.
The purified collagenase (type III, fraction A) came from SIGMA.
The medium for incubating the human skin sections, subsequently named “vehicle” was 0.15 M Tris HCl buffer, pH 7.5, containing 0.01 M of calcium chloride.
The reagents, of analytical quality, came from CARLO ERBA, GIBCO or SIGMA, unless otherwise stated.
The skin sections were prepared from waste from an operation, recovered after abdominal plastic surgery. The individual was a 30-year-old woman. Skin explants 4 cm in diameter were prepared. They were placed on a cork support and frozen at −80° C. 6 μm-thick transverse sections were prepared using a cryomicrotome. They were fixed on glass slides and kept hydrated with the vehicle during the test.
The test samples were all taken up in ethanol before being diluted in the test buffer.
The final concentration of ethanol was maintained constant and equal to 0.1% (v/v) in the two weakest dilutions of the peptide extract (0.01 and 0.1% v/v); It was maintained constant and equal to 1% (v/v) in the strongest dilution (1%, v/v). “Ethanol controls” at 0.1 and 1% (v/v) were prepared. The phosphoramidon was taken up directly in the vehicle.
The peptide extract was tested at 0.01; 0.1 and 1% (w/v). The phosphoramidon was tested at 10 −3 M.
The following samples were therefore present:
Extract: buffer; ethanol (0.1% v/v or 1% v/v); extracted enzyme (0.01; 0.1 and 1%, w/v); Enzyme control: buffer; ethanol (0.1%, v/v); enzyme; Ethanol control (without enzyme): buffer; ethanol (0.1% or 1%, v/v); Ref. product: buffer; ethanol; enzyme; 10 −3 M phosphoramidon.
The dilutions of the test products, of the ethanol and of the reference product were placed on to the skin sections, at 100 μl per section, and pre-incubated for 10 minutes at 37° C. Strips of filter paper (0.16 cm 2 surface area) soaked with vehicle alone (control without enzyme) or containing collagenase at 50 international units (IU)/ml (enzyme control) were then placed over the sections. The slides were placed in a humid chamber at 37° C. for three hours.
After incubation, the sections were rinsed with the incubation medium and stained with Masson trichrome. The activity of the enzyme in the presence and absence of the extract, of the ethanol or of the reference product was evaluated by microscopic observation and scored according to the following scheme:
0:
zero enzymatic digestion
+:
weak enzymatic digestion
++:
average enzymatic digestion
+++:
strong enzymatic digestion.
Photographs of the sections were taken.
The activity of the collagenase in the presence and absence of the test products, of the ethanol or of the reference product was evaluated by image analysis. The image of the stained sections was digitalized on a video screen; the image analysis software (IMAGENIA 2000, BIOCOM®) made it possible to calculate the surface area occupied by the intact collagen fibers. The results were expressed as a percentage of intact collagen fibers per optical field.
The percentage inhibition of the collagenase activity of the extracts at various concentrations of the ethanol and of the reference product was calculated using the following formulae:
For the reference product (directly taken up in the vehicle), the percentage inhibition is calculated using the following formula:
(
%
collagen
fibers
)
ref
product
-
(
%
collagen
fibers
)
enzyme
control
×
100
(
%
collagen
fibers
)
ethanol
control
-
(
%
collagen
fibers
)
enzyme
control
For the extracts diluted in the vehicle containing 0.1% (v/v) of ethanol, the percentage inhibition is calculated using the following formula:
(
%
collagen
fibers
)
ref
product
-
(
%
collagen
fibers
)
enzyme
control
×
100
(
%
collagen
fibers
)
ethanol
control
-
(
%
collagen
fibers
)
enzyme
control
For the extracts diluted in the vehicle containing 1% (v/v) of ethanol, the percentage inhibition is calculated using the following formula:
(
%
collagen
fibers
)
ref
product
-
(
%
collagen
fibers
)
enzyme
control
×
100
(
%
collagen
fibers
)
ethanol
control
-
(
%
collagen
fibers
)
enzyme
control
.
The anticollagenase activity of the extract at various concentrations was studied in an organotypic model of human skin.
In the absence of collagenase (vehicle control), the collagen fibers were intact. In the presence of collagenase (enzyme control), the collagen fibers were almost totally degraded. This result was expected and validated the test.
The phosphoramidon at 10 −3 M, used as a reference product, inhibited the collagenase activity by 16%. This result was expected and completed the validation of the test.
The ethanol, used as an intermediate diluent of the test products was tested at 0.1 and 1% (v/v). It had no effect on the degradation of the collagen fibers by the collagenase.
The peptide extract tested at 0.01; 0.1 and 1% (w/v) inhibited the activity of the collagenase by 2, 24 and 65%, respectively. The morphological observation gave the same result.
In conclusion, under the experimental conditions selected, peptide extract A had considerable anticollagenase activity at low concentrations.
The results of inhibition, for the peptide extract, for the ethanol and for the phosphoramidon, on the digestion of dermal collagen fibers by collagenase are given in the table below:
TABLE 4
Enzymatic
% inhibition of
digestion
the collagenase
Experimental
(morphological
activity (image
condition
Concentration
observation)
analysis)
Vehicle control
—
0
−
Enzyme control
50 IV/ml
+++
0
Phosphoramidon
10 −3
+
+
(M)
Ethanol
0.1
+++
0
(%, v/v)
1
+++
0
Peptide extract
0.01
+++
2
(%, v/v)
0.1
++
24
1
+
65
0: zero enzymatic digestion
+: weak enzymatic digestion
++: average enzymatic digestion
+++: strong enzymatic digestion
V—Antimetalloprotease MMP-2 and MMP-9 activity of the lupin peptides—extracts A, B and C
MMP-2, or gelatinase A, and MMP-9, or gelatinase B, are metalloproteases which degrade specific components of the extracellular matrix: MMP-2 degrades gelatin (=denatured collagen), collagens I, IV, VII and XI, fibronectin, laminin and elastin; MMP-9 degrades gelatin, collagens IV, V and XIV and elastin. They play an important role in photoaging and in the proliferation of endothelial cells.
The anti-MMP-2 and anti-MMP-9 activity of the test products was measured in vitro in a biochemical model of the screening type, based on the use of a purified human MMP-2 and of a recombinant human MMP-9 and of the substrate for the latter, gelatin conjugated to fluorescein (EnzChek™ gelatinase/collagenase kit, MOLECULAR PROBES).
The MMP-2 purified from human fibrosarcoma came from BOEHRINGER MANNHEIM.
The recombinant human MMP-9 came from R&D SYSTEMS.
The DQ-gelatin purified from porcine skin and conjugated to fluorescein was supplied in the EnzChek™ gelatinase/collagenase kit (MOLECULAR PROBES).
The reaction buffer for studying the activity of MMP-2 (RBf1) consisted of 50 mM of Tris-HCl, 0.05% (w/v) of Triton X100 and 5 mM of CaCl 2 , pH 7.5.
The reaction buffer for studying the activity of MMP-9 (RBf2) consisted of 50 mM of Tris-HCl, 0.05% (w/v) of Brij 35 and 5 mM of CaCl 2 , pH 7.4.
Preparation of the Test Products and of the Reference Product
1,10-Phenanthroline was solubilized in the reaction buffers RBf1 and RBf2. It was tested at 8 and 80 μg/ml.
Peptide extracts A, B and C were solubilized in the reaction buffers RBf1 and RBf2. They were tested at 0.01; 0.1 and 1% (w/v).
MMP-2
Before being used, the MMP-2 was activated by incubation for 30 minutes at 37° C. in the presence of APMA diluted to 2.5 mM in the buffer RBf1.
The dilutions of the test products or of the reference product were incubated with the DQ-gelatin, diluted to 25 μg/ml, and the activated MMP-2, diluted to 1.25 μg/ml, for 24 hours at 37° C.
A control corresponding to the “MMP-2+DQ-gelatin” mixture, was incubated in parallel.
For each experimental condition, samples, subsequently named “samples without enzyme”, were incubated in the presence of DQ-gelatin and in the absence of activated MMP-2. These samples made it possible to measure the interference of the test products with the method for evaluating the effects (fluorimetry).
Each experimental condition was performed in triplicate.
MMP-9
The dilutions of the test products or of the reference product were incubated with the DQ-gelatin, diluted to 25 μg/ml, and the MMP-9, diluted to 0.25 μg/ml, for 24 hours at 37° C.
A control corresponding to the “MMP-9+DQ-gelatin” mixture, was incubated in parallel.
For each experimental condition, samples, subsequently named “samples without enzyme”, were incubated in the presence of DQ-gelatin and in the absence of MMP-9. These samples made it possible to measure the interference of the test products with the method for evaluating the effects (fluorimetry).
Each experimental condition was performed in triplicate.
After 24 hours, the signal corresponding to the degradation of the DQ-gelatin was measured by fluorimetry (excitation: 485 nm and emission: 595 nm) For each sample, the value obtained for the “samples without enzyme” was subtracted.
The results were expressed as fluorescence units per sample and as percentage variation relative to the control group.
The groups of data (control group and treated groups) were compared by onefactor analysis of variance (ANOVA 1, p<0.05), followed by a Dunnett's test.
The results are given below:
V.1 - Anti-MMP-2 activity MMP2 activity (as %) (1)/Concentration (% v/v) of 10% by weight solution of Peptide peptide extract extract Control 0.01 0.1 1 C 100 119 111 43 A 100 152 151 68 B 100 110 98 77 (1) Activity expressed relative to the control group in the absence of MMP-2 inhibitor
Conclusion:
The 10% by weight solution of extract of lupin C, tested at 0.01 and 0.1% (v/v) has no anti-MMP-2 activity. When tested at 1% (v/v), it inhibits the MMP-2 by 57%. The 10% by weight solution of extract of lupin A, tested at 0.01 to 0.1% (v/v) has no anti-MMP-2 activity. When tested at 1% (v/v), it inhibits the MMP-2 by 32%. The 10% by weight solution of extract B, tested at 1%, inhibits the MMP-2 by 23%. The phenanthroline, tested at 8 and 80 μg/ml, inhibits the activity of the MMP-2 by 32 and 73%, respectively. This result, which was expected, validates the test.
V.2 - Anti-MMP-9 activity MMP-9 activity (as %) (1)/Concentration (% v/v) of 10% by weight solution Peptide of peptide extract extract Control 0.01 0.1 1 A 100 143 143 61 B 100 146 129 27 (1) Activity expressed relative to the control group in the absence of MMP-9 inhibitor
Conclusion:
The 10% by weight solution of extract of lupin A, tested at 0.01 and 0.1% (v/v) has no anti-MMP-9 activity. When tested at 1% (v/v), it inhibits the MMP-9 by 39%. The 10% by weight solution of extract of lupin B, tested at 0.01 and 0.1% (v/v) has no anti-MMP-9 activity. When tested at 1% (v/v), it inhibits the MMP-9 by 73%.
The phenanthroline, tested at 8 and 80 μg/ml, inhibits the activity of the MMP-9 by 80 and 76%, respectively. This result, which was expected, validates the test.
VI—Evaluation of the effect of the lupin peptides on the amount of MMP-1-9 and -3 in human fibroblasts irradiated with UVA rays
The study was carried out on human dermal fibroblasts in monolayer culture. The cells were pre-incubated for 1 hour at 37° C. in the presence of the reference products and of the test product. Then, the cells were irradiated with a single dose of 10 J/cm 2 of UVA, in the presence of the product to be tested and of the reference products.
Immediately after irradiation, the cells were incubated for 48 h at 37° C., still in the presence of the product to be tested and of the reference products.
The various MMPs are tested in the culture media using specific ELISA kits (Amersham).
Reference Products and Test Product
1,10-Phenanthroline, which is a nonspecific inhibitor of MMPs, and was tested at 80 μg/ml, was used as a reference product.
A 10 μg/ml retinoic acid+10 ng/ml EGF mixture was used for its abilities to induce TIMP1 (TIMP1, Tissue Inhibitor of MMP, physiological inhibitor of MMPs).
A stock solution containing 10% (w/v) of lupin peptides was prepared in deionized water. Using this solution, dilutions were prepared in the fibroblast culture medium. The peptide extract of lupin was tested at 0.5; 1 and 2% (v/v).
Irradiated and nonirradiated control cultures were incubated in parallel, in the absence of the reference products and of the test product.
Processing of Data
The groups of data (control group and treated groups) were compared by one-factor analysis of variance (ANOVA 1, p<0.05), followed by a Dunnett's test. The effects of the reference products and of the test product were thus compared to that obtained in the “irradiated cells” group.
Results:
They are given in the table below and the results are expressed as % relative to the “irradiated cells” group.
Production of MMP (as %) Irradiated cells + lupin Control Irradiated peptides (%, v/v) cells cells 0.5 1 2 MMP-1 24 100 4 3 3 MMP-9 41 100 17 2 0 MMP-3 88 100 3 0 2
Conclusions:
The 1,10-phenanthroline, tested at 80 μg/ml, inhibited by 99% the secretion of MMP-1, by 92% the secretion of MMP-9 and by 97% the secretion of MMP-3, by the irradiated fibroblasts.
The 10 μM retinoic acid+10 ng/ml EGF mixture inhibited by 58% the secretion of MMP-1, by 67% the secretion of MMP-9 and by 44% the secretion of MMP-3, by the irradiated fibroblasts.
These results were expected and validated the reactivity of the test system.
The irradiation at the dose of 10 J/cm 2 increased by a factor of 4.10; 2.42 and 1.13, the respective amounts of MMP-1, -9 and -3 secreted by the fibroblasts. These results were expected and validated the test system with regard to the induction of MMP-1, -9 and -3 by UVA radiation.
The peptide extract of lupin, tested at 0.5, 1 and 2% (v/v), decreased by 96, 97 and 97%, respectively, the amount of MMP-1 secreted by the fibroblasts (p<0.05).
The peptide extract of lupin, tested at 0.5, 1 and 2%, decreased by 83, 98 and 100%, respectively, the amount of MMP-9 secreted by the fibroblasts (p<0.05).
The peptide extract of lupin, tested at 0.5, 1 and 2%, decreased by 97, 100 and 98%, respectively, the amount of MMP-3 secreted by the fibroblasts (p<0.05).
Thus, under the experimental conditions selected, the peptide extract of lupin has considerable inhibitory properties with respect to the production of MMP-1, -9 and -3 by UVA-irradiated human dermal fibroblasts.
VII—Examples of formulae for topical use:
The percentages are expressed as total weight of the composition. The peptide extract of lupin is used in the form of a 10% by weight aqueous solution according to the invention or of a lyophilized powder named powder form peptide extract.
1. Cream acting against red blotches, for normal skin
1. Cream acting against red blotches, for normal skin
Water
q.s. for 100.000
Pentaerythrityl tetraoctanoate
15.0 to 5.0
Glyceryl stearate
10.0 to 2.0
Isodecyl neopentanoate
10.0 to 2.0
Propylene glycol
1.0 to 3.0
Dextrin
1.0 to 3.0
Cyclomethicone
1.0 to 3.0
Soybean (soybean glycine) extract
0.1 to 10.0
Peptide extract of lupin
0.1 to 10.0
(10% aqueous solution)
Titanium dioxide
1.0 to 3.0
Candelilla wax (Euphorbia Cerifora)
1.0 to 3.0
Rice starch (Oriza Sativa)
1.0 to 3.0
Unsaponifiable soybean
0.01 to 10.0
(soybean glycine) oil
Caprylic/capric acid triglycerides
0.5 to 5.0
PEG-100 stearate
0.5 to 5.0
Sophora Japonica extract
0.1 to 10.00
Stearic acid
0.5 to 1.0
Tocopheryl acetate
0.1 to 1.0
Phenoxyethanol
0.1 to 1.0
CI 77891
0.1 to 1.0
Xanthan gum
0.1 to 0.5
Dimethiconol
0.1 to 0.5
Polyacrylamide
0.1 to 0.5
Mica
0.1 to 0.5
Ceteareth-20
0.1 to 0.5
Chlorphenesine
0.1 to 0.5
Carbomer
0.1 to 0.5
Octyl palmitate
0.1 to 0.5
Tromethamine
0.1 to 0.5
Beeswax
0.1 to 0.5
C13–14 Isoparaffin
0.1 to 0.5
DEA cetyl phosphate
0.1 to 0.5
Cetyl alcohol
0.1 to 0.5
Glucose
0.1 to 0.5
Fragrance
0.1 to 0.5
Disodium EDTA
0.1 to 0.5
2. Antiaging preventive cream
%
Water
q.s. for 100.00000
Pentaerythrityl tetraoctanoate
3.0 to 15.0
Isodecyl neopentanoate
3.0 to 15.0
Squalane
1.0 to 10.0
Dextrin
1.0 to 10.0
Cyclomethicone
1.0 to 10.0
Cetearyl alcohol
1.0 to 10.0
Peptide extract of lupin
0.1 to 10.0
(10% aqueous solution)
Ascorbyl glucoside
0.1 to 10.0
Glycerol
1.0 to 10.0
Laureth-23
1.0 to 10.0
Myristyl myristate
1.0 to 10.0
Cyclopentasiloxane
1.0 to 10.0
Nylon-6
1.0 to 10.0
Avocado furan
0.01 to 10.0
Phenoxyethanol
0.1 to 1.0
Cetearyl glucoside
0.1 to 1.0
Fragrance
0.1 to 1.0
Beeswax
0.1 to 1.0
Methylparabene
0.1 to 0.5
Sodium citrate
0.1 to 0.5
Dimethiconol
0.1 to 0.5
Glyceryl stearate
0.1 to 0.5
Disodium EDTA
0.1 to 0.5
Propylparabene
0.1 to 0.5
Sodium hydroxide
0.1 to 0.5
Acrylate/C10–30 alkyl acrylate
0.1 to 0.5
crosspolymers
Xantham gum
0.1 to 0.5
Glucose
0.1 to 0.5
3. Antiaging cream for mature skin
Water
q.s. for 100.0000
Pentaerythrityl tetraoctanoate
1.0 to 10.0
Isodecyl neopentanoate
1.0 to 10.0
Hydrogenated cocoglycerides
1.0 to 10.0
Simmondsia Chinensis (jojoba) seed
1.0 to 10.0
oil
Squalane
1.0 to 10.0
Glycerol
1.0 to 10.0
Cyclomethicone
1.0 to 5.0
Cetearyl alcohol
1.0 to 5.0
Myristyl myristate
1.0 to 5.0
Laureth-23
1.0 to 5.0
Silica
1.0 to 5.0
Peptide extract of lupin
0.1 to 10.0
(10% aqueous solution)
Sclerotium gum
0.1 to 1.0
Avocado furan
0.01 to 10.0
Salicylic acid
0.1 to 10.0
Beeswax
0.1 to 10.0
Polyacrylamide
0.1 to 1.0
Phenoxyethanol
0.1 to 1.0
Glyceryl stearate
0.1 to 1.0
Retinol palmitate
0.01 to 5.0
Cetearyl glucoside
0.01 to 5.0
Nylon-6
0.01 to 5.0
Titanium dioxide
0.01 to 5.0
Fragrance
0.1 to 5.0
Tocopheryl acetate
0.1 to 5.0
Potassium sorbate
0.1 to 5.0
Methylparabene
0.1 to 5.0
C13–14 Isoparaffin
0.1 to 5.0
CI 77891
0.1 to 5.0
Dimethiconol
0.1 to 5.0
Propylparabene
0.1 to 5.0
Sodium hydroxide
0.1 to 5.0
Laureth-7
0.1 to 5.0
Cetearyl alcohol
0.1 to 5.0
Cetyl palmitate
0.1 to 5.0
Cocoglycerides
0.1 to 5.0
Disodiuin EDTA
0.1 to 0.5
CI 77491
0.1 to 0.5
Citric acid
0.1 to 0.5
4. Cream acting against red blotches, for dry to very dry skin
Water
q.s. for 100.00000
Petrolatum
1.0 to 10.0
Hydrogenated cocoglycerides
1.0 to 10.0
Isodecyl neopentanoate
1.0 to 10.0
Simmondsia Chinensis (jojoba)
1.0 to 2.0
oil
Butylene glycol
1.0 to 5.0
Cetearyl alcohol
1.0 to 5.0
Glycerol
1.0 to 10.0
Squalane
1.0 to 10.0
Peptide extract of lupin
0.1 to 10.0
(10% aqueous solution)
Laureth-23
1.0 to 10.0
Titanium dioxide
1.0 to 10.0
Unsaponifiable soybean glycine
0.1 to 10.0
(soybean) oil
Caprylic/capric acid triglycerides
1.0 to 5.0
Phenoxyethanol
0.1 to 1.0
Cetearyl glucoside
0.1 to 1.0
Soybean seed extract
0.1 to 10.0
Fragrance
0.1 to 1.0
Sophora Japonica
0.1 to 10.0
Tocopheryl acetate
0.1 to 1.0
Candelilla wax
0.1 to 1.0
CI 77891
0.1 to 0.5
Methylparabene
0.1 to 0.5
Mica
0.1 to 0.5
Propylparabene
0.1 to 0.5
Ethylhexyl palmitate
0.1 to 0.5
Chlorphenesine
0.1 to 0.3
Acrylate/C10–30 alkyl acrylate
0.1 to 0.3
crosspolymers
Xantham gum
0.1 to 0.3
Disodium EDTA
0.1 to 0.3
Sodium hydroxide
0.1 to 0.3
VIII—Examples of mouthwash solutions
The percentages are expressed as total weight of the composition. The peptide extract of lupin is used in the form of a 10% by weight aqueous solution according to the invention or of a lyophilized powder named powder form peptide extract.
1. 10% aqueous solution peptide extract of lupin + antiseptic
(Triclosan) + antiplaque agent (Gantrez S97BF ®)
Peptide extract of lupin
2
Ethyl alcohol
10
Glycerol
10
Hydrogenated castor oil
0.5
ethoxylated at 40 mol EO
(Cremophor co410)
Poly(methyl vinyl ether/maleic
0.2
acid) (Gantrez S97BF ®)
Sodium hydroxide
0.15
Sodium fluoride
0.05
Cinnamon-mint flavoring
0.1
Triclosan
0.03
Zinc chloride
0.01
Sodium saccharin
0.01
Coloring C.I. 16255 (E 124)
0.0025
Purified water
q.s. for 100
2. 10% aqueous solution peptide extract of lupin + antiseptic
Peptide extract of lupin
2
Ethyl alcohol
10
Glycerol
10
Hydrogenated castor oil
0.3
ethoxylated at 40 mol EO
(Cremophor co410)
Sodium fluoride
0.05
Cinnamon-mint flavoring
0.1
Triclosan
0.03
Zinc chloride
0.01
Sodium saccharin
0.01
Coloring C.I. 16255 (E 124)
0.0025
Purified water
q.s. for 100
3. Powder form peptide extract of lupin + antiseptic
(cetylpyridinium chloride)
Peptide extract of lupin
1
Ethyl alcohol
10
Glycerol
8
Hydrogenated castor oil
0.1
ethoxylated at 40 mol EO
(Cremophor co410)
Sodium fluoride
0.05
Cinnamon-mint flavoring
0.1
Cetylpyridinium chloride
0.05
Zinc chloride
0.01
Sodium saccharin
0.01
Coloring C.I. 16255 (E 124)
0.0025
Purified water
q.s. for 100
IX—Examples of toothpastes
The percentages are expressed as total weight of the composition. The peptide extract of lupin is used in the form of a 10% by weight aqueous solution according to the invention or of a lyophilized powder named powder form peptide extract.
1. Powder form peptide extract of lupin + fluorides
Peptide extract of lupin
1
Sodium monofluorophosphate
0.75
Sodium fluoride
0.10
70% sorbitol
35
Synthetic silica with strong
13
abrasive power
Synthetic silica with weak
5
abrasive power
Sodium carboxymethylcellulose
1.6
Sodium lauryl sulfate
1
Mentholated flavoring
0.85
Titanium oxide
0.5
Sodium hydroxide lye
0.5
Sodium cyclamate
0.3
Menthol
0.15
Sodium saccharin
0.07
Purified water
q.s. for 100
2. 10% aqueous solution peptide extract of lupin + fluorides
Peptide extract of lupin
2
Sodium monofluorophosphate
0.75
Sodium fluoride
0.10
70% sorbitol
35
Synthetic silica with strong
13
abrasive power
Synthetic silica with weak
5
abrasive power
Sodium carboxymethylcellulose
1.6
Sodium lauryl sulfate
1
Mentholated flavoring
0.85
Titanium oxide
0.5
Sodium hydroxide lye
0.5
Sodium cyclamate
0.3
Menthol
0.15
Sodium saccharin
0.07
Purified water
q.s. for 100
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The invention concerns a peptide extract of lupine (lupinus) characterised in that it has a metalloprotease inhibiting activity, in particular collagenase and gelatinase. The invention also concerns a pharmaceutical, cosmetic or nutritional composition comprising a peptide extract, optionally an inert carrier, in particular for treating humans or mammals suffering from a condition or disease related to excessive degeneration of support by a metalloprotease.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of in-situ bioremediation and, in particular, to enhanced reductive dehalogenation of chlorinated hydrocarbons.
[0002] BACKGROUND OF THE INVENTION
[0003] Chlorinated solvents are commonly used for commercial applications. Such solvents can include tetrachloroethene (PCE), trichloroethene (TCE), or other chlorinated volatile organic compounds (CVOCs). Common biochemical transformation products of reactant CVOC's include cis/trans 1,2-dichloroethenes (DCEs'), with the cis isomer the most common product, 1,1-DCE, and vinyl chloride (VC). Both parent and daughter CVOC's have been detected in overburden soil and fractured bedrock groundwater systems in urban as well as rural settings for a variety of reasons, ranging from incidental releases to deliberate dumping. CVOC's often persist in groundwater systems owing, at least in part, to their general physical, chemical, and biological properties, such as low aqueous solubility, high specific gravity, and general recalcitrance to natural biological attenuation.
[0004] In addition to their persistence in groundwater flow systems, CVOCs pose toxicological risks to both human and animal health. Communities are generally increasing their reliance upon groundwater resources to meet potable water demands. In fact, about one half the population of the United States of America presently uses groundwater to supply potable water. While groundwater is often treated for certain biological and chemical contaminants before distribution, existing treatment technologies at potable water supply facilities are generally incapable of removing significant CVOC mass. Given their toxicity and persistence in groundwater flow systems as well as the limited ability of many water treatment systems to remove them, CVOC's can pose significant risk to groundwater resources for prolonged periods of time.
[0005] Given this risk potential, the United States Environmental Protection Agency established Media Cleanup Standards to protect potential sensitive receptors. For CVOC release sites at which potentially responsible parties are required to implement a remedial program to reduce risk to potential sensitive receptors, several remedial technologies are available that can bring sites to closure. Typically, such remedial technologies are selected and implemented as a function of: 1) site hydrogeology; 2) contaminant signature (compound and concentration); 3) costs for engineering design,, capital equipment, construction, operation and maintenance, 4) performance monitoring requirements; 5) present and future property usage; and 6) potential risk to receptors. Groundwater remediation technologies potentially applicable for CVOC releases include, but are not necessarily limited to, the technologies listed below.
[0006] In Situ Air Sparging (IAS). Pressurized air is forced into sparge points installed in the saturated zone to enhance CVOC volatilization from both groundwater and the formation matrix. Typically, IAS is combined with soil vapor extraction in the unsaturated zone to recover CVOCs stripped from the saturated zone. Recovered CVOC mass may be discharged into the atmosphere, physically removed by adsorption onto GAC, or biologically/chemically treated depending on local regulatory requirements and stakeholder preferences;
[0007] Pump & Treat. Groundwater is extracted and treated via either Air Stripping or Carbon Adsorption. Air Stripping includes passing large fluxes of air through groundwater to volatilize CVOCs. As with IAS, recovered CVOC mass may be discharged to the atmosphere or treated depending on local regulatory requirements and PRP preferences. Carbon Adsorption includes passing groundwater through canisters containing Granular Activated Carbon (GAC). CVOCs adsorb onto the GAC, which is periodically re-activated (i.e., heated at high temperature) to remove CVOCs or replaced with fresh GAC. Spent GAC is disposed either as hazardous or solid waste, depending on CVOC content and PRP preferences;
[0008] Chemical Oxidation. Strong chemical oxidizers such as Fenton's Reagent are injected into the contaminant plume to chemically oxidize CVOCs to carbon dioxide, water, and inorganic chloride;
[0009] Monitored Natural Attenuation (MNA). The natural processes of adsorption, biodegradation, hydrodynamic dispersion, volatilization, and hydrolysis are monitored to demonstrate they naturally attenuate CVOCs within a reasonable period of time, typically assumed to be about a decade; and
[0010] Permeable Reactive Walls. Groundwater flows through a granulated (0 valent) metal treatment wall typically oriented normal to the contaminant plume flow path. CVOCs are destroyed via chemical reactions occurring between CVOCs and granulated metals within the wall.
[0011] While many of these remedial technologies have demonstrated effectiveness for managing plume migration (e.g., Pump & Treat, MNA, and permeable reactive walls), several merely transfer CVOCs from one environmental media to another (e.g., Pump & Treat [air stripping] from groundwater to the atmosphere). Furthermore, many technologies are expensive to design, implement, operate, and maintain. Moreover, they have limited effectiveness for treating CVOC source areas, with the exception of IAS and Chemical Oxidation. While IAS and Chemical Oxidation may be effective for source reduction, they are expensive to design, implement, operate, and maintain.
[0012] U.S. Pat. No. 5,554,290 to Suthersan discloses the use of carbohydrates for in situ treatment of contaminated groundwater, however, contaminants listed under that patent include metals and nitrate, but not CAHs. Suthersan does not specifically disclose lactose in the formulation.
[0013] U.S. Pat. No. 6,150,157 to Keasling, et al. discloses Lactose and Yeast Extract as potential components of a remedial additive for enhancing CVOC reductive dehalogenation. However, the present invention explicitly includes Brewer's Yeast due to the presence of intact cell walls that will reduce the degradation rate of that material, whereas Keasling, et al. specifically discloses Yeast Extract. Additionally, the present invention is formulated to first scavenge terminal electron acceptors from CVOC-impacted groundwater systems, and then drive metabolic reductive dehalogenation once competing oxidants are depleted. Because dehalogenation can only occur in anaerobic groundwater systems devoid of these oxidants, the present invention's formulation prepares the groundwater system for reductive dehalogenation by scavenging competing oxidants. The formulation disclosed by Keasling, et al. is specifically for treating groundwater systems that are generally anaerobic (i.e., mostly devoid of competing oxidants). Notably, Keasling, et al. state “preferred carbohydrates are metabolizable by a broad range of anaerobes.” Additionally, Keasling, et al. claim incubating groundwater under “substantially reducing conditions” (i.e., keeping groundwater anaerobic, not changing redox conditions in a groundwater system).
[0014] U.S. Patent Application No. 20020090697 filed to Hince discloses Lactose as a potential component of a remedial additive for enhancing CVOC reductive dehalogenation. The present invention explicitly includes inactive Brewer's Yeast due to the presence of intact cell walls that will reduce the degradation rate of that material, whereas Hince specifically includes an active Yeast culture inoculum. Hince, therefore, includes an active Yeast culture as a bioaugmentation (addition of microbial cultures), not an electron donor and nutrient source as specified in the present invention. Additionally, the present invention is formulated to first scavenge terminal electron acceptors from CVOC-impacted groundwater systems including oxygen, nitrate, ferric iron, and sulfate, and then drive metabolic reductive dehalogenation once competing oxidants are depleted. Because dehalogenation can only occur in anaerobic groundwater systems devoid of these oxidants, the present invention prepares the groundwater system for reductive dehalogenation by scavenging competing oxidants. The formulation disclosed by Hince is specifically for treating groundwater systems that are generally anaerobic (i.e., mostly devoid of competing oxidants) or for scavenging oxygen. For example, Hince indicates that their material was formulated for “creating, enhancing, and maintaining anaerobic if not anoxic conditions by facilitating the biologically mediated removal of the available oxygen from the media. Hince makes no claim that the mixture stimulates nitrate reduction, iron reduction, and sulfate reduction. In fact, Hince specifically includes nitrate as a preferred embodiment of the invention.
[0015] Japan Patent Application No. 2003-055606 to Chandraghatgi, Schaffner (present inventor), et al. discloses Lactose and yeast, as well as other additives, for use in the remediation of contaminated soil, groundwater or bottom deposits; however, Chandraghatgi et al. did not specify the form of the yeast in contrast to the present invention that specified Brewer's Yeast. In addition, the present invention specifies the preferred embodiment of 70% Weight Lactose and 30% Weight Brewer's Yeast. Also, the present invention specifies that Lactose is added both to scavenge terminal electron acceptors and to serve as a fermentable source of hydrogen for driving reductive dehalogenation, whereas Chandraghatgi et al. indicate the role of the Lactose is to stimulate aerobic mineralization processes.
[0016] What is needed is a remedial technology including Lactose and Yeast that effectively manages plume migration and treats CVOC source areas, and is less expensive to design, implement, operate, and maintain.
BRIEF SUMMARY OF THE INVENTION
[0017] The present invention relates generally to in-situ bioremediation, the use of living organisms to reduce or eliminate environmental hazards resulting from accumulations of toxic chemicals and other hazardous wastes. In-situ bioremediation via enhanced reductive dehalogenation has the potential for cost effectively treating CVOC source areas. Enhanced reductive dehalogenation can also effectively manage CVOC plume migration.
[0018] Enhanced reductive dehalogenation ERD involves stimulating the biologically mediated process of reductive dehalogenation, in which chlorine is replaced with hydrogen on the CVOC skeleton, and the CVOC is chemically reduced to a less chlorinated compound. For example, PCE is sequentially dehalogenated to TCE, TCE to DCE, DCE to VC, and ultimately VC to the innocuous end product ethene. Reductive dehalogenation occurs under anaerobic, chemically reducing conditions, typically in the presence of abundant biologically available organic carbon. While co-metabolic reductive dehalogenation may occur (i.e., dehalogenation not beneficial to microflora), the metabolic form (i.e., dehalogenation beneficial to microflora) is associated with more rapid transformation rates, particularly for the more chlorinated CVOC's. During metabolic reductive dehalogenation, certain native microflora use hydrogen as an electron donor and CVOC's as electron acceptors, in the absence of other terminal electron acceptors, in growth-coupled dehalorespiration. During this reaction the microflora use CVOC's as an oxidant substitute to accept the electrons released during metabolism.
[0019] Enhanced reductive dehalogenation typically includes injection of a biological stimulant (biostimulant) into the CVOC plume to enhance reductive dehalogenation. The biostimulant is injected to serve as an electron donor for stimulating native microflora to scavenge alternative terminal electron acceptors (oxidants), which can compete with hydrogen and inhibit reductive dehalogenation. The biostimulant should also be biologically degradable to yield fatty acid metabolites, which can be fermented to hydrogen under anaerobic conditions. These fermentation products, most notably hydrogen, drive reductive dehalogenation.
[0020] The present invention provides an agent for use as a biostimulant in enhanced reductive dehalogenation with a lower overall cost compared to conventional remedial technologies.
[0021] The invention further provides an agent for use as a biostimulant to effectively treat CVOC source areas.
[0022] The invention additionally provides a biostimulant to destroy CVOC mass via enhanced reductive dehalogenation instead of transferring it from one environmental media to another.
[0023] The invention also provides an agent to make the enhanced reductive dehalogenation less disruptive to facility operations as well as decreasing time to site closure.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention is a Lactose—Brewer's Yeast mixture for use as a biological stimulant for enhancing reductive dehalogenation. The mixture includes Lactose (C 12 H 22 O 11 ) and inactive Brewer's Yeast ( Saccharomyces ). This mixture is a suitable electron donor because it is readily biodegradable such that it can stimulate native microflora to scavenge competing terminal electron acceptors including oxygen, nitrate, oxidized iron, and sulfate by stimulating the respective microbially-mediated biochemical processes of aerobic mineralization, denitrification, ferric iron reduction, and sulfate reduction. In addition, the mixture is ultimately fermentable to hydrogen for driving reductive dehalogenation, and may be manufactured with minimal engineering controls to reduce unit cost. Additionally, the mixture may be delivered to environmental systems in either a high aqueous soluble form for batch injections (large volumes of water containing biostimulant in dissolved form) or in a low aqueous soluble form for borehole injections (smaller volumes of water containing biostimulant in slurry form) or injection socks.
[0025] Lactose is a readily biodegradable milk sugar, which can readily stimulate native microflora to scavenge terminal electron acceptors. For example, one gram (g) of Lactose can exert 1.13 g of chemical oxygen demand per liter upon an aqueous environmental system, and Lactose has a five-day biochemical oxygen demand of about 45 grams per liter. Lactose is readily fermented to yield Lactic Acid (CH 3 CHOHCO 2 H), which can be further fermented to hydrogen, the electron donor driving CVOC reductive dehalogenation. For example, results for eight case studies reported by Regenesis, Inc. (2000) indicate that Lactic Acid, among other materials, stimulated CVOC dehalogenation. Importantly, fermentation reactions are relatively slow, in contrast to direct mineralization reactions in which Lactose serves as an electron donor. Therefore, the Lactose is expected to first scavenge terminal electron acceptors from the environmental media, then be fermented to ultimately yield hydrogen. Lactose also has a moderately high aqueous solubility of about 200 g/L at standard temperature and pressure, so it can be readily distributed throughout groundwater flow systems to treat CVOC impacted zones.
[0026] Brewer's Yeast is an additive typically used for enhancing the flavor and texture of food-grade products. The material is a complex micro/macronutrient-enriched growth media, which includes organic and inorganic nutrients and certain vitamins that can support microbial metabolism. In addition to stimulating microflora to scavenge terminal electron acceptors, as does Lactose, the complex organic nutrients are fermentable, and can ultimately yield hydrogen for driving reductive dehalogenation. It has been demonstrated that Yeast Extract amendment stimulated reductive dehalogenation of parent PCE and TCE to 1,2-DCEs in laboratory-scale microcosms within about 180 days. Yeast extract has the same general chemical composition as Brewer's Yeast, however, its cell walls have been lysed. As such, Brewer's Yeast is anticipated to have greater residence time than Yeast Extract in groundwater systems, because of the additional time required for native microflora to break down the cell walls, which consist of long carbohydrate chains composed of polysaccharides.
[0027] A 70% Weight Lactose, 30% Weight Brewer's Yeast mixture is the preferred remedial additive blend for most applications. The rationale for the blend ratio is twofold. While Lactose is expected to stimulate reductive dehalogenation, as previously discussed, Lactose is also selected to serve as an electron donor for stimulating microflora to scavenge alternative terminal electron acceptors from groundwater systems and drive conditions anaerobic and chemically reducing. Lactose comprises a bulk of the mixture (70% Weight ), given that typical groundwater flow systems are aerobic and chemically reducing. Therefore, a large percentage of Lactose will be spent chemically reducing alternative terminal electron acceptors. Brewer's Yeast is expected to primarily serve as a nutrient/vitamin source as well as a fermentable hydrogen source for driving reductive dehalogenation under the anaerobic, chemically reducing conditions largely stimulated by the Lactose. The blend design also assumes the intact cellular walls of the Brewer's Yeast will decrease its biodegradability rate, because those walls must first be lysed before cellular material is released to become biologically available. During this lag period, the Lactose is expected to stimulate microflora to scavenge alternative terminal electron acceptors from groundwater systems.
[0028] The preferred mixture blend design assumes 70% weight Lactose and 30% weight Brewer's Yeast. However, formulations may range from >40% weight Lactose, <60% weight Brewer's Yeast to <85% weight Lactose, >15% weight Brewer's Yeast.
[0029] While the preferred mixture consists of 70% weight Lactose, 30% weight Brewer's Yeast, dextrose or sucrose could be substituted for Lactose, given volatility in the Lactose market. In addition, for certain applications such as borehole injections, it might become necessary to coat sugar grains with vegetable oil to reduce their aqueous solubility and prolong their dissolution into groundwater. Based on field and laboratory-scale research, vegetable oil coating delays dissolution of the mixture by as much as a year. In addition, for treatment of CVOC plumes that exist under strictly anaerobic conditions, already entirely depleted of common terminal electron acceptors, it might become necessary to include fatty acids such as Lactic acid in the mixture formulation.
[0030] The scope of the invention is not to be considered limited by the above disclosure of the preferred embodiments of the invention. Additional embodiments and advantages will be readily seen by those of ordinary skill in the art in light of the following claims.
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The present invention provides a mixture for use as a biological stimulant in in-situ bioremediation via enhanced reductive dehalogenation. The mixture is primarily a mixture of Lactose and Brewer's Yeast for use as an electron donor in the bioremediation process.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an image processing apparatus and method, and a storage medium, and more particularly, to an image processing apparatus and method, and a storage medium which become usable by a user through user authentication.
[0003] 2. Description of the Related Art
[0004] In an image processing apparatus which becomes usable by a user through user authentication, which causes the user to execute a login operation for the user authentication when used, and permits the user which has logged in to use it, when a plurality of users log in at the same time, such users alternately execute respective jobs. Then, after the job is completed, each user executes a logout operation by executing an operation such as depressing a logout button for (for example, Japanese Laid-Open Patent Publication (Kokai) No. 2007-228209).
[0005] However, a user may sometimes forget to execute a logout operation. Particularly, when a waiting time is long until the job is completed, the user may leave the image processing apparatus after instructing the execution of the job. Thereby, even after the job is completed, the image processing apparatus is left in a logged-in state, and may be used without notice by another user. Furthermore, when a predetermined time elapses and the user has not performed any operation, the logout operation of the image processing apparatus may be forcibly executed, and in this case, the logout operation may be executed while the user is using the image processing apparatus, so that it is difficult to set a time for executing the forcible logout operation.
[0006] To resolve the above problem, such a technique exists that an appointment for the logout operation by the user is accepted, and when the appointment for the logout operation is accepted, the logout operation is executed after the job of the user is completed.
[0007] However, in the above conventional technique, it is impossible to inhibit another user to instruct an operation for the job or the execution for a new job between a job start and a job end. In the above conventional technique, when the logout operation is forcibly executed before the job ends, the user becomes unable to instruct setting changes or interruption of the job for the job, of which execution is instructed, which degrades the usability.
SUMMARY OF THE INVENTION
[0008] The present invention provides an image processing apparatus and method, and a storage medium which can realize security improvements without degrading the usability.
[0009] In an aspect of the present invention, there is provided an image processing apparatus, comprising: a user authenticating unit configured to authenticate a user; an operation screen display unit configured to display an operation screen accepting an operation input from the user; a job executing unit configured to execute a job according to an instruction of the user authenticated by the user authenticating unit; a determining unit configured to determine whether or not the job executing unit is executing the job, of which execution is instructed by the user, when the user authenticating unit authenticates the user; and a display control unit configured to control the operation screen display unit so as to display a first operation screen through which the user inputs an instruction for the job in execution when the job executing unit is executing the job, of which execution is instructed by the user, whereas to control the operation screen display unit so as to display another operation screen through which another user inputs an instruction for another job when not.
[0010] According to the present invention, it is possible to inhibit another user to instruct an operation for the job, or an execution for a new job between the job start and the job end, and further, even when the logout operation is forcibly executed before the job end, it is possible for the user to instruct setting changes or interruption of the job for the job of which execution is instructed. As a result, according to the present invention, it is possible to provide an image processing apparatus and method, and a storage medium which can realize security improvements without degrading the usability.
[0011] Further features and advantages of the present invention will become apparent from the following detailed description of exemplary embodiments with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a block diagram schematically showing the configuration of an image processing apparatus according to an embodiment of the present invention.
[0013] FIG. 2 is a view schematically showing the configuration of an operation part 200 in FIG. 1 .
[0014] FIG. 3 is a view showing a logout screen displayed on an LCD display part 201 in FIG. 2 .
[0015] FIG. 4 is a view showing a login initial screen displayed on the LCD display part 201 in FIG. 2 .
[0016] FIG. 5 is a view showing a login in-execution screen displayed on the LCD display part 201 in FIG. 2 .
[0017] FIG. 6 is a view showing an IC card authentication setting screen displayed on the LCD display part 201 in FIG. 2 .
[0018] FIG. 7 is a view showing an example of the configuration of software for causing the image processing apparatus of FIG. 1 to execute login management control.
[0019] FIG. 8 is a flowchart showing the procedure of a first screen display transition process executed by the image processing apparatus of FIG. 1 .
[0020] FIG. 9 is a flowchart showing the procedure of a second screen display transition process executed by the image processing apparatus of FIG. 1 .
[0021] FIG. 10 is a flowchart showing the procedure of a third screen display transition process executed by the image processing apparatus of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The present invention will now be described in detail with reference to the drawings.
[0023] FIG. 1 is a block diagram schematically showing the configuration of an image processing apparatus according to an embodiment of the present invention.
[0024] The image processing apparatus of FIG. 1 includes copy, FAX, print and scanner functions, and can be login-managed by an IC card reader. Hereinafter, a configuration thereof will be described with an operation.
[0025] In the image processing apparatus of FIG. 1 , a CCD 17 and a CIS (Contact Image Sensor) 18 are connected to a scanner interface (scanner I/F) section 10 through an analog front end (AFE) 15 , whereby the read data can be taken in the image processing apparatus without using an individual dedicated circuit.
[0026] A scanner image processing section 20 executes an image processing according to an image processing operation mode (color copy, monochrome copy, color scan, monochrome scan, and the like) for image data developed in a main memory (SDRAM) 100 by the processing of the scanner I/F section 10 .
[0027] When transferring data between the scanner I/F section 10 and the scanner image processing section 20 through a ring buffer area on the main memory 100 , a buffer arbitrating section 77 arbitrates writing and reading for the data.
[0028] A printer image processing section 30 executes area editing and resolution conversion of an inputted image, and outputs the obtained image data to a printer. A printer I/F section 40 outputs an image processing result to a laser beam printer (LBP) 45 connected to the printer I/F section 40 .
[0029] When transferring data between the printer image processing section 30 and the printer I/F section 40 through the ring buffer area on the main memory 100 , a buffer arbitrating section 78 arbitrates writing and reading for the data.
[0030] A JPEG module 50 and a JBIG module 60 execute a compressing and expanding process for the image data conforming to predetermined standards, respectively.
[0031] A memory control section 70 is connected to each of a first bus 83 and a second bus 84 of an image processing system, and a third bus 85 of a computer system, and executes data transfer control for writing and reading data to and from the main memory 100 .
[0032] A DMA controller (DMAC) 90 is, in association with the memory control section 70 , connected to a ROM 95 through a ROM ISA 97 . The DMAC 90 generates and sets predetermined address information for executing DMA control on data transfer between an external device or a user interface control section 170 , and the main memory 100 .
[0033] An image processing DMAC 91 generates and sets, in association with the memory control section 70 , predetermined address information for executing the DMA control on data transfer between each image processing section ( 10 , 20 , 30 , and 40 ) and the main memory 100 .
[0034] For example, the DMAC 91 generates the address information for DMA-transferring the image data read and processed by the scanner I/F section 10 to the main memory 100 for each DMA channel according to types of image reading devices (CCD 17 and CIS 18 ).
[0035] The DMAC 91 generates the address information for reading the image data developed on the main memory 100 according to the DMA channel, and DMA-transfers the generated address information to the scanner image processing section 20 .
[0036] As described above, the DMAC 91 functions as a unit for conducting the DMA control between the image processing sections ( 10 , 20 , 30 , and 40 ) and the main memory 100 in association with the memory control section 70 .
[0037] In the ROM 95 are stored an appropriate control parameter and an appropriate control program data according to types of the image reading devices (CCD 17 and CIS 18 ), and a variety of the control parameters, and the like can be set according to types of the image reading devices. This makes it possible to input the image data according to individual data output formats of the CCD 17 and CIS 18 , thereby eliminating the need for providing a dedicated interface circuit.
[0038] The first bus 83 can transfer data read from the main memory 100 to each processing section ( 10 to 60 ) of the image processing system. The second bus 84 can transfer data read from each processing section ( 10 to 60 ) of the image processing system to the main memory 100 . The first bus and the second bus transfer, in pairs, the image data between an image processing block and the main memory 100 .
[0039] The third bus 85 is directed to a bus of the computer system, to which are connected a CPU 180 , the user interface control section 170 , a mechatronics system control section 125 , control registers in the image processing section, and the DMAC 90 .
[0040] The mechatronics system control section 125 includes a motor control section 110 , and an interrupt timer control section 120 for conducting a driving timing of a motor, and timing control for controlling synchronization of the process of the image processing system.
[0041] An LCD control section (LCDC) 130 conducts display control for displaying a variety of settings, processing situations, and the like of the image processing apparatus on an operation section 200 . The LCDC 130 has a role for transferring information inputted by a user from the operation section 200 to the CPU 180 .
[0042] USB I/F sections 140 and 150 enable the connection with peripheral equipment. In FIG. 1 , such a state is shown that an IC card reader 175 is connected.
[0043] A medium access control section (MACC) 160 is a unit for controlling a timing in which data is to be transferred to the connected equipment, and a timing in which the connected equipment is to be accessed, and the like. The CPU 180 controls a whole operation of the image processing apparatus of FIG. 1 .
[0044] FIG. 2 is a view schematically showing the configuration of the operation part 200 in FIG. 1 .
[0045] In FIG. 2 , a touch panel sheet 202 is put on an LCD of an LCD display section 201 , and the LCD display part 201 displays an operation screen and a soft key of the image processing apparatus of FIG. 1 , and transmits the depressed soft key to the CPU 180 .
[0046] A start key 203 is used when a reading operation for a document image is started, and the like. There is a two-color LED 204 of green and red in a center of the start key 203 , and the color of the start key 203 indicates whether or not the start key 203 is usable.
[0047] A stop key 205 functions to stop an operation in execution. An ID key 206 is used when a user ID of a user is inputted. A reset key 207 is used when the setting by the operation part 200 is initialized.
[0048] A volume adjusting dial 208 is used when sound volume is turned up/down. A numeric keypad 209 is used when a numerical character is inputted.
[0049] FIG. 3 is a view showing a logout screen displayed on the LCD display part 201 in FIG. 2 .
[0050] In FIG. 3 , a logout screen 300 is directed to a screen displayed on the LCD display part 201 of the operation part 200 in such a state that the user does not log in to the image processing apparatus of FIG. 1 (logout state). The logout screen 300 shows a method for executing a login and a logout.
[0051] FIG. 4 is a view showing a login initial screen displayed on the LCD display part 201 in FIG. 2 .
[0052] In FIG. 4 , a login initial screen 400 is a screen displayed on the LCD display part 201 of FIG. 2 after a user logs in to the image processing apparatus of FIG. 1 .
[0053] The login initial screen 400 displays the setting of a job, and while this screen is being displayed, the user can input a job and change the setting for the image processing apparatus of FIG. 1 .
[0054] FIG. 5 is a view showing a login in-execution screen displayed on the LCD display part 201 in FIG. 2 .
[0055] In FIG. 5 , a login in-execution screen 500 is a screen displayed after a job is set on the login initial screen 400 , and the execution of the job is instructed, and is displayed by the CPU 180 on the LCD display part 201 of the operation part 200 . The login in-execution screen 500 displays an in-execution pop-up screen 501 on the login initial screen 400 .
[0056] In the in-execution pop-up screen 501 , the followings are displayed: a situation of the job being executed at the last minute; a stop button 502 for stopping the job in execution; a setting change button 503 for executing setting changes; and a close button 504 for closing the in-execution pop-up screen 501 . The operation is enabled by touching each button.
[0057] FIG. 6 is a view showing an IC card authentication setting screen displayed on the LCD display part 201 in FIG. 2 .
[0058] In FIG. 6 , a setting item 601 of a setting screen 600 is directed to a setting of whether or not user authentication (utilization permission authentication for the image processing apparatus) is required for an operation for the job in execution. In the setting item 601 , for all the jobs of a login user, when user authentication (utilization permission authentication for the image processing apparatus) is required for the operation for the job in execution, “YES” can be set, and when not, “NO” can be set. When “YES” is set, a fact that the same user as the user instructing the job execution is authenticated becomes a condition for enabling the operation for the job in execution. By setting “YES”, the user other than the user instructing the job execution becomes unable to operate for the job in execution, and the security for the job execution is improved. The setting item 601 is displayed by the CPU 180 , and is utilized by a job operation authentication registering module 704 described hereinafter.
[0059] A setting item 602 is directed to a setting for whether or not a logout process is automatically executed after a job is inputted. In the present embodiment, the timing after the job is inputted is directed to a timing (for example, in the case of a copy job, a timing after it is recognized that the start key 203 is pushed) after the image processing apparatus of FIG. 1 accepts a job execution starting instruction by the user.
[0060] In the setting item 602 , when the logout process is not executed after the job is inputted, “NOT EXECUTE” can be set, when the logout process is executed, “EXECUTE” can be set, and when the logout process is executed only when personal information is displayed, “EXECUTE ONLY WHEN PERSONAL INFORMATION IS INCLUDED” can be set. The setting item 602 is displayed by the CPU 180 , and is utilized by a logout setting module 707 , described hereinafter, after the job is inputted.
[0061] FIG. 7 is a view showing an example of the configuration of software for causing the image processing apparatus of FIG. 1 to execute login management control.
[0062] Each of reference numerals 701 to 710 is directed to a software module executed (processed) by the CPU 180 of the image processing apparatus, and is stored in the ROM 95 .
[0063] A user authenticating module 701 obtains user information from an IC card by the IC card reader 175 of the image processing apparatus of FIG. 1 , and executes utilization permission authentication of the image processing apparatus of FIG. 1 . The user authentication is directed to a process required when the image processing apparatus of FIG. 1 is subjected to login, when the setting of the job is changed or the job is canceled, or when the job is newly executed.
[0064] When the setting of the job is changed or the job is canceled, only when the user, who is the same as the user of the job, of which setting is changed or which is canceled, can be authenticated.
[0065] A utilization state recognizing module 702 recognizes the utilization state of the image processing apparatus of FIG. 1 for a removable medium (document, print output material, and removable memory) for the job. The utilization state recognizing module 702 recognizes whether or not reading of all the documents is completed, when the job does not include print output.
[0066] When a job includes print output, the utilization state recognizing module 702 recognizes whether or not processing of all the print outputs is completed, and when it is not completed, the utilization state recognizing module 702 determines that the job is in a removable medium utilization non-completion state. When it is completed, the utilization state recognizing module 702 determines that the job is in a removable medium utilization completion state.
[0067] A job situation recognizing module 703 recognizes whether or not the job of the user authenticated by the user authenticating module 701 is included. When the job is not included, the job situation recognizing module 703 notifies “absence of job”. In a case where the job is included, when the inputted job is in the removable medium utilization non-completion state, the job situation recognizing module 703 notifies “absence of job”, whereas when the inputted job is in the removable medium utilization completion condition, the job situation recognizing module 703 notifies “absence of job”.
[0068] A job operation authentication registering module 704 can register, in the setting item 601 of the setting screen 600 at the time of the IC card authentication, whether or not it is required for the user authenticating module 701 to perform the utilization permission authentication for the operation of the job in execution, of which execution is instructed by the user authenticated by the user authenticating module 701 . The registered values can be reserved and be referred to by a setting reserving/referring module 709 described hereinafter.
[0069] A login/logout screen display module 705 displays the logout screen 300 , the login initial screen 400 , and the login in-execution screen 500 .
[0070] When the utilization state recognizing module 702 recognizes that the inputted job of the user authenticated by the user authenticating module 701 is in the removable medium utilization job non-completion state, a logout possibility determining module 706 determines that the logout is impossible. When the utilization state recognizing module 702 recognizes that the removable medium utilization job is in the removable medium utilization job completion state, the logout possibility determining module 706 determines that the logout is possible. Further, when the login in-execution screen 500 is closed, the logout possibility determining module 706 determines that the logout is possible.
[0071] A logout setting module 707 sets whether or not the logout is executed after the job is inputted at the setting item 602 of the setting screen 600 at the time of the IC card authentication. The logout setting module 707 can set “logout process is not executed”, and “logout process is executed only when personal information is included”.
[0072] The above registered value can be reserved and be referred to by the setting reserving/referring module 709 described hereinafter.
[0073] After receiving a job start instruction by the user authenticated by the user authenticating module 701 , a logout/non-logout determining module 708 determines whether the login in-execution screen 500 is displayed, or the logout screen 300 is displayed.
[0074] When the logout setting module 707 sets that the logout process is executed, the logout/non-logout determining module 708 notifies “logout”, whereas when not, the logout/non-logout determining module 708 notifies “non-logout”. In a case where the personal information is included, when an address and a file name are displayed on the login in-execution screen 500 , the logout/non-logout determining module 708 notifies “logout”, whereas when not, the logout/non-logout determining module 708 notifies “non-logout”.
[0075] The setting reserving/referring module 709 reserves the values set by the job operation authentication registering module 704 and the logout setting module 707 in the main memory 100 . The set values can be read from the main memory 100 .
[0076] A job operation control module 710 controls a job operation by utilizing modules including the user authenticating module 701 , the job situation recognizing module 703 , the job operation authentication registering module 704 , the login/logout screen display module 705 , the logout possibility determining module 706 , the logout setting module 707 , and the logout/non-logout determining module 708 .
[0077] FIG. 8 is a flowchart showing the procedure of a first screen display transition process executed by the image processing apparatus of FIG. 1 .
[0078] Specifically, the first screen display transition process of FIG. 8 is a process of transitioning from the logout screen 300 to the login in-execution screen display state 500 or a login initial screen 400 . This process is executed by the CPU 180 in FIG. 1 .
[0079] In FIG. 8 , while the LCD display part 201 in FIG. 2 displays the logout screen of FIG. 3 , it is determined in step S 801 whether or not the IC card is detected by the IC card reader 175 , and when the IC card is detected, the program proceeds to step S 802 , in which the user authenticating module 701 executes the user authentication based on the information read from the IC card reader 175 .
[0080] As a result of the authentication of the step S 802 , when the user authentication (utilization permission authentication of the image processing apparatus) can be executed (YES to the step S 802 ), the job situation recognizing module 703 determines whether or not the job in execution is included (step S 803 ).
[0081] As a result of the determination of the step S 803 , when the job in execution is included, the login/logout screen display module 705 displays the login in-execution screen 500 of FIG. 5 for the job which is notified to be included in step S 803 (step S 804 ), followed by the program proceeding to a process of FIG. 10 described hereinafter.
[0082] As a result of the determination of the step S 803 , when the job in execution is not included (NO to the step S 802 ), the login/logout screen display module 705 displays the login initial screen 400 of FIG. 4 (step S 805 ), followed by the program proceeding to a process of FIG. 9 described hereinafter. Moreover, in step S 803 , even when a job, of which execution is instructed by the user and which is waiting to be executed, is included, it may be determined that the job in execution is included.
[0083] FIG. 9 is a flowchart showing the procedure of a second screen display transition process executed by the image processing apparatus of FIG. 1 .
[0084] Specifically, the second screen display transition process of FIG. 9 is a process of transitioning from the login initial screen 400 to the logout screen 300 or the login in-execution screen 500 . This process is executed by the CPU 180 of FIG. 1 .
[0085] In FIG. 9 , while the login initial screen 400 of FIG. 4 is displayed (step S 805 of FIG. 8 ), when a variety of settings for executing the job are inputted (step S 901 ) and it is recognized that the start key 203 is depressed, the job is executed, followed by the program proceeding to step S 902 .
[0086] In step S 902 , the logout/non-logout determining module 708 determines “contents of a logout condition after the job is inputted” set by the logout setting module 707 .
[0087] As a result of the determination of the step S 902 , when “the logout process is executed after the job is inputted” is set, the login/logout screen display module 705 displays the logout screen 300 of FIG. 3 (step S 903 ), followed by the program terminating. When “the logout process is not executed after the job is inputted” is set, the login/logout screen display module 705 displays the logout in-execution screen 500 of FIG. 5 on the job started in the above step S 901 (step S 904 ), followed by the program proceeding to a process of FIG. 10 described hereinafter.
[0088] As a result of the determination of the step S 902 , in a case where “the logout is executed only when the personal information is included” is set, when personal information such as a transmission address and a file name is displayed on the login in-execution screen 500 of FIG. 5 , the process of the step S 903 is executed, whereas when the personal information is not displayed on the login in-execution screen 500 , the process of the step S 904 is executed.
[0089] FIG. 10 is a flowchart showing the procedure of a third screen display transition process executed by the image processing apparatus of FIG. 1 .
[0090] Particularly, the third screen display transition process of FIG. 10 is the process for transitioning from the login in-execution screen 500 to the logout screen 300 or the login initial screen 400 . The present process is executed by the CPU 180 of FIG. 1 .
[0091] In FIG. 10 , while the login in-execution screen 500 of FIG. 5 is displayed (step S 904 of FIG. 9 ), the logout possibility determining module 706 determines whether or not the logout is possible (step S 1001 ), when the logout is possible, the program proceeds to step S 1002 , whereas when the logout is impossible, the program proceeds to step S 1003 .
[0092] The determination of the step S 1001 by the logout possibility determining module 706 is executed as follows.
[0093] When the utilization state recognizing module 702 recognizes that the job of the user authenticated by the user authenticating module 701 is in the removable medium utilization job non-completion state, the logout possibility determining module 706 determines that the logout is impossible.
[0094] When the utilization state recognizing module 702 recognizes that the removable medium utilization job is in the removable medium utilization job completion state, the logout possibility determining module 706 determines that the logout is possible.
[0095] In step S 1002 , the login/logout screen display module 705 displays the logout screen 300 of FIG. 3 , followed by program terminating.
[0096] In step S 1003 , it is determined whether or not the operation section 200 accepts operation input by the user for the job in execution, when the operation section 200 accepts the operation input, the job situation recognizing module 703 determines whether or not the accepted operation input is an operation for the job in execution (step S 1004 ). As a result of the determination of the step S 1004 , when the accepted operation is not the operation for the job in execution, the process returns to step S 1001 .
[0097] As a result of the determination of the step S 1004 , when the accepted operation is the operation for the job in execution, the job operation authentication registering module 704 determines whether or not the user authentication (utilization permission authentication for the image processing apparatus) is required for the operation for the job in execution (step S 1005 ).
[0098] As a result of the determination of the step S 1005 , when the user authentication (utilization permission authentication for the image processing apparatus) is required, the program proceeds to step S 1006 , in which the IC card is detected by the IC card reader 175 (YES to the step S 1006 ), and the user authentication (utilization permission authentication for the image processing apparatus) is executed by the user authenticating module 701 based on information read from the IC card reader 175 . When it is determined that the user is correctly authenticated (YES to the step S 1007 ), the operation for the job in execution is executed, with execution of a changing process (step S 1008 ), followed by the process returning to step S 1001 .
[0099] As a result of the determination of the step S 1003 , when the operation part 200 does not accept the operation input by the user for the job in execution, the processes after step S 1009 are executed.
[0100] In step S 1009 , the IC card reader 175 determines whether or not the IC card reader 175 detects the IC card. In the image processing apparatus of FIG. 1 , a plurality of the users can log in at the same time. Thereby, even when the first user instructs the job execution, but does not execute the logout process yet, the image processing apparatus accepts the login by the second user. In this case, the second user can instruct the execution of the job other than the job in execution.
[0101] In step S 1010 , the user authenticating module 701 determines whether or not the user authentication (utilization permission authentication for the image processing apparatus) can be executed based on information read from the IC card reader 175 .
[0102] As results of the respective determinations of the steps S 1009 and S 1010 , when the IC card reader 175 detects the IC card (YES to the step S 1009 ), and when the user authenticating module 701 can execute the user authentication (utilization permission authentication for the image processing apparatus) based on information read from the IC card reader 175 (YES to the step S 1010 ), the login/logout screen display module 705 displays the login initial screen 400 of FIG. 4 through which the job is inputted, followed by the program terminating. This screen enables the user newly authenticated in the step S 1010 to execute the operation input for instructing the job execution.
[0103] It should be noted that the object of the present invention may also be accomplished by executing the following process. That is, the process is executed by supplying the image processing apparatus or an information processing apparatus, or a function expansion unit of the apparatuses with a storage medium for storing a program code (hereinafter referred to as “the control program”) of software of realizing the functions of the above described embodiment, and causing a computer (CPU or MPU) of each of the apparatuses to read the control program stored in the storage medium. In this case, the control program itself read from the storage medium realizes the functions of the above described embodiment, and hence the control program and the storage medium storing the control program configure the present invention. The control program may be downloaded through a network.
[0104] While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all modifications, equivalent structures and functions.
[0105] This application claims the benefit of Japanese Application No. 2009-099028, filed Apr. 15, 2009, which is hereby incorporated by reference herein in its entirety.
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An image processing apparatus which is capable of realizing security improvements without degrading the usability. A user is authenticated, and an operation screen accepting an operation input from the user is displayed. A job is executed according to an instruction of the user authenticated by the user authenticating unit. It is determined whether or not the job of which execution is instructed by the user, is being executed when the user authenticating unit authenticates the user. A first operation screen through which the user inputs an instruction for the job in execution is displayed when the job executing unit is executing the job, of which execution is instructed by the user, whereas another operation screen through which another user inputs an instruction for another job is displayed when not.
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BACKGROUND OF THE INVENTION
The invention relates to a smoothing device of a coating applying unit for coating a moving web. More particularly, the invention relates to deflection compensation apparatus for the support beam of the smoothing device for a web coating unit. The smoothing device supports a doctor element and includes means which maintain the doctor element at the desired pressure against the web or against a counter roller arranged counter to the doctor element and on which the web moves. The beam is likely to sag under the combined effects of gravity and to a lesser extent to counter the effect of the pressure on the doctor supported on the beam.
The smoothing device comprises a support beam which supports the doctor element via a holding means on the support beam. A central support member extends through the typically hollow support beam. At least two rows of hydraulically or pneumatically actuated, i.e. pressure fluid or pressure medium actuated, pressing elements extend longitudinally along the smoothing device and are disposed between the central support member and the support beam. The invention concerns the manner in which the pressing elements are connected with and act upon the support beam.
Such a device has been proposed in British Patent No. 1,202,167. There the support beam is hollow in order to increase the rigidity of the support beam in relation to its weight.
SUMMARY OF THE INVENTION
One object of the invention is to provide an advantageous design of such a support beam in which it is possible to ensure an adjustable direction of the flexion correction forces so that a spreading blade or doctor blade is pressed into engagement evenly in accordance with requirements, also taking flexion of the support beam into account.
In order to achieve this object, in a smoothing device according to the invention, an outer support element in the form of an external tube extends around the central support member and is radially spaced from it and that outer support element or tube, in turn, directly supports the support beam. The external tube has a cross section that is generally circular. At least two rows of hydraulically or pneumatically actuated pressing elements are disposed radially inwardly of the external tube and radially outwardly of the support member for providing the support, and the rows of pressing elements extend along the axial length of the beam. Preferably there are four rows of the hydraulic pressing elements, although two rows generally opposed to the web or opposite roll, or even one row, might perform the necessary supporting function, but not as well as the larger number of rows of pressing elements.
The central support member is a radially symmetric structure. The support member may be in the form of a hollow cylinder or an inner tube, for example. In one suggested version, the support member has an exterior shape which decreases or tapers narrower in cross-section from its widest axial center towards its narrowest axial ends, generally in accordance with an e-function, so that it has a crowned form.
Each hydraulic pressing element may comprise a respective pressure hose. The hoses press in against the support member, on the one hand, and out against the external tube, on the other hand.
Each hydraulic pressing element may alternatively comprise a respective parallel row of pressing pistons which are carried by the support member and press outwardly upon the external tube. The piston array conforms to the cross section of the supported support beam. The pistons have external radii. They are in a substantially symmetrical arrangement. They are preferably pressurized in pairs of opposite pistons. The pressing pistons are shaped at their radially outer ends to define sealing pressurized pockets which press against the inside of the external tube.
Because of expected axial shifting between the support beam outside and the support member inside it, the support beam bears upon the external tube, at least in the axial direction, in a freely sliding manner. For this purpose, intervening support walls are disposed between the support beam and the external tube, and these walls would typically be fastened to only one or the other of those two elements. The support walls between the support tube and the support beam are preferably placed in positions corresponding to the rows of pressing elements so as to transmit the thrust of the hydraulic pressing elements to the support beam.
All of the various supporting elements, including the tube, the support member and the pressing elements, are carried in antifriction bearings for being supported in relation to the support beam. In particular, the support member may be supported at its end by part spherical bearings through an annular member located on the support beam.
Where space is limited and where the cross-section of the support beam, which resists flexion, has to be made very small, the design according to the invention makes possible compensation for the flexion of the support beam. Using control means, it is possible to ensure that the engaging doctor edge is quite straight or that the engaging edge has such a form that there is an even pressing effect of the doctor element on the web of material.
Other objects and features of the invention are described with reference to the embodiments shown in the drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view through one embodiment of a support beam and smoothing device according to the invention.
FIG. 2 is a corresponding longitudinal section through that beam.
FIG. 3 is a cross sectional view through another embodiment of the central support member and of the tube located within the support beam.
FIG. 4 shows a cross sectional view of a controlling means for detecting and correcting flexure.
FIG. 5 is an elevational view of the controlling means.
FIG. 6 is a sketch of another design of the support member.
FIG. 7 is a cross-sectional view of yet another working example of the support device.
FIG. 8 is a cross sectional view of a terminal bearing of the smoothing device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a generally rectangular cross-section support beam 2 for a smoothing device for an applying unit for coating a web. Disposed inside the beam, there is a central support member 4 in the form of a hollow cylinder or tube. The support beam 2 bears on the support member 4 through an external tube 3 located radially between them, and the tube serves as a support element for the beam through the intermediacy of four hydraulically or pneumatically actuated, or more generally, four pressure fluid medium actuated pressure hoses 5. Between the external tube 3 and the support beam 2 there are four pressure hoses 5.
Respective rows of support walls 15 transmit the thrust from the pressure hoses 5 through the intermediate elements to the support beam. The support walls 15 may be attached to the internal tube 3 and may only rest on the internal walls of the support beam 2 in order to make it possible to have sliding relative motion between the support walls 15 and the support beam. In this respect, both the internal walls of the support beam and the sliding surfaces on the support walls 15 may be given a very fine and smooth finish. It is also possible to design the support walls 15 to be continuous in each plane perpendicular to the longitudinal axis of the support beam, so that internally they define a circular recess. On the other hand, the walls 15 may be attached to the support beam 2 and run or rest on the external tube 3. The walls 15 are placed circumferentially to counter the maximum thrust pressure of the hoses 5.
A holding device 6 is located on the support beam 2. It carries the doctor, which is designed in the form of a coating material spreading blade 12. The doctor is carried by a gripping rail 8. The doctor is pressed by a small pressure hose 11 against the web of material, which is marked in broken lines, or against the opposite roll A on which the web is then traveling.
The entire smoothing device 1 is generally mounted in a pivotal manner at its ends, although this is not shown in FIG. 1, so that it is possible to have various different angular settings of the spreading or doctor blade 12 in relation to the tangent to the opposite roll A. The flexion of the support beam 2 may thus take place in different radial planes. Accordingly, the individual pressure hoses 5 would be acted upon by different pressures in a circumferential sequence such that the resulting thrust overrides the line of flexion of the support beam, or so reduces it, or changes it so that there is an even pressing force of the spreading blade 12 on the opposite roll A or on the web of material. In the present case, the flexion of the opposite roll A is also to be taken into account. It is thus possible to act upon the spreading blade 12 via the pressure hose 11 with an even pressure while ensuring compensation, at least in part, via the pressure hoses 5.
Projections 32 are preferably provided in order to establish the positions of the hoses 5.
FIGS. 4 and 5 show in principle a controlling means for the hydraulic or pneumatic pressure medium, i.e., for controlling the level of its pressure. A covering box 29 is secured to the support beam 2, preferably under the beam. On a side wall of the beam, a laser pulse generator 25 is provided which transmits its light pulses towards a receiver 26, which is also secured under the support beam. There are input leads 30 and output electrical leads 31 of the generator and the receiver, respectively. The receiver 26 detects any departures from the linear form of the support beam 2 in both coordinates in directions transverse to the axis of the support beam. Thus, by suitable control of the pressure in the pressure hoses 5, it is possible to correct or compensate for the flexion of the beam. In this respect, the central support member 4, the external tube 3 and the support beam 2 are connected together by means of a rigid holding plate 16 at their ends (FIG. 2).
In the embodiment of FIG. 3, the central support member is in the form of a hollow cylinder 10, which has internal pressure spaces 13 opening at its outer circumference. Like the pressure hoses in FIG. 1, the pressure spaces are distributed symmetrically over the cross section of the support member 10. Respective thrust pistons 14 are slidingly arranged in the pressure spaces. The supply of the driving fluid, which is preferably hydraulic fluid, is via axial ducts 7, transverse lines 9' and holes 9, and furthermore via holes 18 through the thrust pistons. The combined ducts conduct the driving fluid to pressure pockets 17 that are formed in the outer ends of the thrust pistons 14 that are radially outward against the tube. These pressure pockets are respectively sealed off at the sides of each piston. These pistons 14 may be designed with a round cross section or may be in the form of bars and they may be arranged in parallel rows, like the pressure hoses 5 in FIG. 1.
FIG. 6 shows a further variation of the central support member 4'. In this version, the external form of the member is decreased in diameter from its center toward its axial ends in accordance with an e-function, that is, with a crowned form, so that pari passu with the flexure of the member 4', when it is acted upon by pressure by the pressing elements in the form of pressure hoses 5, the engaging surface or effective pressure surface of the member 4' remains substantially constant. On the other hand, it is possible to design the outer form of the member 4' in accordance with the flexure of the opposite roll A so as to provide for corresponding compensation of the flexion of the support beam right from the outset in order that the engaging edge of the doctor element or blade 12 will always engage the opposite roll A with the same pressing thrust along the axial length of the roll A.
It is naturally possible to use fewer pressure hoses, for example, as in FIG. 7, and to place them only in the upper part of the intermediate space between the support member 4 and the external tube 3 and to place them at the side opposite the opposite roll A. It is even possible to make do with only one pressure hose in the upper part of this intermediate space. It is then convenient to arrange the supporting device comprising the support member 4, the pressure hose 5' and the external tube 3, so that it may be turned, as shown in principle in FIG. 8, in relation to the support beam. The rotatable parts are then bearinged via the end plate 16' in relation to the support beam 2 by means of ball bearings 17 at both ends of the support beam 2. On twisting or turning the support beam 2 around the central axis of the device, the support member 4, the external tube 3 and the pressure hoses 5 remain in the given position in space so that the flexion of the support beam 2 may be compensated for at every angle thereof.
The central angle between the radial lines drawn through the middle of each pressure hose is naturally then generally substantially less than 180°. In the case of the four hoses or rows of pressing pistons, preferably the respective oppositely placed, paired pressing elements are ganged in pairs for pressure actuation. This makes possible very accurate control of the flexion of the support beam 2, so that this design is to be regarded as the preferred one.
The four hoses pressing element arrangement is preferably also used in the arrangement in FIG. 8. In this case, the central support member 4" is supported by part spherical bearings 36 including an outer ring 38 in an annular member 34, which is attached to a flange 33 of the support member 2 and is preferably screwed thereto, the screw means not being shown. In this case, free flexion of the support member 4" in relation to the support member 2 and the external tube 3' is made possible. In this case, the external tube 3' is firmly connected to the support beam. The support beam 2 must then not be a continuous box girder and it may be welded to the external support tube 3' in sectors so that it is generally attached to angle members with a sector angle of approximately 90°. Relative twist between the support member 4" and the support beam 2 is prevented by a locking pin 40 fitting into a groove 41 in a terminal support pin 37 of the central support member 4". The part spherical bearing is in addition fixedly located on the pin 37 of the support member 4" by a radial spring 39.
FIG. 8 also shows the arrangement of the pressure hoses 5 in dash-dotted or broken lines. The supply of the hydraulic or pneumatic driving fluid is thought of as being to the opposite end and is not shown.
Although the present invention has been described in connection with preferred embodiments thereof, many variations and modifications will now become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
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The smoothing device has a support beam. The beam is compensated along its line of flexure by a support member arranged centrally in it and which corrects the flexure of the support beam, which is due to the effect of gravity thereon or to a lesser extent due to any counter acting force of the doctor supported on the beam. A tube surrounds and is spaced radially out from the support member. A plurality of hydraulically or pneumatically actuated pressing elements are disposed between the tube and inside of the beam and extend over the length of the beam and are pressurized to support the beam.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/469,372 filed May 11, 2012 entitled Method and Apparatus for Controlling Cooling Temperature and Pressure In Wood Veneer Jet Dryers, which is a continuation of U.S. patent application Ser. No. 12/068,529 filed Feb. 7, 2008 entitled Method and Apparatus for Controlling Cooling Temperature and Pressure In Wood Veneer Jet Dryers, which claims priority from U.S. Provisional Patent Application No. 60/900,356 filed Feb. 9, 2007 entitled Method and Apparatus for Controlling Cooling Temperature and Pressure in Wood Veneer Jet Dryers.
FIELD OF THE INVENTION
[0002] This invention relates to the field of producing wood veneer and in particular to methods and apparatuses for controlling the temperature and pressure in the cooling sections of wood veneer jet dryers.
BACKGROUND
[0003] Applicant is aware of U.S. Pat. No. 5,603,168 which issued to McMahon, Jr. on Feb. 18, 1997 for a Method and Apparatus for Controlling a Dryer wherein it is taught that the cooling section cools into the material exiting the drying chamber of the dryer by blowing ambient air around the material as it travels through the cooling section. A control is provided for maintaining the pressure within the cooling section at a level greater than the pressure in the drying chamber. By operating the cooling section at a slightly higher pressure, leakage of exhaust gases from the drying chamber into the cooling section is inhibited. An automatic control for maintaining the required pressure differential between the cooling section and the drying chamber pressure is described. Pressure sensors are disclosed for monitoring the pressure in the drying chamber and the pressure in the cooling section. A controller was suggested to be connected to the pressure sensors and operatively coupled to a damper for controlling the flow of cooling air thereby controlling the pressure within the cooling section. Alternately, the speed of a cooling air blower may be adjusted. Applicant is also aware of U.S. Pat. No. 4,439,930 which issued Apr. 3, 1984 to McMahon, Jr. Both U.S. Pat. Nos. 5,603,168 and 4,439,930 are incorporated herein by reference.
[0004] Conventionally, the last structural units (sections), typically one to four, sections of veneer jet dryers comprise the cooling zone. They are typically fitted with vane axial-type supply air fans and motors delivering outside air to nozzle systems for direct cooling of the veneer passing through the heating and cooling sections. It is typically desirable to utilize the cooling zone to drop the surface temperature of the veneer to a specified level. This has typically been accomplished by turning certain sections of the cooling zone “on or off” as necessary to achieve the desired temperature, or to utilize an alternating current (AC) variable speed drive on the fan motors to vary the speed of the fans and, thereby, vary the veneer temperature. Being that these cooling sections are typically connected directly, that is, in fluid communication with the heated sections of the dryer, with only a baffle wall separating the two, there has not been the ability to control the flow of cooling zone air into or out of the dryer. This has resulted in either “cool” air being pushed into the heated drying process or heated process air flowing into the cooling zone specifically when the damper described in U.S. Pat. No. 5,603,168 is not present or set too far open.
[0005] The present invention contemplates an improved automatic control for maintaining the required pressure differential between the cooling section and the drying chamber. Pressure sensors are disclosed for monitoring the pressure in the drying chamber and the pressure in the cooling section. A controller connected to the pressure sensors is operatively coupled to a damper for controlling the flow of cooling air out of the dryer thereby controlling the pressure within the cooling section above dryer pressure. Alternately, the speed of a cooling air blower may be adjusted.
SUMMARY
[0006] Among its various objects, the present invention provides for automatically balancing the pressure between an enclosed veneer dryer and its associated cooling section by adjusting the pressure in the first cooling section, both up and down, as needed to inhibit airflow between the adjacent sections.
[0007] Thus, in one aspect of the present invention, the first cooling section, which is attached directly to the last heated dryer section, is modified to create a “pressure seal” for minimizing both the flow of heated process air from the dryer into the cooling zone or the flow of cool air from the cooling zone into the enclosed heated dryer. In one embodiment the first cooling section is fitted, in its discharge vent, with a tube-axial extractor fan and motor controlled by a frequency drive, conjoined with a modulating, balanced-blade damper. The section is mechanically sealed from both the enclosed dryer and second cooling section by two sets of baffle-like “stop-offs” that are mounted between the dryer rolls at the beginning and end of the section, restricting the movement of air in and out of the first cooling section. The stop-offs extend laterally across the veneer flow path and work in conjunction with the veneer conveying rolls. They, therefore, only allow restricted leakage or entrance of air past the pressure seal section entrance and exit.
[0008] Pressure-sensing manifolds are mounted on either side of the stop-offs between the enclosed dryer and first cooling section and are piped to a pressure transducer, which continuously monitors the differential pressure between the heated dryer and first cooling section. The signal from the transducer is processed in the dryer programmable logic controller (PLC) using a PID loop, described below, with split range control and a “near zero” set point, which produces a signal that both modulates the damper through the first half of the control range and controls the speed of the tube-axial extractor fan through the second half of the control range. The effect of this control is to maintain a slightly higher pressure in the first cooling section with a “near zero” pressure differential between the enclosed dryer and first cooling section, that is the “pressure seal” section, under all operating conditions. The resulting controlled condition minimizes pitch buildup in the dryer and cooler, minimizes volatile organic carbon (VOC) in the cooler vent and improves the drying process thermal efficiency.
[0009] In an additional embodiment, the cooler section air supply fans are controlled either by one or individual frequency drives receiving a signal from a proportional-integral-derivative (PID) loop in the dryer PLC and having an operator-established veneer temperature “set point” and a “process variable” measured by an infrared scanner mounted at the dry veneer moisture detector. If reduced cooling is required the air supply fans slow to satisfy the temperature set point. This action lowers the pressure in the in the first cooling section and its discharge damper closes to again balance the pressure in this the cooler “seal” and the extractor fan stops. If increased cooling is required, the air supply fans increase in speed and the pressure seal discharge damper modulates to full open at the end of the first half of the control range and, as more cooling is required, in the second half of the control range the extractor fan begins to increase in speed to satisfy the near-zero pressure “set point” of the first cooling section.
[0010] The supply and exhaust air for the cooling sections are normally taken from and vented to atmosphere, for example above the factory roof, thereby allowing the cooling zone of the dryer to have a “net zero” impact on makeup air to the factory.
[0011] In summary, the wood veneer dryer according to embodiments of the present invention may be characterized in one aspect as including an elongate drying chamber having an input end and an output end and defining a path of movement between the ends. A conveyor conveys product to be dried along the path of movement through the drying chamber. The chamber includes a plurality of juxtaposed heating units sections, each heating unit defining a circulation path for heated air, the path being substantially transverse to the path of movement of the product to be dried. Nozzles forming part of each of the heating units direct heated air into an impinging relationship with the path of movement. An exhaust system extracts gases from an adjacent heating sections. A first pressure sensor senses a pressure in the output end of the drying chamber; a cooling section cools the veneer leaving the output end of the drying chamber. The cooling section includes pressure controlling means for maintaining a pressure in the cooling section that is higher, for example slightly higher than the pressure in the drying chamber while maintaining a near-zero pressure differential between the drying chamber and the cooling section. A second pressure sensor senses a pressure in the cooling section downstream of and adjacent to the output end of the dryer. A flow controller adjusts the rate of the exhaust flow as a function of the difference in pressure sensed by the first and second pressure sensors.
[0012] In one embodiment the flow controller includes a forced air input and a forced air extractor arranged laterally opposed across the path of movement in the first cooling section, and a damper cooperating with the air extractor.
[0013] Thus in some embodiments of the present invention, a method for controlling a wood veneer dryer may include:
a) providing a drying chamber having at least one drying section and corresponding upstream input and downstream output ends, b) providing a cooling section at an output end of the drying chamber; c) monitoring a first pressure of dryer gases at the output end; d) comparing the first pressure with a second pressure in the cooling section; e) adjusting a flow rate of cooling air in the cooling section so that the second pressure is greater than the first pressure and the pressure differential between the first and second pressures is near-zero.
[0019] In one embodiment the control is provided by the use of a PID loop using a split range controller wherein in a first, lower range, that is below the split, the position of the cooling section exhaust damper is controlled to control the pressure differential, and in the second, upper range, above the split, a forced air mover is also employed in a graduated fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] With reference to the drawings in which similar characters of reference denote corresponding parts in each view:
[0021] FIG. 1 is, in plan view, the wood veneer dryer cooling sections according to embodiments of the present invention.
[0022] FIG. 2 is, in side elevation view, the cooling sections of FIG. 1 .
[0023] FIG. 3 is a sectional view along line 3 - 3 in FIG. 2 .
[0024] FIG. 4 is a sectional view along line 4 - 4 in FIG. 1 .
[0025] FIG. 5 is a sectional view along line 5 - 5 in FIG. 2 .
DETAILED DESCRIPTION
[0026] First cooling section 10 is mounted directly to the last, that is most downstream, heated dryer section 12 . Section 10 is modified to create a pressure seal for minimizing both the flow in direction A of heated process air from the dryer air into the cooling zone commencing in section 10 or the flow in the opposite direction of cool air from the cooling zone into the enclosed heated dryer. In one embodiment first cooling section 10 is fitted, in its discharge vent 14 , with a tube-axial exhaust fan 16 and motor 18 controlled by a frequency drive, conjoined with a modulating, balanced-blade damper 20 . Section 10 is mechanically sealed from both the last dryer section 12 and a downstream second cooling section 22 by two sets of stop-offs 24 that are mounted between the dryer rolls 26 in both the upstream and downstream ends of section 10 , thereby restricting the movement of air into and out of first cooling section 10 .
[0027] Pressure-sensing manifolds (not shown) are mounted on either side of stop-offs 24 between dryer section 12 and first cooling section 10 and are piped to a pressure transducer (not shown), which continuously monitors the differential pressure between the heated dryer and first cooling section. The signal from the transducer is used for predictive control and in particular is processed in a programmable logic controller (PLC) using a proportional-integral-derivative (PID) loop. As would be known to one skilled in the art, the PID loop automates what an intelligent operator with a gauge and a control knob would do. The operator would read a gauge showing the output measurement of a process, and use the knob to adjust the input of the process until the process's output measurement stabilizes at the desired value on the gauge. The position of the needle on the gauge is the “process variable” as used herein. The desired value on the gauge is referred to as the “setpoint” herein. The difference between the gauge's needle and the setpoint is the “error”.
[0028] A control loop consists of three parts: measurement by a sensor connected to the process; decision in a controller element; and, action through an output device or actuator such as the extractor fan and damper herein. As the controller reads the sensor measurement, it subtracts this measurement from the setpoint to determine the error. It then uses the error to calculate a correction to the process's input variable so that this correction will remove the error from the process's output measurement. In a PID loop, correction is calculated from the error in three ways: cancel out the current error directly (Proportional), the amount of time the error has continued uncorrected (Integral), and anticipate the future error from the rate of change of the error over time (Derivative). The sum of the three calculations constitutes the output of the PID controller.
[0029] In an embodiment of the present invention the PID loop has a split pressure range control and a near-zero pressure differential set point. The PLC PID loop produces a signal that both modulates the actuation of damper 20 and its associated drive motor 28 through the first half of the control signal range and controls the speed of the tube-axial extractor fan 16 through the second half of the control signal range. The effect of this control is to maintain a near-zero pressure differential between the dryer section 12 and first cooling section 10 , that is the pressure seal section, under all operating conditions. The control minimizes pitch buildup in the dryer and cooling sections 10 , 22 and 30 minimizes volatile organic carbon (VOC) in the cooling section vents and improves the drying process thermal efficiency.
[0030] In an additional embodiment, the cooling section fans are controlled either by one or individual frequency drives receiving a signal from a PID loop in the dryer PLC and having an operator-established veneer temperature set point and a process variable measured by an infrared scanner (not shown) mounted at the dry veneer moisture detector (not shown). If reduced cooling is required the cooling section supply fans slow which lowers the pressure in the seal section and damper 20 adjusts toward closed to maintain the pressure balance in the seal section 10 and the extractor fan 16 stops. If increased cooling is required, the cooling section supply fans increase in speed, damper 20 modulates to full open and, as more cooling is required to maintain the veneer temperature setpoint and the extractor fan 16 begins to increase in speed to meet the cooling section pressure setpoint.
[0031] The first cooling section includes a provision for controlling the rate of exhausted cooling air such that a pressure is maintained in the cooling section that is greater than the pressure in the drying chamber. As a result, the flow of exhaust gas from the drying chamber to the cooling section is inhibited. Cooling air flowing from the inlet duct through the cooling section supply fan and enters an inlet chamber. As is conventional, the cooling air flows through jet nozzles and around the multiple levels of sheet material traveling through the cooling section and ultimately enters an exhaust chamber. From the exhaust chamber, the cooling air is exhausted through the outlet stacks. A damper assembly is positioned between the exhaust chamber and outlet stacks and controls the flow rate of the cooling air. Pressure sensors are positioned in the last drying section and also in the cooling section near the entrance to the cooling section. A differential pressure monitor or controller connected to the pressure sensors monitors for automatically controlling the position of the damper assembly so that a slightly positive pressure at the entrance to the cooling section, as compared to the drying sections, is maintained. As long as the pressure sensed by the sensor is greater than the pressure sensed by the drying section sensor, exhaust gases from the drying chamber will be inhibited from flowing into the cooling section. The position of the damper assembly is controlled by an electrically-operated rotary actuator.
[0032] The supply and exhaust air for the cooling sections is obtained and vented to atmosphere, for example above the factory roof, thereby allowing the cooling zone of the dryer to have a “net zero” impact on makeup air to the factory.
[0033] Cooling section 10 differs from cooling sections 22 and 30 in that cooling section 10 , being the pressure seal section, includes exhaust fan 16 and damper 20 controlled by the PID loop. The intake side of cooling sections 10 , 22 and 30 each, however, include ambient air intakes 32 so as to intake ambient air in direction B from intake stack 34 . A hood 36 may be mounted atop each intake stack 34 . Ambient air is drawn down through intake ducts 32 by supply fans 38 driven by drive motors 40 .
[0034] Ambient air passes through fans 38 downwardly into supply chambers 44 so as to be turned in direction C. The ambient cooling air is thereby forced between the sheets of veneer passing downstream in direction A on rollers 26 thereby cooling the veneer. Once the cooling air has passed between and over the sheets of wood veneer on roller 26 , the now warmed air is turned in direction D in exhaust chamber 46 .
[0035] The warmed air then passes through damper 20 and continues upwardly in direction E through extractor fan 16 so as to be vented from discharge vent 14 through outlet stack 48 .
[0036] In the illustrated embodiment, and in order put the scale of the diagrams into perspective, a ladder 50 and guard rail 52 are illustrated.
[0037] As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.
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An apparatus for drying wood veneer includes an elongate drying chamber including a conveyor for conveying material to be dried from an input end to an output end; and a cooling section for cooling veneer leaving the output end of the drying chamber, the cooling section including a pressure controller for maintaining a pressure in the cooling section that is slightly higher than pressure in the drying chamber while maintaining a near-zero pressure differential between the drying chamber and the cooling section.
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This invention relates to the art of electrodes for alkali metal halide electrolysis and, more particularly, to an oxygen depolarized cathode formed from a mixture of a hydrophobic polymer and an electroconductive material to be used for the production of alkali metal hydroxide and halogen in such a manner as to significantly reduce the voltage necessary for the operation of such electrolytic cells and to increase substantially the power efficiency available from such cells utilizing the electrodes of this invention.
BACKGROUND OF THE INVENTION
Chlorine and caustic are essential, large volume commodities which are basic chemicals required by all industrial societies. They are produced almost entirely electrolytically from aqueous solutions of alkali metal halides or, more particularly, sodium chloride, with a major portion of such production coming from diaphragm-type electrolytic cells. In the diaphragm electrolytic cell process, brine (saturated sodium chloride solution) is fed continuously to the anode compartment to flow through a diaphragm usually made of asbestos particles formed over a cathode structure of a foraminous nature. To minimize back migration of the hydroxide ions, the flow rate is always maintained in excess of the conversion rate so that the resulting catholyte solution has unused or unreacted sodium chloride present. Hydrogen ions are discharged from the solution at the cathode in the form of hydrogen gas. The catholyte solution containing caustic soda (sodium hydroxide), unreacted sodium chloride and other impurities, must then be concentrated and purified to obtain a marketable sodium hydroxide commodity. The unreacted sodium chloride is returned to the electrolytic cells for reuse in further production of sodium hydroxide and chlorine. The evolution of hydrogen gas requires a high voltage thereby reducing the power efficiency possible from such an electrolytic cell thus creating an energy inefficient means of producing sodium hydroxide and chlorine gas.
With the advent of technological advances such as dimensionally stable anodes and various coating compositions therefor which permit ever narrowing gaps between electrodes, the electrolytic cell has become more efficient in that the power efficiency is greatly enhanced since electrolyte resistance in the narrow anode/cathode gap is reduced. Also, the hydraulically impermeable membrane has added a great deal to the use of electrolytic cells in terms of selective migration of various ions across the membrane so as to exclude contaminants from the resultant product thereby eliminating at least some of the costly purification and concentration steps required in the processing of diaphragm cell products.
The largest advancements in electrolytic cell technology have tended to improve the efficiency of the anodic side and the membrane or seperator portion of electrolytic cells. Currently, more attention is being directed to the cathodic side of the electrolytic cell in an effort to improve the power efficiency of the cathodes to be utilized in the process and to create a significant energy savings in the cathode reaction process.
In a conventional chlorine and caustic cell, employing a conventional anode and cathode and a diaphragm seperator therebetween, the electrolytic reaction at the cathode may be represented as
2H.sub.2 O+2e.sup.- yields H.sub.2 +2OH.sup.- ( 1)
The discharge potential of this reaction as measured against a standard hydrogen electrode is -0.83 volts. The desired reaction under ideal circumstances to be promoted at the cathode would be
2H.sub.2 O+O.sub.2 +4e.sup.- yields 4OH.sup.- ( 2)
The potential for this reaction is +0.40 volts. The use of this reaction as opposed to the common hydrogen discharge reaction would result in a theoretical voltage savings of 1.23 volts. The electrical energy necessarily consumed to produce the hydrogen gas which is an undesirable reaction product of the cathode in conventional electrolytic cells has not been counterbalanced efficiently in the industry by the utilization of the resultant hydrogen. While some uses have been made of the excess hydrogen gas, those uses have not made up the difference in expenditure of electrical energy necessary to evolve the hydrogen. Thus, if the evolution of hydrogen gas could be substantially reduced or eliminated from the electrolysis process, it would save electrical energy and make production of chlorine and caustic more energy efficient, while avoiding the separation and disposal problems associated with the production of hydrogen.
The oxygen electrode presents one possibility for the elimination of the production of hydrogen since it consumes oxygen to combine with water and the electrons available at the cathode in accordance with the following equation
2H.sub.2 O+O.sub.2 +4e.sup.- yields 4OH.sup.- ( 3)
It is readily apparent that this reaction is more energy efficient by the very absence of the production of any hydrogen at the cathode and at least theoretically affords the reduction in potential as shown above. Oxygen electrodes are normally porous materials and the reaction is accomplished by feeding an oxygen-rich fluid such as air or pure oxygen to one side of the oxygen electrode where the oxygen has ready access to the electrolytic surface in contact with the electrolyte so as to be consumed in accordance with the above equation. This does, however, require a significantly different structure for the electrolytic cell itself so as to provide for an oxygen compartment on one side of the cathode so that the oxygen-rich fluid may be fed thereto.
Oxygen electrodes have become well-known in the art since many NASA projects to promote space travel during the 1960's also provided funds for the development of a fuel cell utilizing an oxygen cathode and a hydrogen anode to produce electrical current for utilization in a spacecraft by feeding hydrogen and oxygen gas to the electrodes to make water. While this major, government-financed research effort produced many fuel cell components including an oxygen electrode, the circumstances and the environment in which the fuel cell oxygen electrode functions are quite different from that which is experienced in a chlor-alkali cell. Thus, while much of the technology gained during the NASA projects is of value in the chlor-alkali industry with regard to the development of a oxygen electrode, much further development has been necessary to adapt the oxygen electrode to the chlor-alkali cell cathode environment.
Some attention has been given to the use of an oxygen cathode in a chlor-alkali cell so as to increase the efficiency in the manner described to be theoretically feasible, but thus far, the oxygen cathode has failed to receive significant interest so as to produce a commercially effective or economically viable electrode for use in an electrolytic cell to produce chlorine and caustic. While it is recognized that a proper oxygen cathode will be necessary to realize the theoretical efficiencies to be derived therefrom, the chlor-alkali cell will require an electrode significantly different from that of a fuel cell since the electrical potential will be applied to the chlor-alkali cell for the production of chlorine and caustic rather than electrical potential being drawn from the electrodes as in a fuel cell. Therefore, it would be advantageous to develop an oxygen cathode which will approach the theoretical electrical efficiencies possible with an ideal oxygen electrode in the cathode compartment of a chlor-alkali electrolytic cell.
In order to operate efficiently and maintain a reasonable lifetime in a cell environment, the electrolyte should penetrate into the electrode sufficiently to reach the interior surfaces of the electrode and thereby contact the gas in as many places as possible in the presence of the electrode and any catalyst associated therewith. However, the electrode must be sufficiently hydrophobic to prevent the electrolyte from flooding the pores of the electrode and "drowning" the electrode. When drowning occurs, the reaction zone is moved away from the electrolyte side of the electrode deeper into the interior of the electrode. This results in some electrolyte being relatively immobile within the pores of the electrode and somewhat separated from the main body of the electrolyte. Thus, the ions formed by the cell reaction in the interior portions of the electrode cannot readily escape from the reaction zone of the electrode and cell performance drops. This build-up of ions in the reaction zone and the resultant decrease in cell performance is known as "concentration polarization."
There have been many attempts to provide a gas electrode which permits good gas-electrolyte-electrode contact without drowning or polarizing the electrode. It has been proposed to make pores of the electrode smaller on the electrolyte side of the electrode body than those on the gas side of the body so that the combined effect of the surface tension of the liquid electrolyte in the small pores and the pressure of the gas from the opposite side of the electrode prevents the electrolyte from flooding that portion of the electrode having the larger pores. This requires precise gas pressure control which increases the size and weight of the cell. Furthermore, it is difficult to obtain an electrode having a uniform gradient of pore size ranging from large on the gas side to small on the electrolyte side.
Other methods of improving cell performance have included attempts to wet-proof the electrode such as by dipping the electrode in dilute solutions of wax in a low-boiling solvent. By this method, the electrode is rendered somewhat hydrophobic but the wax can block the electrode pores and/or insulate the electrode surface from the desired reaction.
While electrodes for use in fuel cells have not found commercial utility in chlor-alkali electrolysis, their development is pertinent to the search to obtain a viable electrode in a chlor-alkali cell environment. Thus, Reutschi, U.S. Pat. No. 3,062,909, discloses an oxygen electrode comprising a nickel-silver-paladium powder mixture which is sintered to form a porous electrode. Additionally, a metal screen or expanded metal may be incorporated within the sintered mass of metal powder to lend strength to the electrode while not inhibiting the passage of gas through the electrode.
Kometani, et al, U.S. Pat. No. 3,329,530, describes a sintered fuel cell electrode comprising 50 to 95% by volume of a conductive material such as carbon or nickel and from 5 to 50% by volume of a hydrophobic binder component such as polytetrafluoroethylene (PTFE). The electrode is formed by pressing a powder mixture of the components in a mold and then sintering the resultant article at a temperature substantially higher than the melting point of the binder component. No pressure is utilized during the sintering step, however.
LeDuc, U.S. Pat. No. 3,400,019, describes an electrode having a non-metallic substrate such as a polymer material, ceramic material or graphite, having thereon a film of electroconductive metal which is preferably applied by electroplating.
Carson, et al, U.S. Pat. No. 3,415,689, describes an oxygen electrode wherein a spinel catalyst and PTFE mixture is applied to a porous graphite electrode substrate. Preferred spinel catalysts are cobalt aluminate, magnesium aluminate, silver ferroso-ferric oxide and nickle ferrate. The spinel mixture is applied by a painting process on the graphite substrate.
Darland et al, U.S. Pat. No. 3,423,247, describes an electrode having a microporous high surface area catalyzed layer on the electrolyte side of the electrode and a low surface area non-catalyzed, highly hydrophobic area on the gas side of the electrode. With this structure, gas is able to penetrate the macroporous gas side of the electrode while electrolyte is not able to penetrate this area from the opposite side. This condition creates a reaction zone in the central portion of the electrode and avoids flooding and the consequent failure of the electrode.
In Giner, U.S. Pat. No. 3,438,815, an oxygen electrode is produced by applying a coating of noble metal black and PTFE in an aqueous solution which is dried and sintered onto a porous metal substrate, the metal being selected from nickel, copper, valve metals, or noble metals. The metal substrate layer may be produced by sintering a mixture of metal powder and ceramic carrier to produce the porous structure.
Deibert, U.S. Pat. No. 3,457,113, describes a laminar electrode having a hydrophobic layer of carbon and polymer laminated with a hydrophilic layer of metal catalyst and electroconductive material. Optionally, a metal screen may be pressed into the laminate in order to strengthen the resultant electrode. The laminate layers are produced by fusion of the binder component with heat and/or pressure.
U.S. Pat. No. 3,600,230, Stachurski, describes a gas-depolarized electrode comprising a metallic grid or screen upon which a layer of hydrophobic resinous material and fiberous conductive material has been formed to create a surface upon which a second layer of catalytically active material such as platinum or silver is formed using a hydrophobic resinous material as a binder.
In Binder, U.S. Pat. No. 3,854,994, a gas electrode is produced by filtering a slurry of polytetrafluoroethylene powder to obtain a filter cake followed by the step of drawing a solution of carbon powder, graphite fibers and polytetrafluoroethylene through such filter cake to form a second layer on the filter cake first layer. The electrode is then dried and heated to about 330° C. in a non-oxidizing atmosphere. The filter cake is formed on a metal screen of electroconductive, corrosion resistant material.
Gritzner, U.S. Pat. No. 3,923,628, describes a chlor-alkali cell having an oxygen cathode comprising a silver plated copper screen substrate coated with a mixture of platinum black, silver balck or carbon black with PTFE or other fluorinated hydrophobic polymer. Platinum screening may be substituted for copper screening as substrate material. The high cost of these materials has prevented commercial application of this chlor-alkali cell even though a 200 to 800 millivolt advantage (depending on current density) is indicated by the patent.
None of the above electrodes has found commercial utility in the production of chlorine and caustic in an electrolytic cell. The principal limiting factors have been cost of the electrode material, particularly those employing large amounts of precious metals, and electrode life span in the highly corrosive environment of the cathode compartment of a chlor-alkali electrolytic cell.
It is therefore a principal object of this invention to provide a gas-depolarized electrode for use as a cathode in a chlorine and caustic cell which has sufficient porosity and hydrophobicity for efficient oxygen reduction while having a structural integrity which permits extended life in the corrosive environment of a chlor-alkali cell.
It is another object of this invention to reduce the cost of a gas-depolarized cathode for use in a chlorine and caustic cell through the utilization of common electrocatalytic materials employing only small amounts of precious metals.
These and other objects of the invention are accomplished by a novel electrode and process of making same to be described hereinafter.
SUMMARY OF THE INVENTION
In accordance with the invention, a gas depolarized electrode is comprised of a substrate made from a sintered composite of a prefused mixture of carbon and polytetrafluoroethylene and an electrocatalyst deposited thereon, the substrate providing sufficient porosity so that the potential of the reduction reaction of oxygen at the electrode-electrolyte-gas interface is lower than the hydrogen discharge potential at the surface of steel cathodes as now used in alkali-halide electrolysis.
Further in accordance with the invention, a prefused mixture of carbon and polytetrafluoroethylene is utilized to obtain a cathode substrate for use in chlor-alkali processes by sintering the mixture under high pressure and at a temperature in excess of the sintering temperature of the polymer but below its temperature of decomposition.
In accordance with a more limited aspect of the invention, the previously-described prefused, sintered composite electrode substrate incorporates a foraminous metal backbone structure which lends additional structural integrity to the resultant electrode while acting as an efficient current distributor throughout the electrode.
Further in accordance with the invention, the hydrophobic character of the electrode is augmented by the incorporation of a layer of hydrophobic material applied to one side of the substrate.
Further in accordance with the invention, the hydrophobic character of the electrode is increased by employing a prefused mixture of carbon black and PTFE in which there is a large proportion of PTFE in the mix.
Still further in accordance with the invention, a gas-depolarized electrode for use in chlor-alkali processes is made by a method comprising the steps of mixing a prefused composite of carbon black and polytetrafluoroethylene, forming same into an electrode and sintering the electrode under high pressure and at a temperature in excess of the sintering temperature of the polytetrafluoroethylene and below the decomposition temperature thereof to obtain an electrode substrate and followed by the step of depositing an electrocatalyst on the substrate.
Further in accordance with the invention, the electrode is utilized in an electrolytic cell for the production of halogen and alkali metal hydroxide, the cell comprising an anode compartment, a cathode compartment and a separator therebetween, the anode compartment having an anode therewithin and aqueous alkali metal halide electrolyte. The cathode compartment comprises a seperator and an oxygen cathode of the type described parallel thereto with electrolyte between the cathode and the seperator and a gas chamber on the opposite side of the cathode and gas feed means for feeding air or oxygen to the gas compartment. With the application of direct current to the anode and cathode, halogen is evolved at the anode and oxygen is reduced in accordance with the foregoing reaction (2) to produce alkali metal hydroxide in the catholyte. The above-described oxygen cathode comprises a substrate of a sintered composite of prefused mixture of polytetrafluoroethylene and carbon black which may optionally include a reinforcing and current distributing material such as wire mesh, the cathode substrate then being coated with an electrocatalyst. The cathode may also have a hydrophobic backing applied to one side thereof.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The invention will now be described in the more limited aspects of a preferred embodiment thereof. Variations and deviations from the disclosed electrode and process of making same will be apparent to those skilled in the art. It is intended that all such embodiments be included within the scope of the appended claims and that the disclosure of preferred embodiments shall in no way limit the scope of the invention as defined thereby.
In accordance with the invention, a prefused granular mixture of polytetrafluoroethylene and carbon black preferably having a particle size of about 10 microns and having a composition of about 10 to about 70% polytetrafluoroethylene and about 90 to about 30% carbon black is formed into an electrode shape, preferably rectangular, in a sinter press mold. The mold is then compressed at a pressure of 200 to 4,000 psig and heated to a temperature of about 650° to 700° F. This temperature and pressure is then maintained for a period of 5 minutes to 1 hour to effect the sintering and fusion of the polytetrafluoroethylene. The electrode substrate formed has the desired degree of porosity for use as a gas-depolarized electrode for a chlor-alkali cell. The electrode substrate may then be coated with an electrocatalyst as desired.
The principal advantage of the aforedescribed method is that through the utilization of a prefused mixture of PTFE and carbon black, the resultant electrode has a high degree of hydrophobicity compared to a normal, non-prefused mixture while not impairing the gas penetration or occluding the active reaction sites within the porous structure.
Another advantage of the method is that the fabrication of the electrode takes place in one step, that is hot pressing, rather than several steps as with spraying or painting numerous coats of dispersions of polytetrafluoroethylene and carbon black onto a substrate. With such prior spray techniques, numerous cycles of spraying and hot pressing have been necessary to form successive thin coats of material. Careful control of this prior coating process was necessary in that if too thick a coat was formed, mud cracking of the material resulted. With the use of the method of this invention, only one layer of solid is used to produce the finished electrode.
The composition of carbon black and polytetrafluoroethylene used in obtaining the electrodes of the invention is available in various percentage mixtures from Liquid Nitrogen Processing Corporation, Malvern, Pa., as a prefused composite prepared by a proprietary process as a filler for the plastics industry. In applying the composite to use in the present invention, it is necessary to select the appropriate ratio of components for the desired porosity and hydrophobic character of the resultant electrode and sinter press same into a useful product. As is well understood in the art of gas electrodes for fuel cells, the porosity of a polytetrafluoroethylene/carbon electrode is directly related to the carbon loading while hydrophobicity varies directly with the PTFE loading.
The process of sintering the electrode is outlined above stating various parameters for temperature, pressure and time of treatment. Since the process of sintering involves a time-temperature-pressure relationship, however, high temperatures for shorter periods of time can be utilized as well as lower temperatures for a longer period of time. Furthermore, higher or lower pressures may dictate the use of lower or higher temperatures and/or shorter or longer times, respectively. Limitations on the sintering process should not, therefore, be assumed to encompass only those values stated in this description of preferred embodiments but should be understood to encompass any combination which will achieve the desired sintering of the polymer.
In another embodiment of the invention, the composite may be pressed into or onto a support structure such as a polymer fabric or metallic mesh or combinations thereof. Thus, metal screening of iron, steel, nickel, silver, gold, platinum group metals, and valve metals may be utilized. Further, a porous hydrophobic polymer substrate materials such as polyethylene, polypropylene, nylon, TEFLON, or other corrosion-resistant polymers may be employed. When such a reinforcing material is employed, the electrode may be formed by placing the backing material in the mold and adding the prefused composite polytetrafluoroethylene and carbon back to the mold and sintering same under normal procedures for making the electrode in accordance with the invention. Optionally, the polytetrafluoroethylene/carbon black electrode may be preformed and then laminated onto the reinforcing backing.
Electrocatalysts used in the invention may include noble metals, blacks, and mixtures or alloys of these as well as other common catalysts such as silver, gold, non-precious metal oxides and phthalocyahines as well as mixtures thereof. The catalysts may be applied by any of various methods such as painting, spraying, dipping, electroplating or other process common in the art and readily apparent to those skilled in the art of electrocatalysts and electrodes. Also, a pore forming material such as alkaline or pseudo-alkaline carbonates and bicarbonates or the like may be desired or required in the catalyzed layer.
For a fuller understanding of the principles of this invention, there are described hereinafter examples illustrating preferred embodiments of the invention only and not limiting the scope and extent of the invention.
EXAMPLE 1
A prefused mixture of 50% carbon black and 50% PTFE was placed in a 1.5 inch square ram press mold. The material was then heated to 680° F. under a pressure of 200 psig and the temperature and pressure were maintained for 30 minutes to sinter the PTFE. Upon cooling and removal from the mold, the electrode substrate was coated with 0.13 grams of chloroplatinic acid (CPA) applied by spray coating. The electrode was then heated to 400° F. to reduce the CPA to platinum. The electrode was then treated in a sodium borohydride/sodium hydroxide solution for 2 hours to complete the reduction of the platinum. The electrode was then washed with deionized water and placed in a laboratory test cell. The test cell simulates the catholyte side of a membrane-type chlor-alkali cell having a catholyte which is approximately 10 molar sodium hydroxide. A dimensionally stable anode is used along with the cathode which forms one wall of the cell and has an oxygen chamber located on the opposite side of the cathode from the electrolyte. The cathode made as above-described was tested at 1 ampere per square inch (asi) and the potential of the cathodic reaction as compared with a mercury/mercuric oxide electrode ranged from about -0.050 to -0.060 volts. This compares favorably with the cathode potential for mild steel which is about -1.100 volts, compared with the same reference electrode, the oxygen electrode offering about a 1.050 volt advantage over that of a mild steel cathode at that current density.
EXAMPLE 2
A prefused mixture of 50% carbon black and 50% PTFE was cold pressed at approximately 3000 psig. The resultant material was then cut into approximately a 1.5 inch square piece and hot pressed onto a nitric acid etched nickel mesh. The hot press conditions were a pressure of 2000 psig at a temperature of 660° F. for 2 minutes followed by 500 psig pressure for 3 minutes at the same temperature. The initial pressure was to force material through and around the mesh. The lower pressure and 660° F. temperature was then used to sinter the binder. The resultant electrode appeared to have good adhesion. The coupon was then treated with chloroplatinic acid as above with a loading of 1 milligram per square centimeter of platinum resulting. The coupon was then operated in the above-described cell and its potential at 2.0 asi was measured at about -0.190 to 0.200 volts versus the mercury-mercuric oxide reference electrode.
EXAMPLE 3
An electrode produced in the manner of Example 2 was operated at 1 asi in an attempt to determine the lifetime of the electrode. The electrode was operated for approximately 100 days in a test cell as previously described with the potential ranging from -0.080 to -0.100 volts versus the reference electrode. The electrode had not failed by either concentration polarization due to flooding or structural degradation at the time the test was terminated.
EXAMPLE 4
A 30% PTFE and 70% carbon black prefused mixture was applied to a sheet of TEFLON backing material and a nickel mesh material was layed on top of the deposited PTFE-carbon black layer. The laminate was heated to 350° C. at 2000 psig to sinter the PTFE and press the nickel mesh into the composite layer. Upon removal from the press the surface of the laminate was treated with chloroplatinic acid as previously described with a loading of 0.25 to 0.3 milligrams per square centimeter of electrode surface. Reduction of the CPA as above-described was then carried out and the resultant electrode was mounted in the laboratory test cell as above-described under the conditions of the previous Examples. The voltage was measured at 0.5 asi versus the mercury-mercuric oxide electrode at -0.138 volts.
This process would lend itself favorably to continuous roll forming of the electrode whereby the TEFLON fabric would proceed in one direction toward a first station where the prefused mixture of PTFE and carbon black would be applied to the surface thereof, such as by spraying or painting whereupon the material would proceed to a second station where nickel mesh was laid from a roll onto the surface of the PTFE carbon black mixture followed by hot roll pressing of the laminate to sinter the PTFE and produce the desired electrode substrate.
The invention has been described in the more limited aspects of a preferred embodiment and illustrated in specific examples showing the utility of the invention. It is not intended that any such disclosure be construed as a limitation upon the invention but that the scope of such invention shall be interpreted only by the scope of the appended claims.
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An air/oxygen electrode substrate for use as a cathode in alkali metal halide electrolysis processes is formed by compressing a prefused mixture of carbon black and a hydrophobic polymer such as polytetrafluoroethylene under high pressures and at a temperature in excess of the sintering temperature of the polymer and below its decomposition temperature. Optionally, the electrode may be formed having a core comprised of a metal mesh which acts to better distribute the applied voltage and to reinforce the electrode. Further, a sheet of hydrophobic backing material such as TEFLON fabric may be incorporated into the compressed mixture to increase the hydrophobic properties of the cathode. Electrocatalysts may then be deposited on the surface of the electrode substrate to produce an oxygen electrode having a significant voltage advantage over mild steel cathodes in alkali-halide electrolysis cells.
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TECHNICAL FIELD
The present invention generally relates to vehicle stability control and more particularly relates to a method and a device for establishing a value, especially a momentum, produced externally, driving or braking a vehicle.
BACKGROUND OF THE INVENTION
The longitudinal dynamics of a vehicle—speed and acceleration—is influenced by various internal and external values, especially momentums. Within the meaning of this description, internal values/momentums are the motor torque, the brake torque or the normal resistance (which can be described internally by tables based on pragmatic values or by constants or formulas considering the motional status of the vehicle in connection with the characteristics/parameters of the vehicle). These values can be established in a relatively precise manner by various measures so that it is possible to consider their influence on the longitudinal dynamics. Additionally there are also externally produced values resulting particularly variable in addition to the normal resistance described above (which can be described internally). This includes, e.g. the slope descending force when a vehicle is driving on an inclined road. This slope descending force leads to a momentum which influences the longitudinal dynamics of the vehicle. The same applies for wind forces, extraordinary rolling resistances or similar. It is not possible (or only with difficulties) to establish these externally produced values with traditional sensors, so that usually additional sensors are required which have to be eliminated.
However, for some applications it is desirable to know also externally produced values driving or braking a vehicle, especially momentums. An example for such an application would be a starting aid when driving up a hill. Such starting aids shall facilitate the complicated handling of brake, parking brake, clutch and motor. At the same time it has to be assured that the vehicle never rolls back, in order do avoid e.g. collisions with vehicles being parked in downhill direction. If a vehicle shall be started driving up the hill, the rules described schematically in FIG. 4 apply in a first approximation. The weight F G of the vehicle can be decomposed into a normal component F N and a tangential component F T on the wheel of a one-wheel model. Together with the wheel radius r R , F T leads to a slope descending momentum M H according to the formula:
M H =F G ·sin α· r R
In this case α is the angle of inclination. Without further intervention the slope descending momentum M H would cause the vehicle to run down the hill. The brake torque M B and the motor torque M M introduced during the start of the vehicle, counteract against this momentum. An aid for starting up the hill can influence, e.g. the brake torque M B . But the influence has to be such to assure at all times that the inequation
M
H
<M
B
+M
M
is complied with because only in this case the vehicle is definitely prevented from rolling back. In order to satisfy the equation mentioned above, the slope descending moment has to be known.
Similar considerations as above apply in dynamic situations (vehicle speed unlike zero). When driving slowly up the hill in urban traffic, the considerations mentioned above could become an important factor. Also in such cases it is desirable to know the values produced externally and driving or braking a vehicle, especially momentums, in order to influence the vehicle in an adequate manner.
From U.S. Pat. No. 5,455,767 a control for a vehicle drive with an automatic gear is known which determines a correction term by comparing an estimated and a measured output speed representing a basic value for the inclination angle. On the input side a motor torque and a resistance momentum of the vehicle are delivered to a time element. The difference between the estimated and the measured output speed is countercoupled to the rotation angle acceleration.
It is the object of the present invention to indicate a method and a device for establishing an externally produced value, especially such a momentum, which drives and brakes the vehicle.
The externally produced values, and in particular the momentums, are determined by an observer. The observer receives internally produced values, especially momentums, which drive or brake the vehicle, establishes, how the longitudinal dynamics of the vehicle should develop, compares this result with the measured values of the longitudinal dynamics and concludes from possible deviations that there are externally produced values, especially momentums, driving or braking a vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a block diagram of the present invention
FIG. 2 the observer of FIG. 1
FIG. 3 an exemplary model of the vehicle dynamics and
FIG. 4 schematically valid physical connections in an exemplary application.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 schematically describes a first embodiment according to the present invention. The devices 10 to 12 are devices for determining internal or internally produced momentums. In particular a device 12 for determining the motor torque MMotAxis and a device 11 for determining the brake moment MBrakeAxis can be foreseen. In addition, also a device 10 for determining a normal resistance MNormalRes can be foreseen. On the other hand, the devices 10 to 12 work according to certain input values. The devices 11 and 12 can particularly be models and/or tables which model or describe the conduct of the brake and/or the motor/gear and deliver the desired output values.
On the basis of a model and with reference to the input values described above, the observer 13 determines the “theoretical” driving performance or the “theoretical” longitudinal dynamics, particularly the speed, of the vehicle, based on characteristic values even in this case. Characteristic values are, e.g. the tire radius or the vehicle mass. Furthermore the observer 13 receives a theoretical value from an appropriate device 14 which corresponds to the measured value. If the modeling of the longitudinal dynamics is sufficiently precise, the deviation between the theoretical and the measured value can be attributed to values, especially momentums, produced externally and not modeled, so that this external value can be concluded from this deviation.
FIG. 2 shows the observer 13 of FIG. 1 in a more precise representation. The observer 13 represents a model of the driving performance response the longitudinal dynamics of the vehicle, corresponding to the numerals 31 to 36 . Furthermore it shows a device for determining the external value, i.e. the numerals 21 , 22 , 25 . But before illustrating the function of observer 13 on the basis of FIG. 2, the model of the driving performance response the longitudinal dynamics of the vehicle is described on the basis of FIG. 3 which represents again the components 31 to 36 of FIG. 2 for illustration.
The model for the driving performance of the vehicle response for its longitudinal dynamics has to meet at least two conditions in order to be suitable for the present invention.
it must have suitable input and output values and
it must consider static and dynamic effects in a sufficiently precise manner.
The model in FIG. 3 satisfies these requirements. As input values it receives a total momentum which acts on the vehicle. This total momentum MTot corresponds to the total of all accelerating and decelerating momentums. If the total momentum MTot is zero, the vehicle will drive at a constant speed. If it is greater than zero, the vehicle will be accelerated, if it is negative, the vehicle will be decelerated. In the calibration 31 the total momentum is calibrated according to wheel radius and vehicle mass. In this case “calibration” is a proportional conversion serving e.g. for the conversion, normalization or adaptation of values. From this results a value corresponding to the acceleration. This value is integrated in integrator 32 . Thus results a value corresponding to a speed. Furthermore an assembly 33 to 36 is foreseen which imitates the dynamics. In the represented embodiment of the present invention this refers to a PT 1 -member which only gradually communicates to the output changes occurring on the input. The PT 1 -member includes a subtractor 33 , a calibration 34 , an integrator 35 and a feedback 36 introduced at the subtractor 33 . The value of the calibration 34 defines the time constant of the PT 1 -member. The PT 1 -member considers the fact that real systems react practically always with a certain delay to changes of their input values. Thus it is possible to better imitate the vehicle dynamics. The result is an output in the form of a speed VMod, which the model in FIG. 3 has determined as “theoretical” speed of the vehicle on the basis of the total momentum MTot which had been inserted.
The sequence of the single components can also be represented in a different way than that of FIG. 3 . However, the negative feedback 23 , 24 of FIG. 2 should be introduced after the integrator 32 . The device 14 for determining the real vehicle speed VRefFilt can be a sensor emitting an adequate signal. A more complex device can also be foreseen, taking suitable judgement and filtering measures in order to receive signals which are possibly free from interferences.
The vehicle model described with reference to FIG. 3 can be considered as an example. However, also other models can be used which satisfy the requirements mentioned further above.
Referring again to FIG. 2, the use of the model of FIG. 3 in the observer 13 is illustrated. The “theoretical” vehicle speed VMod determined on the basis of the model is compared with the real vehicle speed VRefFilt. In particular the difference between the model speed (also called estimated vehicle speed) and the real speed (also called real vehicle speed) VRefFilt is built in the subtractor 22 . The deviation between estimated vehicle speed and real vehicle speed has to be attributed to externally produced values, and especially momentums, which are not modeled, and thus permits a conclusion to be made with regard to these external values and especially momentums. If the vehicle is running uphill, the externally produced momentum has a decelerating effect. Without considering this external momentum the estimated speed would be too high and particularly higher than the real vehicle speed. If the vehicle is running downhill, the slope descending momentum has an accelerating effect. Without considering this slope descending momentum the estimated vehicle speed VMod would thus be smaller than the real vehicle speed VRefFilt. Thus, from the deviation and in particular from the difference between the estimated and the real vehicle speed can be determined the externally produced value, in particular the externally produced momentum. In order to cause the observer 13 to work altogether in a stable manner, the external momentum already determined can be added with the right algebraic signs to the other momentums already determined (of the devices 10 to 12 ). For this reason it is introduced at the summation point 21 . The device 25 is a calibration which converts the speed difference into the relative momentum errors preferably in a proportional manner. Thus the output of the device 25 , the signal MCorrectionObs is the externally produced momentum that had originally been looked for, which can be used as output signal and can be led back into the observer at the summation point 21 , as already mentioned above.
From the point of view of the control technique also a feedback 23 , 24 can be foreseen which, after the integrator, leads back a signal into the vehicle model corresponding to the difference between the estimated vehicle speed and the real vehicle speed. Thus stability and dynamic characteristics of the model are improved. The countercoupling feedback can be realized e.g. at summation point 33 .
The device according to the present invention can be implemented by discrete components, but also be formed by means of a suitably programmed computer which receives the relative input values, sends the desired output values and has access to the data which are also needed. The Method is executed preferably in a continuous manner or triggered periodically.
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A method is described for determining an externally produced value, especially a momentum, accelerating or decelerating the vehicle, with the following steps: determination of the driving performance of the vehicle on the basis of a model, comparison of the model output values with the relative measuring values or values derived from this, and determination of the externally produced value according to the result of the comparison. The corresponding device includes a model of the driving performance of the vehicle, a comparator for model output values and measuring values or values derived from these and a device for determining the externally produced value according to the result of the comparison.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/324,035, filed Sep. 20, 2001.
TECHNICAL FIELD
[0002] The present invention relates to an aircraft communications system, and more particularly to a telephony communications system.
BACKGROUND OF THE INVENTION
[0003] Aircraft telephony communications systems are systems that allow an aircraft crewmember to place telephone calls through a ground based telephone system such as a Public Switched Telephone Network (PSTN). Thus a crew member may place telephone calls to ground based telephone customers or mobile telephone customers similarly as a person on the ground may place a call to another terrestrial user.
[0004] In present aircraft telephony systems there exists a radio link between the aircraft and the terrestrial PSTN system. One such link may be through a SatCom digital radio system that accesses terrestrial PSTN through communications satellites. Another possible link is through a conventional Flight Phone system as is employed in many commercial aircraft today, that may have either an analog or a digital radio link to the PSTN.
[0005] In order for a crewmember to place a telephone call through the PSTN, typically either the crewmember must remove his headset and utilize a separate telephone handset with a separate control apparatus for, for example, dialing a desired number, or he accesses the radio link to the PSTN through a Multifunction Control and Display Unit (MCDU). The MCDU is a common on-board system that performs many aircraft functions including flight plan management, communications, and the like. An MCDU has a display screen, which may be a CRT, LCD, flat panel display, or other suitable display and an associated control panel consisting of keypads and switches to select the various functions performed by the unit. To place a telephone call through a PSTN, a crewmember must select the telephone function on the MCDU and, using a keypad or other selection mechanism, usually on the MCDU, select or dial the desired number. After selecting the function and number, the crewmember must select the proper function (telephone) on an audio panel to initiate the call. Since the MCDU and the audio panel are usually not conterminously located, the crewmember is required to divert his attention unnecessarily from device to device, thus increasing the workload on the crewmember.
[0006] Consequently, it would be desirable to provide a system in which all, or virtually all, audio related functions may be controlled through a single control point, such as the audio panel.
BRIEF SUMMARY OF THE INVENTION
[0007] In a communications system having a plurality of radio communication modes with an audio component, the audio component of the radio communication modes being controlled through an audio panel, and a radiotelephony mode with an audio component being controlled by a radiotelephony device, the audio component of the radiotelephony mode having an audio input for supplying audio to the radiotelephony device the invention comprises a method for integrating the radiotelephony audio component with the audio panel, by providing an interface between the audio panel and the radiotelephony device, coupling the audio input of the radiotelephony mode to the audio panel, and directing the audio input of the radiotelephony mode to the interface, the interface coupling the audio input of the radiotelephony mode to the radiotelephony device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will hereinafter be described in conjunction with the appended drawing figures, where:
[0009] [0009]FIG. 1 shows a generalized block diagram of an aircraft telephony system.
[0010] [0010]FIG. 2 shows a detailed block diagram of one implementation of the aircraft telephony system of the instant invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0011] The following detailed description of preferred embodiments is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention.
[0012] [0012]FIG. 1 shows a generalized block diagram of an aircraft telephony system 100 in accordance with one embodiment of the invention. The cockpit telephony system comprises an audio panel 102 having a telephony control panel 104 as illustrated in the enlarged view. An aircraft operator (not shown) located within the cockpit 106 of the aircraft can initiate and control a communication session between the cockpit 106 and a communication device 108 connected to a Public Switched Telephone Network 110 .
[0013] In this embodiment of the invention, the audio panel 102 comprises a plurality of buttons or switches 112 , 114 , 116 , 118 , 120 , and 122 for selecting the particular radio the audio of which it is desired to hear through the earphones 124 of a headset 126 worn by the pilot or a crewmember of the aircraft. The headset 126 also has a microphone 128 through which the crewmember can provide audio input to the audio panel. Each of the switches 112 - 122 selects one of the radios on board the aircraft, which may include a first communications radio (not shown) selected by switch 112 for communicating with other communications radios whether airborne, terrestrial, or satellite. Likewise, a second communications radio (not shown) may be selected by switch 114 . Switches 116 and 118 may select first and second navigation radios (not shown) and switch 120 may select another navigation radio such as an Automatic Direction Finder (ADF). These navigation radios may be selected so that a crewmember may listen on his headset to the audio identifier of the navigation facility to which the radio is tuned to verify that the navigation radio is, in fact, properly tuned and the navigation facility is operative. Switch 122 may select a telephony communications radio whereby the crewmember may communicate through his headset with a terrestrial Public Switched Telephone Network (PSTN).
[0014] As previously noted, typically in order for a crewmember to place a telephone call through a PSTN, either the crewmember must remove his headset and utilize a separate telephone handset with a separate control apparatus for, for example, dialing a desired number, or he accesses the radio link to the PSTN through a Multifunction Control and Display Unit (MCDU). To place a telephone call through a PSTN, a crewmember must select the telephone function on the MCDU and, using a keypad or other selection mechanism, usually on the MCDU, select or dial the desired number. After selecting the function and number, the crewmember must select the proper function (telephone) on an audio panel to initiate the call. Since the MCDU and the audio panel are usually not conterminously located, the crewmember is required to divert his attention unnecessarily from device to device, thus increasing the workload on the crewmember.
[0015] By integrating the audio of the telephony system into the audio panel 102 , and incorporating a telephone keypad 104 into the audio panel, a crewmember may now use his usual communications headset 126 to provide audio input to the audio panel 102 . Since the audio panel 102 also has integrated therewith a telephone keypad having a dialing mechanism and the required function keys, the audio panel may be interfaced to an audio controller 132 which converts the signals from the audio panel to the appropriate signals to drive a telephony device 134 which includes a transceiver for communicating with the PSTN 110 .
[0016] [0016]FIG. 2 shows a block diagram of another embodiment of the invention. In this case, an audio panel 202 is provided and an expansion bus 204 couples the audio panel to a cell pad 206 , the function of which is to provide the necessary telephonic control functions such as dialing the phone number and initiating the telephone call. The expansion bus 204 also couples the audio panel 202 to other control panels 208 , such that the audio of other radios 242 may be controlled by the audio panel. The audio panel itself has a series of buttons or switches 210 , 212 , 214 , 216 , and 218 for selecting one of the radios 242 the audio of which it is desired to hear through the earpieces 124 of a headset 126 . The headset 126 also has a microphone 128 .
[0017] The audio panel 202 additionally has a switch 220 which is used to select the telephony system as will be discussed below. On the audio panel there is also a display 222 and a selection knob or switch 224 the functions of which will be explained below.
[0018] An audio processor 226 is coupled to the audio panel 202 by a microphone (mic) bus 228 . The mic bus 228 carries audio and control information between the audio panel 202 and the audio processor 226 . For example, audio input to the audio panel 202 by the microphone 128 of headset 126 is carried to the audio processor 226 and then either to a selected one of the other radios 242 or to the telephony device 230 in the event that the phone switch 220 is selected.
[0019] A telephony device 230 is coupled to the audio processor 226 by a bus 231 which carries audio and discrete signaling such as “off hook”, “ring”, etc. between the audio processor and the telephony device 230 . The telephony device 230 comprises interfaces to phones on the aircraft 232 , such as phones used by cabin crewmembers and “flight phones” that may be used by passengers on the aircraft to place telephone calls through a terrestrial PSTN to other telephones on the PSTN network. Telephony device 230 also comprises a radiotelephony transceiver to which the phones 232 are interfaced, and which, through antenna 234 or other radiating means, transmits and receives audio to and from a terrestrial PSTN 236 . Depending upon the radio modulation technique employed by the telephony transceiver and the PSTN, of course, the audio transmitted and received by the telephony transceiver may be analog or digital and may be in one of many different forms. The telephony device 230 may be of several types, including SatCom (with which transmissions to and from a terrestrial system are directed through a satellite system) or flight phone systems such as Magna Star.
[0020] Also coupled to the audio processor 226 by means of an MAU 244 and an ASCB bus 238 is an MCDU 240 , the functions of which have previously been discussed. One of the functions of the MCDU/MAU pair is to store telephone identification numbers and the like to assist in placing calls through the PSTN. The MCDU/MAU is capable of entering and storing a large number of telephone numbers and other data.
[0021] In operation, a crewmember, using headset 126 , may wish to communicate with an air traffic controller. The crewmember selects the appropriate radio 242 by activating one of the switches 210 , 212 . The audio panel directs the audio from microphone 128 over the microphone bus 228 to the appropriate radio 242 for transmission to the air traffic controller. The audio from the air traffic controller is likewise passed over an audio bus 246 to the audio panel and then to the earphones 124 of headset 126 . If it is desired only to monitor one of the navigation radios to confirm the radio's settings, switch 214 , 216 , or 218 may be activated to select the desired radio 242 . The audio identifier or other information from the navigation facility will be directed over the audio bus 246 to the earphone 124 of the headset 126 .
[0022] If, however, the crewmember desires to place a telephone call to another telephone on the aircraft 232 or to a terrestrial PSTN, phone switch 220 on the audio panel 202 is selected. The crewmember then selects the identifier of the desired phone by means of selection knob 224 or another selection mechanism such as a cell pad 206 or the like. An electronic rotary switch can access a large number of phone identifiers, such as telephone numbers in a local memory. Alternatively, the numbers or identifiers may be stored only in the MCDU/MAU. Display 222 on the audio panel 202 displays the selected identifier. The identifier may be a series of numbers, such as telephone numbers, or may be textual, such as “Cabin” or “Rear” for phones on-board the aircraft, or “operations” for a terrestrial phone of a particular airline office.
[0023] When switch 220 is selected and the telephone identifier is selected, the audio panel directs the control information (phone identifier) and a “send” or other signal over the mic bus 228 to the audio processor. If the actual phone number is stored only in the MCDU/MAU 240 , the audio processor 226 may request the identifier from the MCDU/MAU 240 . The audio processor 230 , through it's interfacing circuitry, converts the telephone identifier, other control information, and audio levels to signals and levels compatible with the particular telephony device in use, and passes those signals and levels over bus 231 to the telephony device 230 . If the identifier is associated with one of the phones on the aircraft, the telephony device connects the crewmember's headset to the appropriate phone. If the identifier relates to a telephone or other user connected to the PSTN, the control and audio from the headset 126 and the audio panel 202 is directed to the telephony transceiver that forms a part of the telephony device 230 for transmission to the PSTN 236 . Likewise, audio returned from the PSTN over the radio link to the telephony transceiver is directed to the audio processor 226 and converted to levels and signals usable by the audio panel 202 over the audio bus 246 . The audio panel 202 then passes the audio information to the headset 126 .
[0024] Thus has been described an aircraft telephony control system wherein telephony features are combined with other radio communications feature in a single control location in order to reduce crew workload when switching from radio communication to radiotelephony. Of course, while the system has been described in terms of an aircraft implementation, the principles can be applied broadly to other similar communication systems.
[0025] While preferred exemplary embodiments have been presented in the foregoing detailed description of preferred exemplary embodiments, it should be appreciated that other variations may exist. It should also be appreciated that these preferred exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the ensuing detailed description will provide those skilled in the art with a convenient road map for implementing a preferred embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary preferred embodiment without departing from the spirit and scope of the invention as set forth in the appended claims.
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A communications system having a plurality of radio communication modes with an audio component, the audio component of the radio communication modes being controlled through an audio panel, and a radiotelephony mode with an audio component being controlled by a radiotelephony device, the audio component of the radiotelephony mode having an audio input for supplying audio to the radiotelephony device. The radiotelephony audio component is integrated with the audio panel, by providing an interface between the audio panel and the radiotelephony device, coupling the audio input of the radiotelephony mode to the audio panel, and directing the audio input of the radiotelephony mode to the interface, the interface coupling the audio input of the radiotelephony mode to the radiotelephony device.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Application No. 60/909,222, filed Mar. 30, 2007.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 6,751,364 (incorporated herein by reference) divulges an image analysis system and method for the grading of meat, predicting quality of meat and/or predicting meat yield of an animal. One embodiment of the invention is particularly designed to capture an image of the 12 th rib cross section of the ribeye and perform an image analysis of the ribeye for grading purposes. The image capturing camera portion of the system has a wedged shaped camera housing for easy of insertion into the ribbed incision. Once the image is captured either digitally or captured and converted to a digital image, an image analysis is performed on the digital image to determine parameters such as the percent lean, total area of the ribeye, total fat area, total lean area, percent marbling, and thickness of fat adjacent to the ribeye, and other parameters. These parameters are used to predict value determining traits of the carcass.
BRIEF DESCRIPTION OF THE INVENTION
The present invention relates to a portable device for determining meat quality with possible minimum error, thus replacing a human grader with computer-assisted grader (artificial vision). Analyzed meat may be bovine, porcine, sheep, horse or poultry meat.
The present application implies developing a new method of measuring parameters such as meat fat, texture and color by means of a method that allows relating said meat quality parameters to values obtained from images.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is the device of the present invention.
FIG. 2 is the main flow diagram of color, texture, and intramuscular analysis of a meat specimen.
FIG. 3 is a flow diagram of sub-routine capture of digital image.
FIG. 4 is a flow diagram of sub-routine that determines texture values.
FIG. 5 is a flow diagram of sub-routine that determines intramuscular fat percentage.
FIG. 6 is a flow diagram of sub-routine that determines color (CIE-Lab coordinates).
DETAILED DESCRIPTION OF INVENTION
The present description comprises some specific technical terms, which will be detailed below in order to avoid misinterpretations regarding other uses thereof or meanings that can be connected to the same terms.
The term “artificial vision” refers to the image captured by an electronic device and the computational interpretation of said image. This term is also known as “computer vision”, and corresponds to a sub-field of artificial intelligence. The purpose of the artificial vision is programming a computer, which due to said programming should “understand” a scene or image features.
The term “channel” refers to a primary meat unit from an animal that was insensitized, bled, skinned, and gutted, where its head was cut at the atlanto-occipital joint, its external genital organs were also cut as well as its limbs, which were cut at carpometacarpal and tarso-metatarsal joints.
The term “meat texture” refers to the sensorial manifestation of foodstuff structure and the way it reacts before the application of forces, such as shear stress. It is considered a food-grade parameter, since it directly produces an effect on the palatability, and said effect is noted only when meat has been subjected to a boiling process. It is directly determined by properties of conjunctive myofibril structures of the cytoskeleton, which differ greatly and depend on specie, race, gender, and age, thus producing an effect on technological and biological variables.
The term “intramuscular fat percentage”, also referred as marbling, relates to the visible fat amount in a meat cut. Intramuscular fat amount produces an effect on meat flavor, tenderness and juicy character, mainly depending on gender, slaughtering age and principally on genetic type. Meat fat quality basically depends on feedstuff composition consumed by the animal during the fattening stage.
Terms such as “color space”, “color modules” or “color systems” correspond to a coordinate system and an area or sub-space within said system, where each color is represented by a single point. A color space allows specifying and visualizing any color. Psycho-physical parameters of color perception are three: brightness, tone, and saturation. In the present invention use of color spaces are as follows:
Color space RGB, which is based on the combination of three different chromatic luminance signals: red (R), green (G), and blue (B). Graphically it is represented by a cube. Gray tones are represented by a straight line linking origin (0, 0, 0) with point (255, 255, 255) over which the three color components have the same magnitude. This corresponds to coordinated space used by electronic devices such as digital cameras and monitors.
Color space “XYZ” utilizes a brightness component (component “Y”) and two coloring or chromaticity components, which corresponds to components “X” and “Z”. Components “X”, “Y”, and “Z” have a value ranging from 0 to 100. Values of each component are obtained by means of integration or adding, which involves a lighting source, object reflectance, and sensitivity curves of a standard human observer. Quantitative colorimetry utilizes three data pieces to calculate colors: the energy of the luminous source (400 to 700 nm), the reflectance of the object and the curves of sensitivity of the eye.
Color space “Lab” represents colors by means of the scale of Hunter Lab, which is one of the easiest scales to interpret in the food industry. It uses parameters L, a, and b, where “L” measures the luminosity in a scale from 0 to 100, where 100 represents the color white and 0 represents the color black, “a” measures red tonalities (+127) until green (−128), and “b” measures yellow tonalities (+127) until blue (−128).
Lab coordinates can be obtained by means of mathematical formulae from values of coordinates XYZ and values of X 0 , Y 0 , Z 0 , that represent the “white pattern” of the system, for example:
L*= 116−( Y/Y 0 ) 1/3 −16
a*= 500·[( X/X 0 ) 1/3 −( Y/Y 0 ) 1/3 ]
b*= 200·[( Y/Y 0 ) 1/3 −( Z/Z 0 ) 1/3 ]
The term “image segmentation” refers to the technique by which an object of interest in an image can be separated from the “background” of the image. It does not necessarily identify the object category. For example, if it relates to a character like the letter “A”, the segmentation only identifies the image area where it is possible to find this character.
From the image a pair of referential points or pixels is selected (the corresponding minimum and maximum value in gray scale).
Each point or pixel of the image is selected according to its proximity with respect to these referential points.
Accordingly, the image points are separated in two categories, which show a similarity in their values of gray level. Particularly, these categories correspond to the group of pixels that correspond to meat and the pixels that do not correspond to meat, i.e., they correspond to the image background.
The term “thresholding” refers to a technique used in image segmentation. Thresholding is the method by which a level of threshold “T” is chosen in order to classify each pixel of the image f (x,y). If the pixel meets or exceeds the threshold property, for example f (x,y)>T, then the pixel is assigned to the object class; otherwise, the pixel is assigned to the background class.
For example, the Otsu's method may be used as a thresholding method. This is an iterative method that calculates an optimal threshold for a standardized histogram comprising two pixel distributions. The method assumes that the histogram is formed by two Gaussian curves, and that threshold T shall minimize the weighted sum of each one of the variances of the present objects.
Device Definition
The objective of the present invention relates to producing a portable device for determining meat quality with the minimum possible error, thus replacing a human grader with a computer-assisted grader (artificial vision). This invention also relates to a method of measuring parameters such as meat fat, texture and color by relating meat quality parameters to values obtained from images captured by a portable device.
The present invention consists of a system capable of objectively measuring meat quality parameters, and use of an image analyzing method captures images of meat quality parameters with no need to manipulate the meat.
The system of the present invention comprises a portable device which captures images of a meat specimen to be analyzed; and uses an image analyzing method to determine meat quality parameters that are measured using understandable units of the meat industry. Finally, the obtained results are displayed on a screen.
The present portable device ( FIG. 1 ) consists of a casing, preferably a tubular-shaped casing (a), that comprises a handle (b) on which a trigger (c) is arranged, and a screen or display (h). Inside the casing (a) an image-capturing device (e) is arranged. A microcontroller (f) is arranged outside of the casing, but may alternatively be arranged inside the casing, and is connected to the trigger and the display, respectively, in order to proceed with the actuation of the device and the data display. Furthermore, inside the casing a lighting system and a light backscatter system (g) are provided to obtain a uniform image without optical aberration. The device of FIG. 1 further comprises a camera support (d).
Other components of the portable device (not shown in FIG. 1 ) are electric power- and data feeder cables, which transfer the captured image to a required portable personal computer. Furthermore, a polarizing lens can be added to reduce brightness, and a filter to correct the color temperature in the opening zone (i) of the image-capturing device (e). Surface (j) corresponds to the device portion that comes in contact with the sample to be analyzed.
Some relevant aspects to be considered for the measurement of meat quality parameters are meat origin (sheep, bovine or other meat), meat type, etc. in order to determine quality parameters properly.
Image analysis is performed on a computer by an image analyzing method, which has been particularly designed for this purpose and is actuated by capturing an image. The analysis of said image is performed and parameter results are displayed both on the screen of the computer and on the display of the device of the present invention, where said parameters were measured with user understandable units.
The indicated analysis performed by a certain method allows measurement of three quality parameters of meat such as meat texture, meat color, and intramuscular fat percentage. The values of each are displayed in a comprehensible form to the user (i.e. in measurement units used in foodstuffs science).
The method for obtaining said meat parameters begins with positioning and contacting the portable device to a meat specimen, where said portable device comprises a lighting system to homogenize the light inside said apparatus, and an image capturing device which captures a specimen image.
The method for obtaining meat quality parameters from an image is semi-automatic, as the method is controlled by a computational program that is run by the operator once the image capturing device is triggered. Said programming activates the image capturing device and subsequently processes the captured image and displays the processed image on a screen. Once the computational programming is run, it checks the device status, which includes verification of the status of the image capturing device, among others. Verification of the status of the image capturing device checks feeding status, memory status, communication with the computer, etc. If there is any erroneous parameter, the programming shows an error message; if not, said programming goes through an automatic configuration process of the device intended for the image capturing process. The configuration states image format, image storage location (which can be either a temporal location or a location for storing the corresponding image for future verifications), exposure time, focus adjust, diaphragm opening, white balance, etc. Once ready, the image is captured and stored in a previously selected address. Subsequently the programming checks the image capturing device once more.
In the present invention the artificial vision is used for determining meat quality parameters.
In order to perform the image analysis a technique using Artificial Neural Networks (ANN) is utilized. Artificial Neural Networks are capable of “learning”, such as through backpropogation techniques, and due to this feature said artificial neural networks can transform data captured from an image into data of any other nature (conventional methods), such as data obtained by a Warner-Bratzler colorimeter, etc. Artificial Neural Networks (ANN) are prepared such that they can connect an inlet value to an outlet value. In the present invention said inlet value corresponds to a value obtained from data selected from the captured specimen image, whereas said outlet value refers to the result of the respective parameter, which is obtained by a physical or chemical method regarding the same specimen.
Outlet values for each parameter are intramuscular fat percentage, meat texture and color, which are determined by means of the following physical techniques:
Determination of Intramuscular Fat
The method of determining intramuscular fat percentage is based on the technique relating to the use of a graduated jig according to National Cattlemen's Beef Association; United States Department of Agriculture.
In said method a tag-blog is provided on the wet specimen which shows a squared grid drawn thereon. Then the operator proceeds to count those zones corresponding either to meat or fat inside said squared grid. Intramuscular fat percentage is calculated by means of a simple rule of three.
Texture Determination
The method for determining meat texture is based on Warner-Bratzler's technique.
From each meat cut cores cylinders, also referred as “cores”, having a diameter of about 1.27 cm and a height of about 2.5 cm are obtained, wherein each cylinder shall be oriented parallel to muscle fibers. Then temperature is adjusted to 1-3° C., and subsequently said specimens are subjected to room temperature. After 5 minutes each cylinder (core) is sheared by means of a Warner-Bratzler probe executing a cut perpendicular to muscle fibers once at a rate of 200 mm/min and an approach rate of 80 mm/min and a pre-load of 0.01 Kg.F.
A texturometer having a maximum load cell of 500N (DO-FB05TS Model 2003, Zwick, Ulm, Germany) was utilized. Texture is expressed as Maximum Force at Kg.F with a mean value of 6 measurements.
Color Determination
Method for determining meat color was carried out by measuring specimen reflectance. Said reflectance analysis was performed on a Miniscan XE Plus model N o 45/0-1 Hunterlab, which utilizes CIELAB system expressing results in terms of variables L, a and b. Six measurements of each specimen are performed and made on the specimen surface. Equipment is programmed at an observation angle of 10° with illuminant D65, which is similar to daylight, using an absolute scale for coordinates L, a and b, wherein color is defined in a three-dimensional and spherical space. A mean value of the 6 measurements represent the value of each variable.
The image analyzing method comprises the following stages: color analysis, texture analysis, and analysis of meat fat percentage. The obtained results are finally displayed on screen in a user understandable manner.
Meat Texture Analysis
Texture analysis is performed by means of an analysis sub-routine, which begins with the recovery of an image stored in a defined address in the computer hard disc. To this, an image clustering function is applied, which cuts or segments the image to be analyzed, selecting from said image only areas representing a meat image, and the remaining elements are discarded (image background). Then the image is subdivided in several sub-images of less size, e.g., of 128×128 pixels. Each of these images is analyzed to determine whether they correspond to meat or background (background is black; if image contains black pixels it will be discarded). Finally considered images are subjected to a Wavelet analysis by which a vector comprised of 8 RMS values for each sub-image or sub-area is obtained. Once this data is obtained and by means of a co-relation made by the prepared Artificial Neural Network, obtained variables are converted to a single shearing-force value. Obtained values for each image are averaged at a final stage, and said mean value, which is referred as F TOTAL , is the value corresponding to the mean texture measurement.
Analysis of Intramuscular Fat Percentage
Another relevant parameter is the mean quality measurement, which corresponds to the intramuscular fat percentage contained in a meat cut.
The process for obtaining the value of intramuscular fat percentage begins with the recovery of an image stored in computer hard disc. Then the program accentuates interest zones of said image by means of simple linear and non-linear operations, such as multiplying the image by itself, filtering undesired brightness, adjusting intensity, etc. In this manner a superior contrast between image and background is reached. Image segmentation is then performed in order to separate background from the interest zone.
Image coordinates RGB are converted into coordinates CMY (better resolution) and then the colored image is converted into a gray-scale image. Subsequently a thresholding method is applied, which uses an adaptive method to look for the proper threshold according to a histogram of the image being analyzed in order to achieve a discrimination among different gray tones that correspond to white and black.
The white and black pixels are counted, thus obtaining fat and meat areas in the cut. Subsequently areas corresponding to fat and meat are calculated and they are converted into intramuscular fat percentage contained in the cut. This result is finally displayed on a screen.
Color Analysis of Meat Specimen
The color obtaining process begins with the recovery of an image stored in a computer hard disc. Subsequently the number of pixels of this image is reduced and then the image portion to be analyzed is segmented by means of a function referred to as clustering, considering meat zones only. From this image coordinates RGB are obtained, which are specimen representative. Then the artificial neural network converts RGB color space into XYZ color space of colored zones (meat zones) and differentiates colored zones through data co-relation to convert previous coordinates into XYZ coordinates, and then into CIE Lab coordinates. Finally CIE Lab coordinates are displayed and recorded, thus obtaining mean color of the analyzed meat cut and the program is ready to start again.
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A system, method and device for grading of meat such as bovine, porcine, sheep, horse or poultry meat among others. The device of this invention is a portable tool, which is approached toward a meat specimen to be analyzed and captures an image. The device then objectively relates the image to meat quality parameters by means of an image analyzing method. The device and method solve, in a practical, fast and satisfactory way, the problem of determining meat quality parameters such as texture, color, and contained intramuscular fat percentage.
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FIELD OF THE INVENTION
The present invention relates to a printing apparatus which receives ink from an exchangeable ink cartridge and prints characters and the like on a print media while jetting ink droplets through nozzle orifices thereof.
BACKGROUND OF THE INVENTION
For example, an ink jet printing apparatus comprises a print head and an ink cartridge for containing ink therein. In the print head, a drive signal is applied to piezoelectric elements, heating elements or the like. Ink is pressurized by energy generated by those elements, and caused to be jet out in the form of ink droplets through nozzle orifices.
A print quality is determined by a resolution of the print head, and depends largely on viscosity of ink and a spread of ink in the print medium. For this reason, study and development are made for the improvements of ink characteristic, print head driving method adaptable to the characteristics of like ink, and maintenance conditions of purging periods in purging ink for preventing the clogging of the print head, the purging of ink from the print head being capped, and the like.
A remarkable improvement of the print quality of the printing apparatus is achieved when the ink characteristic and the print head driving method are both improved in harmony with each other. Manufacturers can incorporate such technical results of the development into the products. When a situation arises where altered control data must be loaded into the printing apparatus after delivered to the market, it is necessary to return the printing apparatus to its factory and replace an old storing means with a storing means storing the altered control data. This is almost impossible when considering the cost and labor to effect such work.
Accordingly, an object of the present invention is to provide a novel ink jet printing apparatus which can easily and automatically alter the print head driving method and the maintenance condition for removing the clogging of the print head in accordance with a change of the specification of ink, and an ink cartridge in use with the ink jet printing apparatus.
Ink as a chemical product is contained in the ink cartridge. Even if the ink cartridge run out of ink, there is a chance that ink is left in the ink cartridge. Therefore, ink per se as a chemical product and noncorrosiveness of high polymer material of the ink cartridge will contaminate environments. To avoid this, it is desirable to collect ink cartridges that run out have ink of, and refill the used ink cartridges with new ink and use the regenerated ones again. However, the regenerated products are somewhat degraded in reliability performance. For this reason, it is necessary to secure a satisfactory print quality, to consider an adverse affect on the print head, and to announce that the product is a regenerated one.
A second object of the present invention is to provide a novel ink jet printing apparatus which can secure a reliable print quality and satisfactory functionality of a regenerated ink cartridge, and an ink cartridge in use with the ink jet printing apparatus.
SUMMARY OF THE INVENTION
According to the present invention, there is provided an ink jet printing apparatus comprising: an ink jet print head mounted on a carriage reciprocatively moved relative to a print medium; an ink cartridge for supplying ink to the ink jet print head; print control means for outputting a drive signal to the ink jet print head in accordance with print data; head maintenance control means for discharging ink not contributing to print so as to secure a normal ink discharge from the ink jet print head; control data storing means for storing control data for the print control means and the head maintenance control means; and ink characteristic data storing means for storing ink characteristic data based on a nature of ink, and being disposed on the ink cartridge; wherein a control mode of either of the print control means and the head maintenance control means may be altered by the ink characteristic data.
With such a construction, the control conditions for the ink jet printing apparatus can be altered, without any aid of users, in compliance with the characteristic of ink in the ink cartridge and a reliability deteriorative variation ensuing from the reuse of the ink cartridge. Therefore, the operation mode of the ink jet printing apparatus may be altered in accordance with the composition of ink, which will greatly influences the print quality and the maintenance condition. When the used ink cartridge is used, the maintenance condition may automatically be altered in accordance with the number of the reuses of the ink cartridge.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIGS. 1 is a view showing an overall construction in an ink jet printing apparatus embodying the present invention;
FIG. 2 is a view showing a printing mechanism in an ink jet printing apparatus embodying the present invention;
FIGS. 3(a) and 3(b) are views showing a black ink cartridge used in the ink jet printing apparatus;
FIGS. 4(a) and 4(b) are views showing a color ink cartridge used in the ink jet printing apparatus;
FIG. 5 is a graphical representation of a variation of an electrical resistance between paired electrodes provided in the ink cartridge with respect to an amount of residual ink;
FIG. 6 is a view showing a layout of an ink characteristic data storing means and a data reading means on the ink cartridge;
FIGS. 7(a) to 7(d) are perspective views showing some embodiments of the ink characteristic data storing means provided on a black ink cartridge;
FIG. 8 is a block diagram showing a control unit for carrying out various controls in accordance with the nature of ink by use of the ink cartridge;
FIG. 9 is a view showing an ink cartridge;
FIG. 10 is a diagram showing a cartridge regeneration equipment used for regenerating such used ink cartridges;
FIGS. 11(a) and 11(b) are views showing embodiments of used ink cartridges, and FIGS. 11(c) and 11(d) are views showing conductive patterns on the ink cartridges after those are used one time and two times;
FIG. 12 is a view showing a process of packing the used ink cartridge;
FIG. 13 is a view showing another ink cartridge to which the present invention is applicable; and
FIG. 14 is a diagram showing a control unit of an ink jet printing apparatus using the ink cartridge of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will be described with reference to the accompanying drawings.
FIGS. 1 and 2 are views showing an overall construction and a printing mechanism in an ink jet printing apparatus embodying the present invention. In the figures, reference numerals 1 and 2 are a black ink cartridge and a color ink cartridge. These cartridges are attached to and detached from a carriage 8, which carries thereon black print head 6 and a color print head 7, by inserting the cartridges through a window 4 formed in a case 3.
As is well known, the print heads 6 and 7 have each a plurality of reservoirs for receiving ink from the ink cartridge, and a plurality of pressure generating chambers communicatively coupled with nozzle orifices for jetting ink droplets. A pressure applying means operates in response to a drive signal and pressurizes the pressure generating chamber associated therewith. In turn, the pressure generating chamber causes ink to jet out in the form of an ink droplet through the nozzle orifice associated therewith. In preparation for the next jetting of ink droplet, ink is supplied to the pressure generating chamber.
In a specific form of the pressure applying means of the pressure generating chamber, a diaphragm is used which is formed of an elastic plate-like member, which forms a part of the pressure generating chamber. The diaphragm is elastically deformed by a piezoelectric element. In another specific form of the pressure applying means, a heating element is used, which is energized by a drive signal applied thereto to heat and evaporate ink in the pressure generating chamber.
The carriage 8, coupled with a motor 10 by means of a timing belt 9, is moved parallel to a platen 12 while being guided by a guide member 11. The print heads 6 and 7 are mounted on the surface of the carriage 8, which faces a print sheet 13. A holder 16 with levers 14 and 15, which assist the attaching/detaching of the ink cartridges 1 and 2, is provided on the upper surface of the carriage 8.
Numerals 17 and 18 are capping members for sealing the black print heads 6 and 7. The capping members are coupled with a pump unit 20 for receiving a power from a paper feed motor 19. In a print rest period, the capping members 17 and 18 seal the surfaces of the nozzle apertures of the print heads 6 and 7 to prevent ink at the nozzle apertures from being dried. When the nozzle orifices are clogged, the capping members 17 and 18 seal the nozzle orifice surfaces of the print heads 6 and 7, and in this state, a negative pressure is applied to the print heads 6 and 7 from the pump unit 20, whereby ink is forcibly discharged or purged from the print heads.
FIGS. 3(a) and 3(b) are views showing a specific example of a black ink cartridge. In the figure, numeral 30 is a substantially cuboidal container with an open end, the widthwise length of the container gradually increasing toward its open end. To secure an easy joining of the container to other members by thermal welding, the container is formed by injection molding polymer, such as polypropylene, polyethylene, polystyrene or the like. The container 30 has a room for containing a porous body 31 made of elastic material suitable for absorbing at least ink. In the present embodiment, the container is divided, by a partitioning plate 32, into a foam room 33 and an ink room 34 for directly containing ink.
An ink supply port 35 that will receive an ink supply needle of the black print head 6 is formed in the lower end of the foam room 33. The open end of the container 30 is sealingly closed by a cover 38 having an ink injection port 36 and an air communication port 37, which are slightly spaced from each other. The ink injection port 36 of the cover 38 is located closer to the ink supply port 35 of the foam room 33 when horizontally viewed.
A protruded part 39 is formed on the bottom of the foam room 33. The protruded part 39 cooperates with the cover 38 to compress the porous body 31. An ink inflow port 40 is formed in the upper end of the protruded part 39. A port passage 41 is extended from the ink inflow port 40 to the ink supply port 35. A packing means 42 is put in the port passage 41. The packing means 42 will be fit to the ink supply needle of the print head, liquid tightly. An air shut-off film 43, which will be broken when the ink supply needle is applied thereto, is applied and bonded to the ink supply port 35. In the figure, reference numeral 44 designates a through-hole through which the foam room 33 communicates with the ink room 34.
FIGS. 4(a) and 4(b) show views showing a specific example of a color ink cartridge. The structure of this ink cartridge is substantially the same as of the black ink cartridge. A container 45 with an open end is substantially cuboidal in shape, and the widthwise length of the container gradually increases toward its open end. The container 45 is divided into a plurality of rooms by walls 46. Each room is partitioned, by a partitioning wall 48, to form a foam room 49 and an ink room 50 for directly containing ink. A through-hole 47 is formed in the lower part of the partitioning wall 48.
Ink supply ports 51 that will receive ink supply needles of the color print head 7 are formed in the lower end of the foam room 49. The open end of the container 45 is sealingly closed by a cover 54 having an ink injection port 52 and an air communication port 53, which are slightly spaced from each other. The ink injection port 52 of the cover 54 is located closer to the ink supply ports of the foam room 49 when horizontally viewed.
Protruded parts 56 are formed on the bottom of the foam room 49. The protruded parts 56 cooperate with the cover 54 to compress a porous body 55. An ink inflow port 57 is formed in the upper end of each protruded part 56. A port passage 59 is extended from the ink inflow port 57 to the ink supply port 51. A packing means 60 is put in the port passage 59. The packing means 60 will be fit to the ink supply needle of the print head 7, liquid tightly. A film 61, which will be broken when the ink supply needle is applied thereto, is applied and bonded to the ink supply port 51.
In the construction of each of the ink cartridges 1 and 2, the ink cartridge is divided into the foam room and the ink room, and these rooms store ink in different ways. Any ink cartridge, if it contains at least the porous body 31 or 55 impregnated with ink, will work as the ink cartridge 1 or 2 does, in spite of the presence of the ink room 34 or 50.
In the ink cartridge thus constructed, it is necessary to check an amount of ink in the cartridge. One way to check the ink amount is to count an amount of ink consumed in the printing apparatus. In case where conductive ink is the ink to be measured in its amount, a couple of electrodes 62 and 63 (64 and 65), separated a fixed distance from each other, are located near the ink supply port to detect a liquid level of ink present in the container. These electrodes are disposed crossing the container wall in a manner that one part of each electrode is extended inward from the inner wall of the container while the other part is extended outward from the outer wall of the container. Those parts outside the container form terminals 62a and 63a (64a and 65a) to be connected to an external device.
An electrical resistance between the couple of electrodes 62 and 63 (64 and 65) varies with respect to an amount of ink remaining in the ink cartridge 1 (2) as indicated by a curve denoted as A in FIG. 5. The graph shows that the resistance value rapidly increases in a region of small quantities of residual ink. As seen from the graph, it is possible to reliably grasp a residual ink amount by presetting the following resistance values; a resistance value Ln between those electrodes 62 and 63 (64 and 65) measured in a state that a residual ink amount is such that it is very small but the print is possible, viz., a resistance value at the ink near end, and a resistance value Le between those electrodes measured in a state that the residual ink amount is such that ink is almost used up and a further print is impossible because the air bubbles are stuch in the print head 6, 7.
The ink cartridge thus constructed, as shown in FIG. 6, includes an ink characteristic data storing means 70 and a data reading means 71 for reading data from the ink characteristic data storing means 70. As shown, the ink characteristic data storing means 70 is attached to the surface of the ink cartridge an access to which is easy; bottom, side or upper sides of the cartridge. The data reading means 71 is firmly attached to the cartridge holder 16.
Turning now to FIGS. 7(a) to 7(d), there is illustrated some embodiments of the ink characteristic data storing means 70. In an embodiment of the ink characteristic data storing means shown in FIG. 7(a), an electrical storing means 72, such as a magnetic bubble storing element or a nonvolatile semiconductor storing element, is provided, and a series of contacts 73 connectable to the contact electrodes of the data reading means to making an access to the electrical storing means are disposed close to the electrical storing means. An embodiment of the storing means shown in FIG. 7(b) comprises a code pattern 74, for example, a bar code, formed by use of an optical ink, a magnetic ink, the like. An optical detector, a magnetic head, or the like may be used for the data reading means. An embodiment of the storing means shown in FIG. 7(c) comprises an array of protruded pieces 75 regularly arranged. A plurality of limit switches arranged in association with the array of the protruded pieces are used for the data reading means. These switches are selectively turned on and off. Another embodiment of the storing means is shown in FIG. 7(d). In this embodiment, a plurality of conductive patterns 76 are arranged to be put at predetermined positions. Contacts, which are put at the positions corresponding to those of the conductive patterns 76, form the data reading means. Data is stored in the form of presence and absence of the conductive patterns.
Such control data may be:
1) States of a drive signal to cause the print head 6 (7) used to jet an ink droplet; a drive voltage, an application time of the drive voltage, a rate of change of the voltage or current, or the like.
2) Conditions of a flushing operation: flushing period, the number of ink droplets shot forth for the flushing, continuance of flushing operation, drive voltage and its application time for causing the print head to jet an ink droplet, a rate of change of the voltage or current, or the like. The flushing operation is performed during the printing period to prevent the clogging of the nozzle orifices. In the operation, the printing operation is stopped and the print head is moved to the ink receptacles, and ink droplets are purged from the nozzle orifices into the receptacles, irrespective of the print data.
3) Conditions of the sucking operation: a sucking pressure of the sucking pump, sucking rate, operation time, an amount of suction, and the like. The sucking operation is performed, for example, when the ink cartridge is replaced with a new one. In the operation, a negative pressure is applied to the nozzle orifices to purge ink therefrom.
4) In the case of the regenerated cartridge, the number of uses of the cartridge.
FIG. 8 is a block diagram showing a control unit for carrying out various controls in accordance with the nature of ink by use of the thus constructed ink cartridge. The black ink cartridge 1 is used in this embodiment. Substantially the same control unit is available for the color ink cartridges, as a matter of course.
In the figure, reference numeral 80 is a print control means which controls the carriage drive motor 10 in accordance with print data received from a host computer which causes a head drive means 81 to output a drive signal to drive the black print head 6. Numeral 82 is a suction control means for controlling a sucking time and a sucking force. When the black ink cartridge 1 is replaced with another cartridge or the black print head 6 is clogged, the suction control means 82 is used. In this case, the black print head 6 is sealed with the capping members 17, and a negative pressure is applied to the sealed black print head 6. Numeral 83 is a flushing control means having a function to control a period at which a flushing operation is performed, and a time for which the flushing operation continues, and another function to output a drive signal to the head drive means 81 to start the flushing operation. The flushing operation is executed, during a print period, to prevent the black print head 6 from being clogged with ink of an increased viscosity. In the flushing operation, the printing operation is stopped for a given period and the black print head 6 is driven to discharge ink droplets irrespective of print data. The print control means 80, head drive means 81, suction control means 82, and flushing control means 83 are essential in executing the minimum functions required for the ink jet printing apparatus.
Numeral 84 is a data read-out means. The data read-out means 84 responds to a signal output from the data reading means 71 and 71' attached to the carriage 8, for example, and reads data from the ink characteristic data storing means 70 of the black ink cartridge 1 and outputs the read out data to a control data read-out means 85 and a control data writing means 86, which will be described later.
The control data read-out means 85, referred to just above, refers to a control data storing means 87 to be given later and selects an optimum print condition from the contents stored in the storing means in accordance with the ink nature, for example, of the black ink cartridge 1, and transfers the selected one to the print control means 80, suction control means 82 and flushing control means 83. The control data writing means 86 updates data stored in the control data storing means 87 when the data read-out means 84 outputs data to request the version up of the printing apparatus.
The control data storing means 87 is a nonvolatile semiconductor storing means, e.g., flash memory, which is easily electrically reprogammable and capable of holding data without being destroyed when no electric power is supplied to the printing apparatus. The control data storing means 87 stores data of the factors determining the characteristic of a drive signal, which are adjusted in connection with ink in the black ink cartridge 1 attached to the printing apparatus. Examples of the factors are: voltage, application time, a rate of changing of voltage and current, period at which the flushing operation is performed, continuance of the flushing operation in time, time duration of a sucking operation, and sucking force.
Numeral 90 designates a resistance detecting means for detecting an electrical resistance value between the electrodes 62 and 63 of the ink cartridge for the purpose of ink end detection. A detection result is applied to an ink amount detecting means 91 and an ink nature detecting means 92. When an electrical resistance value between the electrodes 62 and 63 increases to reach a reference value Ln (see FIG. 5), the ink amount detecting means 91 causes a display 93 to display an ink near end message directing a user to replace the ink cartridge with a new one. When the resistance value reaches another reference value Le, the ink amount detecting means 91 causes the display 93 to display an ink end or, if necessary, outputs a signal to stop the printing operation.
The ink nature detecting means 92, just referred to above, judges whether or not ink filling the black ink cartridge 1 is suitable for black print head 6 depending on an electric conductivity of ink that can be known from an electrode-to-electrode resistance in the ink full state of the black ink cartridge 1. The result of the judgement is applied to the control data read-out means 85.
An operation of the thus arranged control unit of the ink jet printing apparatus will be described.
Upon power on, the print control means 80 reads control data from the control data storing means 87, and waits for input print data. In this state, print data is input to the control unit. Then, the print control means 80 causes the head drive means 81 to output a drive signal to form dots defined by the print data under control of control data output from the control data storing means 87.
A size of a dot formed on a print sheet with an ink droplet discharged from the black print head 6 depends on a viscosity of ink and a permeability of ink into the print sheet. For this reason, in printing dots, a drive energy is used which is suitable for the characteristic of the ink contained in the black ink cartridge 1 now loaded, whereby an amount of an ink droplet is optimumly adjusted to keep a print quality at the highest level. The amount of the ink droplet may readily be reset by controlling a voltage and application time of the drive signal, changing rates of the voltage and current in accordance with data from the control data storing means 87.
A printing operation continues for a give time, and a clogging occurrence time, which depends on an evaporation characteristic of ink of the black ink cartridge 1, elapses. Then, the print control means 80 moves the carriage 8 to a nonprint region and causes the black print head 6 to face an ink receptacle, for example, the capping members 17. And it drives the black print head 6 to discharge a fixed number of ink droplets. As the result of the discharging operation, ink whose viscosity was increased in the black print head 6 is discharged into the capping members 17. Then, ink suitable for the print is discharged from the black ink cartridge 1, and the printing operation will continue while keeping a fixed print quality level.
When the printing operation continues for a long period and ink is used up in the black ink cartridge 1, the old black ink cartridge 1 is detached from the cartridge holder 16 and a new black ink cartridge 1 is attached to the holder. The detaching and attaching of the black ink cartridge 1 is detected by the data reading means 71. Then, the data read-out means 84 reads ink characteristic data on the new black ink cartridge 1 from the ink characteristic data storing means 70.
When the ink of the new black ink cartridge 1 is improved and requires an alteration of the control conditions, the control data writing means 86 updates data in the control data storing means 87 in accordance with the data on the black ink cartridge 1 that is stored in the ink characteristic data storing means 70.
When the replacement of the black ink cartridge 1 ends, the suction control means 82 moves the carriage 8 to the capping position, and seals the black print head 6 with the capping members 17. Then, it controls a suction force and a suction time of the pump unit 20 on the basis of the updated suction control data stored in the control data storing means 87, causes the print head to discharge ink at the suction pressure and time suitable for the ink viscosity of the black ink cartridge 1 attached. In this case, air bubbles that entered, together with ink, into the black print head 6 are also discharged, to thereby preventing a print defect.
When such a maintenance operation ends and a printing operation starts again, the print control means 80 reads the updated control data from the control data storing means 87, and causes the head drive means 81 to output a drive signal suitable for the ink characteristic, for example, viscosity, in the replaced black ink cartridge 1. In this way, the printing operation is performed in the best condition without requiring a user's adjustment although the ink characteristic has been changed.
When the printing operation continues for a preset time and it reaches a flushing period determined by the ink characteristic of ink in the black ink cartridge 1, the flushing control means 83 move the carriage 8 to the nonprint region, and directs the black print head 6 to the ink receptacles, for example, capping members 17. Thus, the printing apparatus can continue the printing operation while keeping a required print quality, although the ink characteristic has been changed.
In such a case where the printer is not used for a long time and the print head 6 may be clogged, a cleaning button 95 on a control panel 94 of the case is pushed or a timer contained in the machine issues a cleaning signal. In turn, the suction control means 82 moves the carriage 8 to the capping position, and seals the print head 6 with the capping members 17 in preparation for a forcible charging of ink. The suction control means controls a suction force and a suction time of the pump unit 20 on the basis of the suction control data of the control data storing means 87 to purge ink in a condition suitable for the loaded ink cartridge 1. As a result, ink whose viscosity is extremely increased is forcibly discharged and the clogging of the print head is removed.
When a black ink cartridge 1 filled with ink improved in its characteristic for print quality improvements is delivered from a manufacturer without any announcement on the characteristic improvement, the printing apparatus of the invention accepts such an ink cartridge since control data may be automatically updated before the black print head 6 is driven or the maintenance condition may be altered. In other words, if control data suitable for ink is stored in the ink characteristic data storing means 70 of the ink cartridge 1, the manufacturer can change the specifications of ink as desired. The manufacturer can provide more varied products.
If a memory of a relatively large memory capacity, such as a semiconductor storing means, is used for the ink characteristic data storing means 70, catch phrases, logotypes and the like that may legally be registered as a copyright may be stored in the form of protected data in the storing means. In this case, the data read-out means 84 is given an additional function to allow the printing only when the data read-out means 84 confirms the protected data in a coincidence manner. By so designed, an unwanted situation is unlikely to arise where an excessive amount of incorrect ink, which is supplied not through regular sales channels, is mistakenly injected into the print head. The result is to minimize the damage of the print head and the loss of the user.
The ink cartridge having the electrodes 62 and 63 for detecting an ink end in the ink cartridge 1 is in an ink full state immediately after replacement of the ink cartridge 1. Therefore, a resistance value between the electrodes 62 and 63 is not dependent on an amount of ink left in the ink cartridge, but dependent only on a conductivity of ink (in the ink full region in FIG. 5). Therefore, in this state a conductivity of ink can be measured.
When the ink cartridge 1 is replaced with another cartridge, the ink nature detecting means 92 measures a conductivity of ink in the ink cartridge 1 by use of a signal from the resistance detecting means 90. The means 92 compares the measured one with the reference value Rs produced between the electrodes for a conductivity of ink suitable for the black print head 6 (hatched range in FIG. 5). When the measured resistance value falls within a preset range Rs±ΔR, the ink nature detecting means judges that the ink used is suitable for the print head, and executes the subsequent process.
When it is out of the preset range Rs+ΔR, (inks exhibiting resistance characteristics denoted as B and C), specific control data for a protection operation is stored in advance into the control data storing means 87, and the control conditions of the suction control means 82 and the flushing control means 83, both for maintenance, are altered.
To be more specific, for the forcible discharging of ink, the suction time is set to be somewhat long, whereby an ink exchanging rate of the black print head 6 is increased. The flushing period during the printing operation is set to be short, whereby the flushing is performed frequently. One flushing time is set to be long, whereby the amount of ink to be discharged is increased. Where the ink discharging amount is increased, the print quality is little deteriorated even if the ink tending to clog the print head 6 is used. The ink that may damage the print head 6 is quickly consumed, the replacing period of the ink cartridge 1 is reduced, and consequently the damage of the print head is minimized.
In the case of the ink cartridge after ink contained therein is completely used up, the container of the cartridge experiences only its attaching and detaching to and from the print head 6, and there is a less chance of being damaged. Therefore, such a cartridge can be used again if some parts, for example, packing and sealing pieces, are replaced with new ones. As shown in FIG. 9, an indication 96 indicative of a lot number, usually a bar code, is printed on a preset location of the ink cartridge 1. The lot number may be used to specify a type of the printing apparatus or the print head suitable for the ink cartridge, composition of ink, and a factory to manufacture the ink cartridge with the lot number.
FIG. 10 shows an example of a cartridge regeneration equipment used for regenerating such used ink cartridges. A conveying means designated by reference numeral 100, for example, a belt conveyor, conveys a pallet 101 capable of holding an ink cartridge 108 in a fixed posture along a lot number reading means 102, removal means 103, washing means 104, ink filler 105, and data writing means 106 arranged in this order.
A regenerating process controller 107 judges the number of uses of the ink cartridge 108 by use of data read out of the bar codes on the ink cartridge. When the ink cartridge is used five times or larger, the regenerating process controller produces a signal for transmission to the removal means 103 to cause it to discard the ink cartridge. Thus, only the ink cartridge that is used a few times is washed with the washing means 104, and then is conveyed to the ink filler 105. The ink filler removes ink still left in the ink cartridge, and fills the ink cartridge with new ink. After the refilling, the data writing means 106 prints data indicative of reuse, for example, data specifying the number of uses of the ink cartridge.
The ink filler 105 includes a chamber body 111 forming an injection/discharge chamber 110 that may be opened and closed, and a cover member 112 that may also be opened and closed. The cover member 112 is provided with an ink suction/injection needle 113 to be inserted into the ink injection port 36 of the ink cartridge, and an exhaust pipe 114 communicatively connected to the air communication port 37. The ink suction/injection needle 113 is connected to a suction means by way of a passage switch valve (not shown), and a fixed-amount ink supplying means. The injection/discharge chamber 110 is connected to a vacuum pump (not shown).
In the ink filler thus constructed, the ink cartridge 108 is put in the injection/discharge chamber 110, and the injection/discharge chamber 110 is sealed with the cover member 112. As a result, the ink suction/injection needle 113 is inserted into the ink injection port 36 of the ink cartridge 108, and the residual ink is purged out by the suction means. A pressure in the injection/discharge chamber 110 is reduced by the vacuum pump, and the passage switch valve is turned to the fixed amount ink supplying means which in turn supplies ink to the ink cartridge 108. Thus, the ink injection is carried out under a reduced pressure condition. Therefore, a long life of product quality is guaranteed.
Upon completion of the filling of ink, a total number of uses of the ink cartridge 1 is stored in the ink characteristic data storing means 70 thereof or a storing means exclusively used for that data storage. Here, the ink filler completes its ink filling operation. The total number of uses of the ink cartridge is preferably stored in the form of patterns that are impossible to alter, modify and change and easy to see. Embodiments of such patterns are illustrated in FIGS. 11(a) and 11(b). The patterns illustrated are conductive patterns 120 and 121 that may be cut, and the number of conductive patterns corresponding to the total number of uses of the ink cartridge are formed on an easy-to-see location on the ink cartridge by printing, for example. The conductive patterns 120 and 121 are cut as visually and clearly recognized, corresponding to the number of regenerations of the ink cartridge as shown in FIGS. 11(c) and 11(d).
Contact electrodes are formed at locations coincident with contact portions 120a, 120b, 120c, 120d of the conductive patterns 120 and 121 when the ink cartridge 1 is set to the cartridge holder 16 or the lever 14 or 15 of the cartridge holder 16. Data on those patterns are read out by the data read-out means 84, and used for altering the control conditions by the control data read-out means 85. Specifically, for the forcible discharging of ink, the suction time is set to be somewhat long, whereby an ink exchanging rate of the black print head 6 is increased. The flushing period during the printing operation is set to be short, whereby the flushing is performed frequently. One flushing time is set to be long, whereby the amount of ink to be discharged is increased. Where the ink discharging amount is increased, the print quality is little deteriorated if a reliability of the ink cartridge is reduced as result of the reusing of the cartridge.
The ink cartridge 122 thus refilled with ink is packed, for securing its good storage, such that at least the ink supply port 123 thereof is covered with a damper member 124, and put into an air shut-off bag 125 and a pressure within the bag is reduced. The ink cartridge 126, sealingly put in the air shut-off bag 125, is packed into a box 127, and then the box contained ink cartridge is delivered to a market.
Seals 128 indicating a regenerated or disposal product are printed on the bag containing the ink cartridge. In this case, some means, such as the number of seals, color or design, which is capable of clearly showing the number of reuses of the cartridge is preferably formed on the box 127. If so done, a mutual reliance between the manufacturer and the user will be enhanced.
While in the above-mentioned embodiment, the ink cartridge is mounted on the carriage, the present invention may be applied to the ink cartridge of the type in which the cartridge is mounted on a case and supplies ink to the print head by way of an ink tube. An embodiment where the present invention is embodied in such type of the ink cartridge is shown in FIG. 13. The ink cartridge in this embodiment is made up of a flat ink bag 131 for sealingly containing ink therein, a hard case 132 for receiving the ink bag, and a cover 133.
The flat ink bag 131 follows. For securing a gas barrier function, an aluminum foil is sandwiched with two films into an aluminum laminated film. Of those films, the outside film is a nylon film, for example, and the inside film is a polyethylene film, for example. Two aluminum laminated films are layered one on the other. Three sides of the resultant film are bonded together by heat welding, and an ink supply port 134 of a plastic molded product is attached to the remaining side thereof. The ink supply port 134 is sealed with a septum 135 made of an elastic material, e.g., rubber, which receives an ink supply needle attached to the extremity of the ink jet printing apparatus. In the figure, numeral 136 is a detecting plate for detecting an amount of ink in the ink bag 131.
As shown in FIG. 14, the ink cartridge 137 is mounted on the case, and communicatively connected through an ink tube 138 to a subtank 139. The subtank 139 supplies ink to the black print head 6.
The ink characteristic data storing means 70 is provided on the hard case 132 or the cover 133 of the ink cartridge 137. The data reading means 71 is mounted on the case. The control conditions may automatically be altered in accordance with ink characteristics and the number of reuses of the ink cartridge by use of the control unit as already stated. The thus constructed ink cartridge 137, usually, detects an amount of residual ink on the basis of a displacement of the detecting plate 136. Alternatively, electrodes 140 and 141 are attached to the flat ink bag 131. In this case, ink nature is detected by use of a conductivity of ink, and the maintenance conditions are altered as in the above-mentioned manner. When the ink cartridge 137 is reused, the residual ink may be purged from the ink cartridge, and new ink is injected into the ink cartridge as in the above-mentioned case, by use of an ink injection/discharge needle, if it is put to the septum 135.
In the embodiments described above, description is made on the case where specification for ink is altered and the ink cartridge is processed for reuse by the manufacturer. A modification is allowed where an optimum control condition that is set in the printing apparatus is stored into the ink characteristic data storing means 70 of the ink cartridge. Where a plural number of print media whose ink absorbing characteristics are greatly different are used for print, the control conditions best for the print media may automatically be set up in the ink jet printing apparatus by merely exchanging the ink cartridge with a suitable one.
As seen from the foregoing description, the control conditions for the ink jet printing apparatus can be altered, without any aid of users, in compliance with the characteristic of ink in the ink cartridge and a reliability variation ensuing from the reuse of the ink cartridge. Therefore, the operation mode of the ink jet printing apparatus may be altered in accordance with the composition of ink, which will greatly influences the print quality and the maintenance condition. When the used ink cartridge is used, the maintenance condition may automatically be altered in accordance with the number of the reuses of the ink cartridge. Therefore, a satisfactory print quality is secured, the reuse of the ink cartridge is possible, and the ink cartridge that may contaminate environment may be collected.
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An ink jet printing apparatus has an ink jet print head mounted on a carriage reciprocally movable relative to a print medium, an ink cartridge for supplying ink to the ink jet print head, a print control apparatus for outputting a drive signal to the ink jet print head in accordance with print data, flushing control apparatus for discharging ink, not contributing to print, in order to secure a normal ink discharge from the ink jet print head, and a control data storing apparatus for storing control data for the flushing control apparatus. A control mode of either of the print control apparatus and the head maintenance control apparatus may be altered by data from an ink characteristic data storing apparatus, provided on the ink cartridge, for storing control data based on the nature of ink.
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This is a continuation of prior U.S. application Ser. No. 10/876,449 filed on Jun. 28, 2004, now U.S. Pat. No. 7,497,953 which claims benefit from the provisional application Ser. No. 60/487,244, filed on Jul. 16, 2003, which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
A water treatment method using a unique synergistic combination of water treatment components performing treatment steps automatically and continuously applied to the make-up and recirculation waters in evaporative cooling towers, and to apparatus for the application of such a method.
BACKGROUND OF THE INVENTION
Cooling towers are widely used in H.V.A.C. and Industry. The towers will normally employ evaporation of water, and heat exchange the building HVAC circulating water, to cool water. The evaporation results in the concentration of dissolved solids in the cooling tower recirculation water. Scale, principally in the form of calcium carbonate, can build up, thereby reducing the rates of heat transfer and hence the efficiency of the tower. The water is also suitable for the growth of biological contaminants such as bacteria and algae. Biofouling organisms, using organic nutrients collected by scale deposits, attack system surfaces with corrosive acids to further increase dissolved particulate contamination. Conventional chemical treatment, particularly since chromates were banned by E.P.A., in practice, does not control scale, corrosion or microbiological contamination, and produces the potential liability of toxic discharge water into the environment, and handling barrels of toxic chemicals.
U.S. Pat. No. 4,830,761, Leach et al. disclose a method of recirculation cooling tower basin water through a series of filter bags in order to reduce the amount of particulate contamination. In U.S. Pat. No. 6,332,978, Cushier et al. teaches a combination of filtration and treatment with redox media to reduce contamination in recirculation cooling tower waters. However, scale is not controlled, backwashing cycles are mandatory, and the copper compounds used plate out onto the metals of the equipment. Ozone treatment, among other disadvantages, does not prevent scale formation and is restricted in application. The known prior art methods do not eliminate scale, and do not offer 24 hour/day, automatic, effective protection against legionella, scale, corrosion and microbiological contamination.
BRIEF SUMMARY OF THE INVENTION
The present invention provides an improved method and apparatus for automatically eliminating scale, minimizing particulate contaminants, legionella and controlling corrosion, fouling & microbiological contamination in cooling tower recirculation water, 24 hours per day.
In particular, the invention provides a first Module A for the treatment of incoming make-up water, and a second Module B for the treatment of the cooling tower recirculation water. The first Module A directs some incoming make-up water through an iodine canister ( 18 ), and also through a micromineral suppressant canister ( 20 ), containing zinc, in order to provide metered, low levels of iodate and zinc, to suppress bio-organic contamination throughout the tower. All incoming make up water also passes through a physical type, self-cleaning water conditioner ( 22 ), which prevents the formation of scale dissolves old scale and inhibits corrosion.
The second Module B includes a pump ( 24 ) that recirculates the tower sump water through a strainer ( 26 ), a centrifugal separator ( 28 ) and a physical type, self-cleaning water conditioner ( 30 ) which maintains the water in an unsaturated state. The strainer ( 26 ) removes the larger particulates and any debris that gets into the tower ( 32 ). The centrifugal separator ( 28 ) brings the particulates down to minus 40 microns throughout the recirculation system, in addition the conditioner ( 30 ) produces large calcium carbonate particles, which in turn coagulate with the organics, and are blown down by the separator ( 28 ) and a “blow-down” valve.
An alternative second Module B can consist of a bypass pipe installed across the cooling tower recirculation pump inlet and outlet pipes; with the separator ( 28 ), conditioner ( 30 ) and flow meter ( 34 ) mounted in this by pass pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 . is a schematic representation of a typical cooling tower which illustrates with Module “A” and Module “B” a preferred method and apparatus for automatically treating water according to the invention;
FIG. 2 . is a schematic representation of the self-regulating zinc generator ( 20 ), which in conjunction with FIG. 3 schematic is attached to the make up water line ( 36 );
FIG. 3 . is a schematic representation of the self regulating iodine generator ( 18 ), which in conjunction with FIG. 2 is attached to the make up water line. ( 36 );
FIG. 4 . is a diagrammatic drawing of a laser particle test result before hard water entered the conditioner;
FIG. 5 . is a diagrammatic drawing of a laser particle test result, in the same water as in FIG. 4 , after the water had passed through the same conditioner.
DETAILED DESCRIPTION
Cooling towers are designed to work on an evaporative process in conjunction with a heat exchanger/chiller condenser ( 14 ). A tower ( 32 ) will typically include baffles or fill and spray bars ( 16 ) or like elements having increased surface areas over which warm water cascades. At the same time, cooling tower fans (not shown) move air over the cascading water to increase evaporation and lower the water temperature. The resultant cooled water is cycled back through a chiller condenser ( 14 ) where it picks up heat and is then returned to the tower ( 32 ) to be cooled. As the water evaporates in the tower ( 32 ), the dissolved solids in the water which collect in the tower sump ( 10 ) become concentrated. To maintain a constant water volume within the system, make-up water must be continuously added to compensate for the water lost through evaporation in the tower ( 32 ), and through ‘blow-down’.
Scale builds up in the chiller condenser ( 14 ) and in the fill and spray bars ( 16 ) in the tower ( 32 ) with conventional chemical treatment. This scale reduces the heat transfer efficiency of the condenser ( 14 ). In addition, the cooling tower water is subjected to biological contamination by airborne micro-organisms from the air, which are sucked into the tower ( 32 ) by the fans. Microbiological contamination of this type entering the cooling tower recirculation water is a major cause of corrosion of metallic surfaces due to bio-film formation. Known chemical water treatment processes result in having to ‘rod-out’ chiller condenser tubes ( 14 ) and/or “acid-wash”, to reduce excess energy costs, and protect the system from severe damage.
To prevent and control the problems of scale and fouling, high corrosion rates (usually >3 m.p.y. with conventional chemical treatment), and low cooling tower life span the present invention automatically performs several functions, some by themselves and others in conjunction with one another, as follows:
FIG. 1 is a schematic representation of a cooling tower treatment system illustrating the present invention. A typical cooling tower installation, portions of which are illustrated in FIG. 1 , includes a make-up water line ( 36 ) discharging fresh water into the tower sump ( 10 ) continually replacing the total amount of water loss from evaporation and sump discharge water losses. A cooling tower recirculating pump(s) ( 12 ) circulates cooled water from the tower sump ( 10 ) through the condenser side of a heat exchanger ( 14 ), where it picks up building heat from the evaporator side of the chiller ( 14 ), and then from there is piped to a spray bar system ( 16 ) mounted at the top of the tower ( 32 ). The water from the spray bars ( 16 ) cascades down into the tower sump ( 10 ), and then is piped back into the condenser side of the heat exchanger (chiller) ( 14 ).
In this preferred embodiment a typical cooling tower is fitted with the groups of components identified as Module A and Module B in FIG. 1 , which go to make up the invention.
Module A, which treats incoming make-up water, consists of an iodine generator canister ( 18 ), (see FIG. 3 ) a mineral suppressant generator canister ( 20 ) (see FIG. 2 ) and a physical type water conditioner ( 22 ).
Module B schematically depicts a side stream sump recirculation line, consisting of a strainer ( 26 ), a pump ( 24 ), a separator ( 28 ) & a physical-type water conditioner ( 30 ). Conditioner ( 22 ) used in Module A, and conditioner ( 30 ) used in Module B are physical type, self-cleaning, require no chemicals or electricity, and are maintenance free. Depending on water quality, physical type water conditioners such as capacitance or magnetic designs may be used that can produce large sized calcium carbonate particles in hard water, as measured by independent laser particle counts ‘before’ and ‘after’ hard water passes through the conditioner, as shown in FIG. 4 and in FIG. 5 ; also producing a minimum increase of 300% turbidity and 200% suspended solids. A capacitance type unit that may be used in either or both Module A and Module B is disclosed in U.S. Pat. No. 5,695,644. A suitable magnetic unit is disclosed in U.S. Pat. No. 4,422,933.
Conditioners other than those mentioned above can also be used if they offer the above required characteristics.
The conditioners ( 22 ) and ( 30 ), prevent the formation of scale, cause the dissolution of old scale and inhibit corrosion throughout the system. With the scale removed, and automatically maintained that way, the ferrous and ferric oxides then combine to form magnetite on the piping surfaces. Without the presence of scale, nutrients for micro-organisms are reduced to a minimum. In addition to a scale free environment, a very clean water system is maintained by a centrifugal separator ( 28 ) that reduces particulate contaminants down to minus 40 microns in the system (manual or automatic blow-down). Further reduction in the number of contaminant particles is achieved by the action of the conditioners ( 22 ) & ( 30 ) which automatically produce large sized calcium carbonate particles throughout the recirculation water system on a continual basis when treating hard water. These growing calcium carbonate particles coagulate with the organics thereby preventing further corrosion as a result of the elimination of the organic nutrients, and are continually removed from the system by the sump recirculation line separator ( 28 ) and by the ‘blow-down’ valve ( 38 ). This blow down valve ( 38 ) is a valve which can be installed in alternative places but usually into a pipe which eminates from the sump ( 10 ). It is actuated electrically by a timer, which in turn is signaled electrically from the make up water line meter. This water meter is pre set to signal the timer for (say) every 25 gallons flowing through the make up water pipe ( 36 ). The timer can be adjusted for controlling the concentration of the chlorides in the cooling tower water. The strainer ( 26 ) installed before the sump recirculating pump ( 24 ) eliminates larger particles and debris.
Water that has been cooled by evaporation in the tower ( 32 ) is collected in the sump ( 10 ). The cold sump water is piped back into the chiller condenser ( 14 ) by the main recirculation pump(s) ( 12 ). The heated water exiting the chiller condenser ( 14 ) is returned to the tower ( 32 ) for evaporative cooling. The water in the sump ( 10 ) is cycled through Module B by a pump ( 24 ). Larger particulate contaminants are removed from the water by a strainer ( 26 ). Particle size of scale and other contaminants throughout the cooling tower system is reduced below minus 40 microns by the Model B separator ( 28 ). Water directed back to the sump ( 10 ) passes through a water conditioner ( 30 ), which further ensures elimination of calcarious and organic contaminants, maintaining the recirculation water in an unsaturated mode, with the continual production of large calcium carbonate particles. Incoming make-up water is treated in Module A by the iodine conditioner ( 18 ), zinc conditioner ( 20 ) and water conditioner ( 30 ).
The make up water assembly incorporates two ‘see through’ type similar canisters containing zinc in one canister ( 20 ) and iodine in the other canister ( 18 )
In the zinc canister ( 20 ) at the bottom of the vertical canister there is an inlet tube ( 40 ), with nozzle holes ( 42 ) designed to exit the water into the nozzle cone ( 44 ), creating a deep penetration scrubbing action on the zinc. In the iodine canister ( 18 ) there is an inlet tube ( 46 ) with holes ( 48 ). This design does not have a nozzle cone since a lesser action is desirable. This internal design difference is to obtain the maximum desired water action for each of the two elements, ensuring consistent results, i.e., the scrubbing action on the zinc, which is less desirable on the iodine. The feed water for the two canisters ( 18 ) and ( 20 ) is derived from some of the make-up water being diverted from the make up water pipe ( 36 ) by an adjustable valve, located in the make up water line, between an inlet pipe and an outlet pipe to the generators. This water passes through the iodine canister ( 18 ), to introduce iodine; and some of this make up water diverted into the micro-mineral suppressant canister ( 20 ), for zinc to be metered in amounts sufficient to control bio-organic contaminants. The iodine is discharged from the iodine canister ( 18 ) through a ‘see through’ type horizontal flexible tube to a needle valve, that controls the iodine discharged back into the make up water main pipe ( 36 ). Concentrated iodine is very aggressive, so all materials used have to be neutral to iodine. The micro-mineral suppressant canister ( 20 ) internal parts and design to generate zinc, has to be constructed to a modified fluidized bed principle for ensuring that the surfaces of the zinc are constantly self-scrubbed when operating, for consistent erosion release, giving an on-going accuracy of correct metering, even for small injections, the metering being controlled by the aforementioned adjustable valve in the make up water line.
An additional benefit offered by the invention is that, as the water concentrates, build up of total dissolved solids, hardness (as CaCO3), TDS, conductivity levels are reduced by about 40%, as compared to conventional chemical treatment, thereby permitting increased cycles of concentration, and considerable water savings. This occurs because the calcium carbonate particles produced by the conditioners combine with the organics, which together then have a specific gravity heavy enough to be automatically discharged. As an example, in Great Lakes Water, cooling tower water use and discharge is reduced by at least 25%. In addition to this water savings, in hard make up water situations, even more water is saved compared to chemical treatment which has to ‘soften’ this water before use, involving the additional cost of an appropriately sized water softener, plus having to use quantities of salt. In addition to this expense, the ‘softener’ has to be regenerated on a regular basis (such as twice/week), which uses up large quantities of water. The system, according to the invention, does not require a softener in hard water. Cooling towers using chemical treatment, use vast quantities of water, whereas according to the invention, up to 40% water use and discharge can be saved.
The above description explains how the total recirculation water is treated, which creates and maintains a very clean system, a mandatory condition for effective prevention of microbiological contamination. The invention adds to this bacterial control by automatically and accurately metering into the make up water line ( 36 ), as described below <250 p.p.b. of zinc, and <200 p.p.b. of iodine for bacteria kill. The iodine, then has a final adjustment to reflect 1 p.p.m. in the recirculation water. The iodine becomes iodate, due to the aeration of the sump cascading water. The iodate in a clean system, at 1 p.p.m., kills legionella up to 99.99999% (U.S. Dept. of Health—Atlanta). The zinc, when present at only 50 p.p.b., kills pseudomonas & other pathogens. Pseudomonas when present is harmful because it regenerates bio-nutrients which are a major source of nutrients for legionella. The iodate penetrates under bio-films, even penetrates amoebas thereby killing legionella. Algae is efficiently controlled by the combination of iodate and zinc.
Each canister holds enough zinc and iodine to last 2 to 3 years before a refill is required. This replenishment is a simple operation, and takes approximately 20 minutes. A test valve or tap ( 50 ) in provided in module A. By opening this valve ( 50 ) and collecting a sample of the water, it is possible to sample the iodine content of the make up water, and thus ensure that the percentage is adjusted to produce optimum results.
Depending on water quality, other metals at <500 p.p.b. may possibly be used in addition to, or in place of zinc. The water quality throughout the system is always maintained to potable standards, when the make-up water is of potable quality.
To summarize the operation, water that has been cooled by evaporation in the tower ( 32 ) is collected in the sump ( 10 ). The cold sump water is piped back into the chiller condenser ( 14 ) by the main recirculating pump(s) ( 12 ). The heated water exiting the chiller condenser ( 14 ) is returned to the tower ( 32 ) for evaporative cooling. The water in the sump ( 10 ) is cycled through Module B by a pump ( 24 ). Larger particulate contaminants are removed from the water by a strainer ( 26 ). Particulate size of scale and other contaminants throughout the cooling tower system is reduced below minus 40 microns by the separator ( 28 ). Water directed back to the sump ( 10 ) passes through a water conditioner ( 14 ), which further ensures elimination of calcarious and organic contaminants, maintaining the recirculation water in an unsaturated mode, with the continual production of large calcium carbonate particles. Incoming make-up water is treated in Module A by the zinc, iodine and a water conditioner ( 22 ).
The make up water assembly consists of two ‘see through’ type similar canisters containing zinc in canister ( 20 ) and iodine in canister ( 18 ), the difference in the two canisters being basically that the water discharge holes at the bottom of the vertical canister inlet tube are designed to exit the water into a nozzle cone ( 44 ) for the zinc, but directly out into the canister, above the disc, for the iodine. This internal design difference is to obtain the maximum desired water action for each of the two metals, ensuring consistent results. The feed water for the two canisters is derived from some of the make up water being diverted from the make up water pipe ( 36 ) through the iodine canister ( 18 ), to introduce iodine, which converts to iodate with the aeration in the tower; and some of the make up water diverted into the micro-mineral suppressant canister ( 20 ), for zinc to be metered in amounts sufficient to control bio-organic contaminants. The iodine is discharged from the iodine canister ( 18 ) through a ‘see through’ type flexible tube to a needle valve, that controls the iodine discharged into the make up water main pipe ( 36 ). Concentrated iodine is very aggressive, so all materials used have to be neutral to iodine. The micro-mineral suppressant canister ( 20 ) internal parts and design have to be constructed to a modified fluidized bed principle for ensuring that the surfaces of the zinc are constantly self-scrubbed when operating, for consistent erosion release, giving an on-going accuracy of correct reading, even for small injections. To attain the scrubbing of the zinc surfaces, FIG. 2 shows the inlet water entering the conventional filter exit into the upper canister centre, and being discharged out of the bottom of the internal vertical tube, through equally spaced and angled holes ( 42 ) discharging into a cone ( 44 ). This creates a swirling action on the zinc granules, contained in the canister ( 20 ) resulting in the scrubbing of the zinc surfaces, which prevents the surfaces from oxidizing.
All the make-up water then passes through the Module A water conditioner(s) ( 22 ), which changes the water into an unsaturated state, dissolves old scale, and inhibits corrosion.
The system shown in schematic FIG. 1 is for the purposes of illustration only, and is not intended to be limiting, since cooling towers are designed with many different types of configurations, including, but not restricted to, direct & indirect evaporative cooling towers, ‘coolers’, mechanical draft, hyperbolic towers etc.
The invention can operate efficiently for any type or size of cooling tower. Persons could generate additional embodiments without departing from the spirit of the claimed inventions. For instance, all or part of the make up water assembly could be applied to controlling microbiological contamination in water systems, for example to control legionella etc. The schematics provided are to facilitate understanding of the invention only. Also water quality for the make-up water varies over a wide range, and therefore has to be treated accordingly sometimes before entering the make up water line. ( 36 ).
This water treatment method greatly improves the operation of cooling towers; namely, in the permanent elimination of scale build-up on all tower and heat exchanger surfaces; in the effective control of biofouling; in the related suppression of biofilm sponsored corrosion and in the eradication of tower contamination by biological growths, particularly of pathogenic organisms, such as legionella. This results in a very effective, 24 hour/day, 7 days/week automatic control of scale, fouling, corrosion, and microbiological contamination. The system ensures minimal heat transfer losses and pollutional water discharges, with greatly reduced water and energy consumption, applied chemical quantities and operational and ownership costs, and greatly extended cooling tower life. The foregoing is a description of a preferred embodiment of the invention which is given here for the purposes of illustration. The invention is not to be taken as restricted to any of the specific features as described but comprehends all such variations as come within the scope of the following claims.
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An automatic, self-regulating method of water treatment for use in water circulating towers in which water is evaporated, and make up water is added, with components which synergistically function to cut chemical, energy, water, corrosion, pollution, and maintenance costs, by passing the water through a Water Conditioning unit to prevent adhering evaporation scale deposits along with their content of concentrated biofouling nutrients from forming on the flooded surfaces of the tower and its associated water flow circuit, adding a trace level of iodine to the input make-up water to enhance the further disinfection of nutrient-deprived surfaces from any residual biofilm and chance pathogen contaminations, and adding a trace level addition of zinc ions in the water such as by an assured treatment feeder to the input make-up flow for inhibiting residual iodine-resistant algal and bacterial organisms of hazard for restoring bionutrient tower conditions, such as within sun-lit environments, and apparatus for carrying out the foregoing method.
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BACKGROUND
1. Field of the Invention
The disclosure relates to a tuner input circuit, and more particularly to a tuner input circuit in which a low noise amplifier (LNA) and a band pass filter (BPF) allowing a broadcast signal received from an antenna to pass therethrough before inputting to a tuner are integrated with each other in one chip, thereby realizing a device in small size.
2. Discussion of the Background
In general, static electricity is collected into a human body or machine to raise the potential difference and then suddenly flows toward a lower potential, which is called an electrostatic discharge (ESD). The ESD is to discharge high voltage of about several kV to several tens of kV for a short time of several μs.
A device affected by the ESD must be equipped with a protective circuit against the ESD so that the device obtains the resistance against the ESD. For example, when high voltage is applied to a device such as a tuner through an antenna due to the ESD, since the ESD voltage is greater than the internal voltage of a circuit device provided in the tuner, the internal circuits of the tuner may be broken, so that the failure of the tuner may be caused. Accordingly, in order to prevent the failure of the tuner, an ESD protection circuit must be added.
In addition, until the signal received through the antenna is input to the tuner, the signal passes through a CB trap, an ESD diode, and an LNA. Since the above devices include capacitors and inductors, the devices may serve as limitation factors in realizing a PCB in micro-size.
In addition, the above devices represent different performances due to the difference in a time constant and a pattern therebetween. Further, the interference exists between multi-channels, so that the reliability of the devices must be improved.
FIG. 1 is a block diagram showing a tuner input circuit according to the related art.
Referring to FIG. 1 , the tuner input circuit according to the related art includes capacitors connected between an antenna (ANT) and a tuner 200 to cut off a DC component of a signal input from the antenna (ANT), a CB trap 100 to trap a signal having a specific frequency band among signals passing through the capacitors, an EST diode 150 having a cathode connected between the capacitor and the connection terminal of the tuner 200 and an anode connected to the ground, and an LNA 160 .
As shown in FIG. 1 , since the above devices include a plurality of capacitors and a plurality of inductors, the devices occupy the most part of a PCB space. Accordingly, the devices may serve as limitation factors in realizing the device in micro-size.
SUMMARY
The embodiment of the disclosure provides a tuner input circuit which can be realized in small size by providing an LNA and a BPF in one integrated circuit.
According to the embodiment of the disclosure, there is provided a tuner input circuit including an integrated circuit including an LNA and a BPF embedded in one chip.
As described above, according to the embodiment of the disclosure, the tuner input circuit can be realized in small size by providing the LNA and the BPF in one integrated circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a tuner input circuit according to the related art;
FIG. 2 is a block diagram showing a tuner input circuit according to the embodiment of the disclosure; and
FIG. 3 is a graph showing a frequency characteristic of a band pass filter.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Hereinafter, exemplary embodiments of the disclosure will be described in detail with reference to accompanying drawings. The details of other embodiments are contained in the detailed description and accompanying drawings. The advantages, the features, and schemes of achieving the advantages and features of the disclosure will be apparently comprehended by those skilled in the art based on the embodiments, which are detailed later in detail, together with accompanying drawings. The same reference numerals will be assigned to the same elements throughout the whole description.
FIG. 2 is a block diagram showing a tuner input circuit according to the embodiment of the disclosure. An integrated circuit 300 according to the embodiment may be formed in the form of a single chip. The integrated circuit 300 may be provided therein with a low noise amplifier (LNA) 340 and a band pass filter (BPF) module 350 .
In addition, a signal received through an antenna may passes through an impedance matching module 310 , an electrostatic discharge (ESD) module 320 , and a CB trap 330 before the signal is input into the LNA 340 . The input return loss of −10 dB or more may be satisfied by the impedance matching module 310 . In order to omit additional impedance matching, the length and the thickness of a pattern from the input of an antenna to the integrated circuit 300 may be adjusted, and may be modified according to designs.
The ESD module 320 has high voltage of about several kV to about several tens of kV and discharges the voltage for a short time. The ESD module 320 prevents the application of the overvoltage.
The signal, which has passed through the ESD module 320 , may be input to the CB trap 330 . The CB trap 330 traps and filters a specific frequency band of a signal which has passed through the ESD module 320 .
The impedance matching module 310 , the ESD module 320 , and the CB trap 330 may be selectively formed at the outside of the integrated circuit 300 .
The signal, which has passed through the CB trap 330 , is input into the LNA 340 . The LNA 340 selectively operates with the characteristic of a low noise ratio and a high amplification degree and low-noise amplifies an RF signal received from the antenna
The LNA 340 selectively operates by DC voltage supplied thereof. If the received RF signal represents a weak electric field, the LNA 340 low-noise amplifies the received RF signal. If the received RF signal represents a strong electric field, the LNA 340 is turned off to by-pass the RF signal. In other words, a by-pass path may be formed at the LNA 340 .
The signal, which has passed through the LNA 340 , is input to the BPF module 350 . Since the BPF module 350 cuts off remaining signals except for a signal having a specific frequency band, the frequency band is changed according to the channel selection. Accordingly, the BPF module 350 may communicate with a controller 380 to change the frequency band. The communication scheme may include an international institute of communication (IIC) scheme, but the embodiment is not limited thereto.
FIG. 3 is a graph showing a frequency characteristic of a band pass filter. As shown in FIG. 2 , the band pass filter has a characteristic of passing only one frequency band. The band pass filter has two cutoff frequencies fc 1 and fc 2 serving as upper and lower limit frequencies that may easily pass through the band pass filter. In the case of a narrow frequency band, only the central frequency may be marked. The central frequency may be changed through the communication with the controller 380 .
Signals, which have passed through the BPF module 350 , may be distributed by a Balun 360 . The Balun 360 is a passive device to convert a balanced signal into an unbalanced signal, or to convert an unbalanced signal into a balanced signal. The Balun 360 refers to a matching transformer used when feeding power through a coaxial cable. The balanced signal refers to a signal transmitted when the ground surrounds a central signal line like a coaxial cable, and the unbalance signal refers to a signal transmitted when the ground is provided below or at both sides of the signal line like a PCB.
As described above, according to the embodiment of the disclosure, the tuner input circuit can be realized in micro-size by providing the LNA and the BPF in one integrated circuit.
Any reference in this specification to “one embodiment,” “an embodiment,” “example embodiment,” etc., means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with any embodiment, it is submitted that it is within the purview of one skilled in the art to effect such feature, structure, or characteristic in connection with other ones of the embodiments.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
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Disclosed is a tuner input circuit. The tuner input circuit includes an integrated including a low noise amplifier and a band pass filter embedded in one chip.
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CROSS REFERENCES TO RELATED APPLICATIONS
Application Ser. No. 780,468, filed of even date herewith contains related subject matter to that of this application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to apparatus for monitoring selected conditions of liquid, such as engine coolant in a vehicular radiator, and more particularly to a sensor which can be used to provide remote indication of the degree of corrosivity of the coolant, the presence or absence of the coolant at a selected level in the radiator or both conditions as desired.
2. Description of the Prior Art
Vehicular cooling systems are composed of several components which include the radiator, circulating pump, passages in the engine block and associated tubing. Since the system is composed of metallic parts, there is a need to prevent, or at least mitigate, corrosion in order to prolong the useful life of the system. To this end it has become common practice to add chemical substances to the coolant liquid which serve to inhibit corrosion of the metal surfaces which come in contact with the liquid. Such substances are known as inhibitors and generally form a film on the metal surfaces thereby protecting them from corrosion. Thus, commercially available permanent antifreeze includes an inhibitor which is effective in preventing corrosion, however, over the course of time the corrosion inhibiting characteristic of the liquid can become less effective due to various factors.
At the present time the use of aluminum for cylinder heads and cooling systems in automobiles is becoming more common. Aluminum cylinder heads run hotter than iron cylinder heads. This combined with aluminum's higher susceptibility to corrosion leads to the potential for a phenomena known as "hot transport corrosion." This is a process whereby aluminum corrosion products are transported from the hottest areas, typically in the head, to the coolest, that is, the radiator. These contaminants interfere with good heat transfer and degrade the heat rejection capability of the system. Aluminum heads are also less tolerant to overheat conditions than iron and run the risk of warping at elevated temperatures which can result from a low coolant condition. Also, the aluminum used in radiators and heater cores is more susceptible to corrosion than the traditional copper-brass system which makes proper maintenance more critical to prevent failure due to perforation.
In U.S. Pat. No. 4,147,596, assigned to the assignee of the present invention, a system is disclosed and claimed in which a potential measuring circuit employing at least two electrochemical electrodes composed of dissimilar metals is located so as to be immersed and in contact with coolant liquid. The electrodes are mounted in a tubular housing which is provided with a threaded portion so that it can be screwed into a threaded bore of a wall confining the coolant liquid. When the inhibiting characteristic is effective, a first range of electrical potential exists between the electrodes; however, when the inhibiting characteristic becomes ineffective for any reason, a second range of electrical potential exists therebetween. Upon reaching a threshold level, as the potential moves into the second range, indicating means are actuated to provide a suitable indication of the condition.
In U.S. Pat. No. 4,253,064, also assigned to the assignee of the present invention, another condition of the coolant is sensed utilizing the same electrodes which are part of a coolant inhibition characteristic condition sensing system. In that system the presence or absence of liquid is determined by making use of the electrical resistance between the two electrodes without causing any appreciable current through the liquid which current would adversely effect the ability to sense the coolant inhibition characteristic condition. The resistance between the electrodes serves as part of a feedback network in a feedback oscillator. The feedback oscillator incorporates a dc measuring amplifier for measuring the electrode potential as an indication of the corrosion inhibition characteristic of liquid in which the electrodes are immersed. The same amplifier provides the amplification necessary for oscillation when the resistance between the electrodes increases to a threshold level indicating an absence of liquid. The feedback network includes a capacitor which not only determines the frequency of oscillation, along with appropriate resistance, but also blocks any possible DC current which might otherwise flow through the electrodes. The sensing of liquid presence or absence is accomplished between a first electrode and ground while the second electrode may be directly grounded, coupled to ground through a large capacitor or resistor or separated from the first electrode by an electrically insulative barrier and thus coupled to ground through the liquid clinging to the insulator separating the second electrode from ground.
However the use of the feedback network in both the coolant inhibition characteristic sensing function and the level sensing function tends to limit the flexibility of the system. For example, adjusting the threshold sensing parameters of one function sometimes may affect the other function. The use of the feedback network in both functions also subjects the system to some degree of noise sensitivity which could cause nuisance tripping under certain conditions. Another limitation of the prior art involves the fact that the electrochemical sensing of corrosivity requires the sensing of negative potentials. In dealing with this the prior art provided a negative power supply which rendered the system more complex and costlier than desirable. Another limitation was the output format of the system (DC output for corrosivity and AC output for low level). This made sensor output difficult to decode.
It is an object of this invention to sense electro-chemical potentials of electrodes in a liquid, including potentials below ground, as an indication of corrosivity of the liquid as well as sensing the presence or absence of the liquid using a common set of electrodes. Another object is the provision of a system which can be used to sense either the function of corrosion inhibition effectiveness of a liquid or the function of the presence or absence of such liquid or both functions if desired. Yet another object is the provision of a sensor used for either or both functions which is readily mounted on a vehicular cooling system which is inexpensive yet reliable and long lasting. Another object is the provision of a sensing system for sensing the functions of liquid corrosivity and liquid level for which the threshold values for the function are readily and independently calibratable and one which has selected hysteresis which is also calibratable. It is another object of theinvention to provide an engine coolant condition sensor assembly which is inexpensive to manufacture and is easily installed in a liquid reservoir in a tamper proof manner. Another object is the provision of such a sensor assembly which houses not only the sensing elements but also electronics used to process or condition the electrical signal generated by the sensing elements and transmit it to a remote location, such as the instrument panel of an automobile, to give visual or audio indication of the condition of the coolant.
Other objects, advantages and details of the apparatus provided by the invention appear in the following detailed description of the preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plane view of a sensor assembly made in accordance with the invention;
FIG. 2 is a front elevation of the FIG. 1 assembly;
FIG. 3 is a bottom view of the FIG. 1 assembly;
FIG. 4 is an side view of the FIG. 1 assembly;
FIG. 5 is a cross sectional view taken on line 5--5 of FIG. 2 with the addition of a tubular coupling of an automotive radiator on which the sensor assembly is mounted and with the circuit components on circuit board 32 and the encasing potting material not shown;
FIGS. 6 and 6a are enlarged elevation view, front and side respectively, of a bimetal sense electrode;
FIG. 7 is an enlarged view in cross section of a sensor assembly taken on line 7--7 of FIG. 1 with the circuit components on circuit board 32 and the encasing potting material not shown;
FIG. 8 is a block diagram of custom integrated circuits used in the sensor assembly to process and transmit the electrical signals generated by the electrodes;
FIG. 9 is a schematic diagram showing a potential level shifting portion of the input/conditioner integrated circuit of FIG. 8;
FIG. 10 is a schematic diagram showing the processing integrated circuit; and
FIG. 11 is a flowchart showing an algorithm which can be used in controlling the energization of the warning lights indicating a low coolant liquid level and a failure of corrosion inhibition.
Dimensions of the parts shown in the drawings may have been modified for purposes of clarity of illustration.
SUMMARY OF THE INVENTION
Briefly, in accordance with the invention a sensor assembly housing has a first generally tubular compartment open at one end which is adapted to be telescopically received in a tubular coupling of a vehicular radiator. A pair of spaced "O" rings provide a liquid tight seal between the tubular compartment and the coupling. First and second electrodes, elongated elements each having a generally U-shaped configuration in cross section taken perpendicular to its longitudinal axis, are disposed in the tubular compartment with a fixed end attached to a rivet which extends through an "O" ring seal into a generally parallelepiped configured second compartment. The second compartment contains a circuit board mounting electronics used to condition the electrical signals received by the electrodes and transmit them to a remote location such as an engine control module and the dashboard of the vehicle. The electronics are potted in the second compartment to provide an effective environmental seal. A connector shroud extends from one side of the second compartment to permit attachment to an appropriate wire harness.
According to a feature of the invention, the housing has side wall means formed with grooves adapted to receive a spring wire locking element. The locking element has first opposed portions adapted to be received in the grooves and second opposed portions which are adapted to be received under a lip formed on the outer distal end of a tubular coupling of the radiator. In mounting the sensor assembly to a radiator, the spring locking element is placed with the first opposed portions received in the grooves of the housing walls. The second opposed portions of the wire project inwardly so that at their at rest position they are spaced from one another a distance which is less than the outer diameter of the tubular coupling. The housing is merely pushed onto the tubular coupling with the second opposed portions being cammed away from each other until the outer lip is passed at which point the second opposed portions of the wire spring back toward each other under the lip to securely lock the housing onto the coupling. In order to remove the housing the free ends of the wire are pried apart to move the second opposed portions of the wire away from each other a distance greater than the outer diameter of the lip.
According to another feature of the invention the electronics comprise two integrated circuits, the first containing two PMOS devices which allow sensing of negative potentials and also provide isolation between the electrodes and between the electrodes and ground. These devices shift a negative potential to a positive potential which is outputted to a bipolar integrated circuit.
According to a feature of the invention the operation threshold for corrosion inhibition sensing is adjustable by changing either a current reference resistor or a bias resistor which are separately connectable to the bipolar integrated circuit. The hysteresis of the corrosivity sensing is adjustable by connecting a resistor between two designated pins of the bipolar integrated circuit.
According to yet another feature of the invention the level sensing portion uses the impedance between the two electrodes and is adjustable over a wide range of resistance threshold by varying a resistor-capacitor leg that connects to the bipolar integrated circuit. A capacitor is used as a noise filter to improve the switching characteristics of the sensor while two diodes are used to provide a 1.4 volt band of hysteresis.
According to a feature of the invention the output of the low level and corrosive circuits contained within the bipolar integrated circuit are combined into a logic network that results in a low level indication overriding a corrosivity warning.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings numeral 10 indicates a sensor assembly made in accordance with the invention. Assembly 10 includes a housing 12 preferably molded of suitable electrically insulative material such as Zytel, a trademark of E. I. duPont de Nemours & Co. for glass filled nylon, having a first generally tubular compartment 14. The side wall of tubular compartment 14 is provided with two circular grooves 16, 18 spaced from one another along the longitudinal axis of the tubular compartment. "O" rings 20, 22 are disposed in the respective grooves to provide a fluid tight seal between the compartment 14 and a tubular coupling 24, shown in FIG. 5, in which the compartment is received.
With particular reference to FIGS. 3 and 5-7, first and second electrodes 26, 28 are disposed within compartment 14, each having a base plate 26.3, 28.3, welded to a rivet, 26.1 and 28.1 respectively, which extends through a respective aperture in wall member 14.1 for connection with electronics to be described below. "O" rings 26.2 and 28.2 are received around the rivets and are disposed in grooves formed in wall member 14.1 in communication with the respective apertures to provide a fluid tight seal. Suitable connectors, such as connector 26.5 interconnect the rivets with the electronics as well as capture "O" rings 26.2, 28.2 in their respective grooves.
The outer portion of tubular compartment 14 is preferably formed with a taper 14.2 to facilitate the placement of the compartment into tubular coupling 24.
Housing 12 has a second compartment 30, generally configured as a parallelepiped, to accommodate electronics used to condition the signals received from the electrodes and transmit the conditioned signals to a remote location such as the dashboard of a vehicle. The electronics are mounted on a circuit board 32 as will be described infra and are potted therein by any suitable electrically insulative potting material to provide an effective environmental seal.
A connector shroud 34 extends laterally from one of the side walls of compartment 30 and encloses spaced terminals GND, VOUT and VCC which extend through the wall of the compartment from circuit board 32. A suitable wiring harness (not shown) is receivable in the shroud for connection to the thermal. Preferably a locking tab 34.1 is provided on shroud 34 to lock the harness in its position of connection with the terminals.
Electrode 26 is a reference electrode and is preferably formed of silver but could also be formed of other standard commercial reference material such as the calomel family, silver alloys including Ag/Ag halide and Ag/AgO, the copper family such as Cu/Cu halide and Cu/CuSO 4 or other stable reference material.
Electrode 28 is a sense electrode and is preferably formed of a clad element having a first layer 28.6 of steel bonded to a second layer 28.8 of aluminum. These materials are especially adapted for use with cooling systems which embody aluminum components, as taught in U.S. Pat. No. 4,147,596 mentioned supra. If the sensing system of the present invention is used in other environments, then other sense electrode materials could be used depending on the materials used for the components to be monitored.
Electrodes 26, 28 are elongated elements extending in a direction generally parallel to the longitudinal axis of the tubular compartment 14 and are formed with a base plate 26.3, 28.3 bent at an angle of approximately 90° to the remainder of the electrode. The base plate is welded or otherwise suitably fixed and electrically connected to a rivet as described above. The remainder of the length of the electrode is generally U-shaped with respect to a cross section taken perpendicular to the longitudinal axis of compartment 14, the side walls of the U-shape providing mechanical strength to the electrode.
Housing 12 is also provided with opposed side wall members 36, 38 depending downwardly from wall 14.1 with grooves 36.1, 38.1 formed at opposite ends of each wall member. A spring wire locking element 40 is received in grooves 36.1, 38.1 and is used to lock the assembly to a coupling member such as the tubular coupling 24 of a vehicular radiator. Element 40, best seen in FIG. 3, may be formed of a length of stainless steel or other suitable wire material and is bent into a generally rectangular configuration with opposite ends 40.1 spaced slightly apart in the middle of one of the legs of the rectangle. Opposed legs 40.2 and 40.3 are generally straight while opposed legs 40.4 and 40.5 are bent inwardly so that opposed portions 40.6 and 40.7 in respective legs 40.4 and 40.5 are at a distance from one another which is less than the outer diameter of an outwardly extending lip 24.2 formed on the free distal end of tubular coupling 24 (see FIG. 5).
The assembly 10 is normally provided to the vehicle manufacturer with lock element 40 already disposed in grooves 36.1, 38.1 so that all that need be done in installing the assembly is to push it onto tubular coupling 24. As the coupling engages the spring element 40, it pushes portions 40.6 and 40.7 further apart until element 40 passes beyond the lip at which point the portions 40.6 and 40.7 spring back toward one another and against the outer wall of tubular coupling 24 below lip 24.2. In this regard, it is preferred that lip 24.2 be formed with a taper 24.3 (FIG. 5) to facilitate the outward camming action of portion 40.6 and 40.7 as the assembly is installed.
With the assembly mounted in its locked position, there is no danger of it becoming accidentally dislodged or loose, as would be the case if a conventional threaded connection were used. Further, the need for protecting threads of a conventional connection from damage prior to installation is obviated and the time required for installation substantially reduced compared to connection techniques using threaded members.
If it is desired to remove the assembly, ends 40.1 are pushed apart until portions 40.6 and 40.7 are spaced from one another a distance greater than the diameter of lip 24.2 at which point the assembly can be slipped off the coupling.
The circuitry used in practicing the invention will be described with particular reference to FIG. 8 showing a block diagram of the electronic components mounted on circuit board 32 and FIGS. 9 and 10 showing schematically such circuitry. The circuit utilizes two surface mounted, custom integrated circuits, the first a CMOS chip SN 28880 (referred to below as '80) and the second a bipolar chip SN 28881 (referred to below as '81). As seen in FIG. 8 V IN and R IN represent the coolant liquid in which electrodes 26 and 28 are immersed. As the corrosion inhibition characteristic of the fluid varies, the potential difference generated between the two varies. The R IN varies based on whether the electrodes are immersed or not, that is, when inundated there may be, by way of example, an R IN resistance on the order of one hundred ohms but when the level of the coolant falls below the electrodes exposing them the R IN increases beyond ten thousand ohms.
RO' is a one megohm resistor connected between electrode 28 and V CM (V common mode) which is in turn shown connected to ground. V CM and RO' comprise a representation of the electrode potentials and resistances with respect to engine ground.
The '80 device is constructed using CMOS technology in order to provide low input leakage, high input impedance to obviate the possibility of electrode loading as well as to allow sensing of potentials a volt below the negative supply rail, which in the present case, is ground, and comprises PMOS transistors Q1' and Q2'. The input from electrode 28 through pin VCR- of the '80 device is connected to the gate of Q1' and the input from electrode 26 through pin VCR+ is connected to the gate of Q2'.
Each input of the '80 integrated circuit is preferably provided with electrostatic discharge (ESD) protection comprising diodes D2-D10--fixed effect transistors FET 1-FET 6 network to protect the circuit components from both positive and negative voltage spikes. As seen in FIG. 9, networks comprising devices D1-D10, RP 1, 2 and T1-T10 provide ESD protection and bias to the circuit inputs of the '80 circuit and insure very low current leakage into the electrode probe inputs at elevated temperatures. Leakage greater than 100 nano amperes over an extended period of time would degrade the electrochemical potential developed by the electrodes.
Transistors Q1' and Q2' level shift the potentials of the circuit inputs VCR- and VCR+ from the electrodes from a low as much as one volt below ground up to a level above ground with their outputs taken from the FET sources and supplied to VCRO- and VCRO+ pins which are connected to the '81 integrated circuit.
Thus the '80 IC allows the '81 bipolar IC to see potentials within its common mode range (above ground) while providing little or no input leakage current which would adversely effect sensor potentials.
Turning back to FIG. 8, resistor R TH connected between pin VCRO- of the '80 device and VCRI- of the '81 device sets the threshold at which the system works as will be referred to in more detail below. In order to negate the offset error introduced by the use of resistor R TH causing different current flow between the two transistors Q1' and Q2', resistor R DN (drain) is connected between the drain of transistor Q2' and ground to balance the current flow through the transistors.
Capacitor C1' coupled between pin VCR- and ground is an AC decoupling capacitor which allows use of the same electrodes for sensing of both level and corrosion inhibition. Capacitor C2' connected between electrode 26 and pin VLV+ of the '81 device is also part of the decoupling network.
Pin VCRO- of the '80 device is connected to pin VCRI- of the '81 device through resistor R TH while pin VCRO+ is connected directly to pin VCRI+ of the '81 device. As mentioned above, the potentials seen at pins VCRI- and VCRI+ are shifted up from the potentials seen at the electrodes so that both potentials are positive.
Resistor R1' is serially connected to capacitor C3' and both are connected between pin VLV- of the '81 device and ground. Changing the values of these components will change the threshold value of the level sensing function as will be described in more detail below.
A resistor R BIAS is connected between pin BIAS of the '81 device and ground. This resistor determines the amount of current which passes through resistor R TH . A change in the value of resistor R BIAS will therefore change the current reference. The current reference also provides positive hysteresis. For example, if the device were triggered at 300 mv, it would not turn off until a selected lower value is reached, for example 200 mv. In the preferred embodiment the device is initially set at a hysteresis value of 100 mv by connecting the HYSI pin to the BIAS pin. This value can be changed by connecting a resistor (not shown) between the HYSX pin and the BIAS pin. These options are schematically shown by the switches connected to pin HYSI and HYSX and interconnected by dotted lines on FIG. 8.
The dashed line block labeled coolant condition sensor is essentially a high impedance differential amplifier Q3' that receives the sense and reference potentials which have been level shifted by the PMOS transistors.
The level sensing portion comprises differential amplifiers Q4', Q5', and buffer Q6'. Capacitor C4' connected between pin VLVO and ground serves as a time delay to filter out any noise.
Resistor RH20 is connected between the supply voltage VCC and the positive input to amplifier Q4' while resistor RH21 is connected between that input and ground. Resistors RH22 and RH23 are respectively connected between the output of amplifier Q4' and its negative and positive inputs.
The output of amplifier Q4' is fed to the input of dual comparator Q5'. Diodes Q73 and Q74 are connected across the positive and negative inputs to comparator Q5' which in turn are connected through respective resistors RH24', RH25' to VCC and ground. Thus the diodes provide approximately a ±0.7 v comparator threshold range. That is, if there is a low level condition with the electrodes out of the liquid, amplifier Q4' begins to oscillate between ground and the positive supply rail. If there is any noise, the ±0.7 volts serves as a buffer so that the input to amplifier Q5' must go that much above or below in order to flip back and forth.
The output from amplifier Q5' is fed to hysteresis buffer Q6' which then is fed to a logic block composed of nor gates. The logic ensures that the corrosivity function is overridden by the level function so that a low coolant level condition takes precedence over the sensing of the corrosion inhibition characteristic of the coolant.
The output drive block indicated by dashed lines provides high current switching on the order of tens of milliamps. The buffers shown in effect represent two switches to ground. With a low level condition the two shut off so that VOUT pulls to VCC. When a corrosive condition occurs, the upper switch turns on which pulls the output to ground. During a normal condition the lower switch turns on to ground resulting in a voltage divider comprising R7' and R8' and giving half of the value of VCC.
With particular reference to FIG. 10 showing schematically the '81 device, the dashed line section CCS (coolant condition sensor) BIAS identified as A, comprises transistors Q70-72 and Q56-63 which serve as current sources to insure proper circuit bias in several device transistors.
Dashed line (Section B) comprises the Coolant Condition Comparator (Q3' of FIG. 8). The inputs VCRI- and VCRI+ are outputs from the '80 device. Transistors Q1-5 form a standard differential amplifier whose output feeds both the CCS Hysteresis (Section C) as well as the Output Logic (Section E). Current sources, transistors Q54, Q55 of the Bandgap Reference (Section D) connected as current mirrors supply bias current to the bases of transistors Q1 and Q2. The current sourced by transistors Q54 and Q55 whose bases are connected to the collector of transistor Q6 is determined by the resistor value connected to the BIAS pin 3 which is in series with emitter of transistor Q6.
Current supplied by transistor Q55 is also injected across the threshold resistor R TH . The resulting voltage drop across this resistor determines the comparator threshold voltage. A potential at the VCRI+ input there is greater than the voltage drop across resistor R TH will turn off transistor Q5. This turns on transistor Q31 in the Output Logic (Section E) which allows current to bias transistors Q37 and Q38 on. A potential below the threshold value results in turning on transistor Q32 which in turn sinks bias current away from Q37. This results in shutting off Q37 which turns off output transistor Q38. Due to the external resistors R7', R8' (see FIG. 8) connected to VOUT1/VOUT and VOUT2 a corrosive indication results in a VOUT below 1 volt, a non-corrosive indication of approximately 2.5 volts and a low level indication above 4 volts. The output of the comparator section also feeds into the CCS Hysteresis (Section C).
The CCS Hysteresis (Section C) provides an adjustable amount of hysteresis for the coolant condition comparator and comprises transistors Q49-50, 64 and 65 and diode Q51. Input pins HYSI, HYSX and BIAS are used 20 to set up the integrated circuit for either of two modes: internal or external hysteresis. The internal mode uses a connection between HYSI and BIAS. During a corrosive condition transistor Q5 is off which results in transistor Q49 turning on and Q50 off. Transistor 25 Q71 can then push bias current through diode Q51 which in turn flows through pin HYSI and through the R BIAS resistor connected to ground at the BIAS pin. A decrease in the current through transistor Q6 occurs which in turn decreases the current flow through 30 transistors Q54 and Q55. This results in a decreased voltage drop across the threshold resistor R TH .
A noncorrosive condition causes transistor Q5 to turn on resulting in no current flow through Q51. This increases current through transistors Q6, Q54, and Q55.
The HYSX pin is used for external hysteresis. A resistor connected between pins HYSX and BIAS allows an adjustable hysteresis value. The current flow or absence of flow through Q65, R18 and the external resistors sets the hysteresis thresholds. Transistor Q64 biases the emitter of transistor Q65 at VCC/2.
The Bandgap Reference Section D of the circuit provides a well regulated reference which is utilized by other portions of the circuit and comprises transistors Q7-Q11 and Q58-Q63. A nominal 1.235 volt reference is supplied at the emitter of transistor Q6 (R BIAS pin). Resistor Q15 matches resistor R BIAS while transistor Q6 and Q7 VBE's are also matched. Transistors Q52 and Q53 are current mirrors used to minimize the bias current offset errors for transistors Q6, Q54 and Q55. Diode Q12 and Q13 are used in conjunction with transistor Q69 and Q66 to provide a two VBE potential allowing the bandgap to power up properly on application of power to the circuit. The current flow through Q54 and Q55 is a function of the bandgap voltage divided by the resistance at the BIAS or HYSX pins.
The Output Logic (Section E) uses inputs from the Coolant Level Buffer With Hysteresis (Section I) and the Coolant Condition Comparator (Section B) portions of the circuit. These inputs cause the Output Logic Circuit, (Sections F and J) to properly drive the output driver circuit to provide the appropriate output to the analog instrumentation input. The logic is configured to allow a low level indication to override both a noncorrosive and a corrosive indication. A corrosive coolant results in transistors Q5 being off, Q31, on and Q32 off. This in turn allows Q70 current to bias transistors Q37 and Q38 on. With the resistor configuration on the output as described supra, this results in a sensor VOUT of less than one volt.
A noncorrosive condition causes transistor Q5 to turn on, transistor Q31 turns off and Q32 turns on, and bias current is taken away from the Driver #1 (Section F). Transistor Q34 turns off in addition to Q31, therefore providing bias current to Driver #2 (Section J). The resulting indication is one half of VCC. If there is a low level condition, transistor Q48 turns off which results in a turn on of both Q35 an Q33. This results in a turn off of Output Drivers #1 and #2 and a VOUT indication above 4 volts (assuming a 5 volt power supply).
The output pin VOUT1 of Driver #1 (Section F) is connected to two resistors (see FIG. 8), one to VCC, R8' and the other to R7'. The other end of R7' is connected to VOUT2. Pin VOUT1 is tied directly to the output VOUT. Resistors RH32 and RH34 are bias resistors and RE35 provides short circuit protection. Transistor Q36 turns on if the drop across resistor RE35 is above the transistor VBE. The turning on of Q36 limits the output current and protects Q38 from an overload condition.
The output in VOUT2 of Driver #2 (Section J) is connected to resistor R7' (FIG. 8) which is in turn is connected to input VOUT1. Resistors RH33 and RH36 are bias resistors and RE37 provides short circuit protection with transistor Q39 functioning in a manner similar to transistor Q36 of Section F.
The coolant level OP-AMP (Section G) comprises an input stage composed of transistors Q14-Q20, Q79 and Q80. Transistor Q69 is a current source used to provide a proper bias at the VLV+ pin input through resistors RH20 and RH21. Resistors RH22 and RH23 go from the output of the OP-AMP back to the inputs setting up the unstable oscillator front end. Capacitor C2 serves to improve the stability of the OP-AMP.
The resistor and capacitor R1'/C3' connected to the VLV- input (FIG. 8) form one leg of the unstable oscillator input. If the impedance of the other leg is greater, the OP-AMP breaks into oscillation. Otherwise a steady state output voltage results.
The output of the OP-AMP feeds directly into the inputs of two differential input pairs Q22, Q23 of the coolant level comparator (Section H). The remaining two inputs are taken from the resistor/diode divider leg formed by RH24, Q73, Q74 and RH25. This leg provides the threshold for these two differential amplifiers (in this case acting as comparators).
With no coolant level OP-AMP oscillation Q28 is turned off which results in a discharged capacitor which is connected to the VLVO pin. Oscillation causes Q28 to turn on which results in a charged capacitor and a turning off of transistor Q48.
During an adequate coolant level condition transistor Q28 is off and Q43 is on and Q47, Q46 and Q78 of Coolant Level Buffer with Hysteresis (Section I) are all turned on. Q67 and Q68 provide two VBE hysteresis with Q67/Q68 turning on or off dependent upon the state of the coolant level comparator. The capacitor provides a filtering time constant for the signal from the comparator. When transistor Q43 is turned on, Q48 is on and when Q43 is off so is Q48.
FIG. 11 shows a flowchart of an algorithm which can be used in conjunction with the engine control module (ECM) shown in dashed lines in FIG. 8 to obtain the desired performance including early warning to the driver of the vehicle of a low coolant condition which can lead to engine overheating and damage as well as early warning of a corrosive coolant condition which can lead to engine or cooling system failure. A selected number of samples, e.g. six, of low level indications will turn on an "add coolant" light in the dashboard of the vehicle (not shown). The light is turned off by a selected number of samples, e.g. six, of a normal coolant condition. The "change coolant" light (not shown) is turned on after a selected number of corrosive coolant samples (e.g. six). This light remains on for the remainder of the driving cycle, regardless of the add coolant indication.
Electrical performance characteristics of a system built in accordance with the invention are shown in Table I as follows:
TABLE I______________________________________ TYPI-CHARACTERISTICS MIN CAL MAX UNIT______________________________________Supply Voltage (VCC) 5.0 VOLTSSupply Current (ICC) 5 MACorrosivity Threshold 200 400 MV(V CAL)Level Threshold (R LEV) 0.5 10.0 K OHMS"Corrosive" Output 1.0 VDC(VOUT)"Noncorrosive" Output 2.0 2.5 3.0 VDC(VOUT)"Low Level" Output 4.0 VDC(VOUT)Operating Temperature -40 +125 DEG CRange______________________________________
This system incorporated components shown in Table II as follows:
TABLE II______________________________________IC SN 28880 (14 pin)IC SN 28881 (8 pin)C1', C4', C5' .1 μf monolithic ceramic chip capacitorC3' .0047 μf monolithic ceramic chip capacitorC2' .01 μf monolithic ceramic chip capacitorR7' 300 ohm thick film chip resistorR8' 348 ohm thick film chip resistorR1' 1.0K ohm thick film chip resistorR.sub.TH, R.sub.DN select resistor -PCB 32 printed circuit boardR.sub.BIAS 6.1K ohm thick film chip resistor______________________________________
Sensor systems made in accordance with the invention can of course be employed with liquids other than automotive coolants such as heat transfer liquids used in connection with energy systems or machine tools or the like.
In the foregoing specification, the invention has been described with reference to a specific exemplary embodiment thereof. However, it will be evident that various modifications and changes may be made thereunto without departing from the scope of the invention as set forth in the appended claims. The specification and drawings are accordingly, to be regarded in an illustrative rather than in a restrictive sense.
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A dual function sensor particularly useful with vehicular coolant systems indicates when a coolant liquid becomes corrosive to such cooling system materials as well as when the liquid falls to a low level condition. A reference and a sense electrode are used to probe the condition of the coolant liquid. Integral electronics provide signal conditioning and transmitting to indicate both corrosive and low level coolant conditions. The sensor assembly mounts directly onto a tubular coupling on the vehicle radiator by pushing the assembly onto the coupling until a spring wire element snaps past a lip formed on the free distal end of the coupling. An electrical connector shroud extends from the assembly and accommodates a mating male connector which is pushed onto the shroud until a clip mounted on the male connector snaps over a locking tab located on the shroud. The male connector typically is connected to an engine control module (ECM).
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FIELD OF THE INVENTION
[0001] The present invention relates to a technology of exchanging electronic documents, such as electronic mails, between a plurality of devices.
BACKGROUND OF THE INVENTION
[0002] An electronic document exchanging devices are used to convert an electronic document prepared in one format to another format when exchanging electronic documents between devices of different types. Examples of such electronic document exchanging devices are the routers, switches, firewalls etc.
[0003] The conventional electronic document exchanging device is arranged to send the electronic documents only to the specific destination. Precisely, the transfer destination is fixed, and it can not be changed depending on the contents of document. Moreover, these devices can not divide a document or merge two or more documents depending on the length of the document or stay time permitted for each destination. In addition, these devices can not judge whether it is possible or not to exchange or relay the electronic document. Also, these devices can not control the number of the documents to be exchanged or relayed when there are excess of document.
SUMMARY OF THE INVENTION
[0004] It is an object of this invention to provide a technology in which it is possible to change the destination depending on the contents of document, divide a document or merge two or more documents depending on the length of the document or stay time permitted for each destination, judge whether to exchange or relay the electronic document, and control the number of the documents.
[0005] According to one the method and device of one aspect of the present invention, electronic document received from a source device is analyzed. From the result of this analysis it is decided whether to transmit the electronic document to some other destination device or decide the destination of the electronic document that is to be relayed. Electronic documents to be relayed are divided or merged in accordance with a predetermined length of the electronic document and allowable stay times for respective destination device. The divided or merged electronic document are transmitted to the destination device.
[0006] The computer program according to another aspect of the present invention makes a computer realizes the method according to the present invention.
[0007] Other objects and features of this invention will become apparent from the following description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a diagram showing an embodiment of the electronic document exchanging device of the present invention;
[0009] [0009]FIG. 2 is a flowchart of the operation of merging to or more messages by the device of the present invention;
[0010] [0010]FIG. 3 is a flowchart of the operation of sending a message by the device of the present invention; and
[0011] [0011]FIG. 4 is a flowchart of the operation of deleting a part of a message by the device of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] One embodiment of this invention will be explained below with reference to the accompanying drawings. However, this invention is not limited only to this embodiment.
[0013] [0013]FIG. 1 is a diagram showing an embodiment of the electronic document exchanging device of the present invention. This electronic document exchanging device 1 is comprised of the message control section 2 which receives an electronic document M and analyzes the contents of the electronic document. Furthermore, the electronic switching device 1 includes the message separating section 3 which divides the electronic document, message merging section 4 which merges two or more electronic documents, message cutoff section 5 which stops a flow of the electronic documents when the number of electronic documents per unit time exceeds an allowable value, and message transmitting section 6 which transmits the electronic documents.
[0014] Each electronic document is, for example, a message having a plurality of character strings, and contains a start code and an end code. The electronic document is generated on a device that has not been shown in the figure.
[0015] The electronic document M from the start code to the end code is sequentially received by a serial port of the electronic document exchanging device 1 . The following are examples of electronic documents.
[0016] *Feb. 4 20:37:43.027: %LINK-3-UPDOWN: Interface Serial0, changed state to up(0×0a)
[0017] *Feb. 9 12:06:37.020: %SYS-2-MALLOCFAIL: Memory allocation of 18180 bytes failed from 0×601605AD, pool I/O, alignment 0(0×0A)
[0018] *Feb. 4 20:37:43.919: %LINK-5-CHANGED: Interface Ethernet2, changed state to administratively down(0×0A)
[0019] In these examples, each electronic document starts with a character string which indicates date and ends with the line break code (0×0A). The line between the date and the line break code becomes one line.
[0020] The message control section 2 analyzes the received electronic document M, and determines whether to relay the document or decides where to relay the document. These decisions are made in accordance with certain one or more predetermined conditions. For example, when the document includes specific key word such as the following, then only the document is relayed.
[0021] “change”: a line including the character string change “down” & “Ethernet2”: a line including the two character strings down and Ethernet2
[0022] If the message control section 2 decides that the document is not to be relayed, that specific document is deleted. On the other hand, if the message control section 2 decides that the document is not to be relayed, then the document is converted to a format that is acceptable by the destination device and a transmission output is generated. This transmission output is generated as a transmission waiting list for each transmission destination at a message output side interface.
[0023] The message separating section 3 sequentially removes messages from the transmission waiting list and checks whether the length of the message exceeds the predetermined length. When the length exceeds the predetermined length, the message separating section 3 divides the transmission output into two or more electronic documents and sends these electronic documents to the message merging section 4 . On the other hand, the message is sent as is to the message merging section 4 when the length is less than or equal to the predetermined length.
[0024] The message merging section 4 waits for the next electronic document intended for a transmission destination, until the allowable stay time of that transmission destination elapses. In the allowable stay time, the message merging section 4 merges a plurality of electronic documents into a single electronic document which is the designated electronic document length or less, and sends the electronic document to the message cutoff section 5 . If the allowable stay time has elapsed, the electronic document is deleted.
[0025] The message separating section 3 and message merging section 4 are the ones that divide or merge an electronic document in accordance with the length of the document and allowable stay time of the transmission destination.
[0026] The message cutoff section 5 checks whether the generated frequency of the electronic documents (the number of electronic documents per unit time) generated in the message separating section 3 and message merging section 4 exceeds an allowable value. If the frequency exceeds the allowable value, the electronic documents are not send until the frequency becomes is less than or equal to the allowable value. The electronic documents are sent to the message transmitting section 6 when the frequency is less than or equal to the allowable value.
[0027] The message transmitting section 6 outputs the electronic documents which are divided or merged such as described above in the electronic document format acceptable to the transmission destination.
[0028] It is mentioned above that the message control section 2 performs the conversion of the format of the electronic document. However, such conversion may be performed by the message transmitting section 6 .
[0029] The functions of each of the sections of the electronic switching device 1 may be realized by executing a computer program in a computer provided with the necessary hardware such as a CPU and memory.
[0030] Operation of the electronic switching device 1 will be described in more detail now. In the electronic document exchanging device 1 , the message control section 2 judges whether to relay the received document. If the electronic document M is to be relayed it is sent to the message separating section 3 for each transmission destination. The message separating section 3 divides documents those exceed a predetermined length and sends the divided document to the message merging section 4 . The message merging section 4 merges the electronic document in accordance with the procedure which is shown in FIG. 2.
[0031] As shown in FIG. 2, when the electronic document is input (step ST 21 ), the message merging section 4 decides the frequency of generation of the documents (step ST 22 ). The message merging section 4 judges whether the frequency exceed an allowable value (step ST 23 ). If the frequency is equal to or less than the allowable value, the electronic documents are temporarily stored (step ST 24 ). If there already exists a document in this memory then the new document is merged with the old (already existing document). Thus, the memory stores a queue of documents as a single electronic document. On the other hand, if the frequency is less than the allowable value, the electronic document is sent (step ST 25 ).
[0032] The electronic document stored in the memory as mentioned in step ST 24 are sent in accordance with the procedure shown in FIG. 3. Namely, the queue in which the electronic document is stored is checked (step ST 31 ) . If an electronic document is stored in the queue, even if the electronic document has been changed because of merging, the (merged) electronic document in the queue is sent (step ST 32 ) if the predetermined constant time has elapsed since the initial electronic document was stored.
[0033] As described above, the electronic document which is merged in the message merging section 4 is sent to the message cutoff section 5 . The message cutoff section 5 stops the flow of the electronic document in accordance with the procedure of FIG. 4.
[0034] As shown in FIG. 4, when the electronic document is input (step ST 41 ), the message cutoff section 5 decides the frequency of generation of the documents (step ST 42 ) . The message cutoff section 5 judges whether the frequency exceed an allowable value (step ST 43 ). If the frequency exceed the allowable value, the electronic document is not send for a predetermined time (step ST 44 ). Finally, the document is sent (step ST 45 ). If the frequency is equal to or less than the allowable value, the electronic document is sent immediately (step ST 45 ).
[0035] The electronic document exchanging device 1 acquires electronic documents which are output from, for example, network servers, routers etc., as well as observation devices, control devices, and various equipment used for communications and other applications. The electronic document exchanging device may be used to analyzes the message, and inform the result to a managing computer or the like through an electronic mail. Similarly, the electronic document exchanging device may be used to monitor generation of breakdowns or abnormalities in a device and report the generated breakdowns or abnormalities to a managing computer or the like through an electronic mail.
[0036] Furthermore, the electronic document exchanging device may be used to send electronic documents for executing the commands which are needed for an object device in accordance with requirements from devices which are at remote places. In this case, the electronic document exchanging device can grasp or detect the situation of the object device in accordance with jobs which are sent from a managing computer.
[0037] The “computer program” according to the present invention is a data processing method described in an optional language or description method, regardless of a format of a source code or a binary code. The computer program is not necessarily structured as a single unit, and includes a program that is decentralized into a plurality of modules and libraries, and a program that co-operates with a separate program as represented by an OS (Operating System) thereby to achieve the function thereof. In each unit shown in the embodiments, known structures and procedures can be used as a structure for reading the recording medium, a reading procedure, and an installation procedure after the reading.
[0038] Although the invention has been described with respect to a specific embodiment for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art which fairly fall within the basic teaching herein set forth.
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Electronic documents are exchanged between a plurality of devices. Electronic document received from a source device is analyzed. From the result of this analysis it is decided whether to transmit the electronic document to some other destination device or decide the destination of the electronic document that is to be relayed. Electronic documents to be relayed are divided or merged in accordance with a predetermined length of the electronic document and allowable stay times for respective destination device. The divided or merged electronic document are transmitted to the destination device.
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BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to an opening roller for an open-end spinning device with numerous combing teeth designed for combing out fibers out of a sliver, and which are arranged in numerous windings or ring-formed rows extending in circumferential direction of the opening roller, with at least a part of the helixes or ring-formed rows comprising zones with reduced combing effect or entirely without combing-out effect.
Usually opening rollers are provided with a fitting of combing teeth or combing needles in order to comb out fibers, which are to be spun into a yarn, from a fed-in sliver. The combing teeth are normally arranged on the opening roller in rows or helixes, extending in circumferential direction of the opening roller and with spaces between them, the spaces forming grooves.
On an opening roller to be used for the production of an even yarn, the combing teeth are uniformly made and arranged in rows or helixes equidistant from each other. Due to their contour, the combing teeth are suitable for combing out individual fibers from a fed-in sliver as soon as the fibers are released from the nipping line of the sliver feeding device. The combed-out fibers mainly reach the grooves formed by the rows or windings of the combing teeth and are taken along by the rotating opening roller to a fiber feed channel. Due to the prevailing under pressure there and to the effect of the centrifugal forces exerted by the opening roller, the fibers are released from the fitting and reach the fiber feed channel.
In order to generate the necessary centrifugal forces for the releasing of the fibers, the opening roller must rotate at a high number of revolutions. The fibers held at the nipping line are subject to numerous strokes from the combing teeth of the opening roller, the opening roller rotating at high speed, before they are released from the nipping line and combed out of the fiber beard by the combing teeth. The high number of strokes from the combing teeth lead frequently to mechanical damage of the fibers.
An opening roller having at least one discontinuity is known from the German patent application 40 24 786 A1. The discontinuity can consist in a zone without combing-out effect being provided in a row of combing teeth, or in a groove filled with an insert which thereby partly reduces the transport function of the opening roller.
The discontinuity is arranged on the fitting in such a way that, during the spinning process, varying amounts of fibers are fed into the fiber feed channel in order to be able to produce an uneven yarn.
An object of the invention is to manufacture an opening roller with which the mechanical stress of the fibers is reduced without giving rise to an uneven yarn.
This object is achieved in that the zones with reduced or entirely without combing-out effect are so designed and arranged relative to the combing teeth that the fibers are combed out of the sliver evenly.
The arrangement of zones with reduced or entirely without combing-out effect in place of combing teeth results in the number of strokes carried out on the fibers until their release from the nipping line being reduced. The number of combing teeth can be reduced by such an amount, and replaced by zones with reduced or entirely without combing-out effect, that the combing-out effect needed for the release of the necessary amount of fibers for spinning is just sufficient.
The design and arrangement of the zones with reduced or entirely without combing-out effect results in the more careful treatment of the fibers during combing-out from the sliver not having an effect on the evenness of the yarn. The spinning element can be continuously fed with a mainly constant amount of fibers. The grooves are maintained, so that the transport of the released fibers is not disturbed.
In an advantageous development, the zones with reduced or entirely without combing-out effect are arranged distributed over the axial width of the opening roller. A good evenness is hereby maintained during fiber release.
It is further advantageous to distribute the zones with reduced or entirely without combing-out effect evenly over the opening roller, namely over its axial width and/or in circumferential direction.
In an advantageous development, a zone with reduced or entirely without combing-out effect is so designed that it comprises at least one so-called "modified tooth", (whose function differs from that of a normal combing tooth), projecting from the opening roller. The modified tooth is so designed that it can transport fibers but has no, or only a reduced, combing-out effect. The modified teeth, projecting from the opening roller in place of the combing teeth, enable a careful treatment of the fibers during the combing-out process, and also the forming of grooves, which ensure an even transport of the released fibers.
In an advantageous development, the modified tooth projecting from the opening roller has the contour of a tooth whose face angle is smaller than that of a combing tooth. Due to the smaller face angle, a combing-out effect of the tooth is avoided or at least reduced.
In an advantageous development, a zone with reduced or entirely without combing-out effect is formed on the extended back of a combing tooth or a tooth with a smaller face angle. The tooth tip and the tooth face of the combing tooth form a zone with combing-out effect, while the area of the extended tooth back forms a projecting modified tooth, which is then part of a zone with reduced or entirely without combing-out effect.
In an advantageous development, the combing teeth and the radially projecting modified teeth together form a continuous wall in circumferential direction of the opening roller, whereby in the area of the zones with reduced or entirely without combing-out effect, the contour of the combing teeth and the contours of the invention are formed into the continuous wall.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of an opening device of an open-end spinning installation constructed according to a preferred embodiment of the invention;
FIG. 2 is an enlarged top view of the circumferential side of a ring mounting of the opening device opening roller of FIG. 1;
FIG. 3 is a section along the line III--III of FIG. 2;
FIG. 4 is a partial view of the circumferential side of a ring mounting of an opening roller in another embodiment;
FIG. 5 is a section partial view, similar to FIG. 3, of a ring mounting of an opening roller in another embodiment;
FIG. 6 is a partial view, similar to FIG. 5, of a ring mounting of an opening roller in another embodiment;
FIG. 7 is a partial view, similar to FIG. 5, of a ring mounting of an opening roller in another embodiment;
FIG. 8 is a partial view, similar to FIG. 5, of a ring mounting of an opening roller in another embodiment;
FIG. 9 is a partial view, similar to FIG. 5, of a ring mounting of an opening roller in another embodiment;
FIG. 10 is a partial view, similar to FIG. 5, of a ring mounting of an opening roller in another embodiment;
FIG. 11 a view, similar to FIG. 3, of a ring mounting of an opening roller in another embodiment; and
FIG. 12 is a partial view, similar to FIG. 5, of an opening roller in another embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The opening device 1 shown in FIG. 1 comprises mainly an opening roller 3 and an opening roller housing 2, which houses the opening roller 3 rotating in arrow direction A.
The opening roller 3 comprises a cylindrical base body 12 and a ring mounting 13 which is attached to the base body 12 and which carries a fitting with combing teeth 14 and contains zones 19 without combing-out effect (see FIG. 3), which will be explained at a further point.
A feeding device 5 for feeding a sliver 9 is arranged upstream from the opening roller 3. The feeding device 5 comprises mainly a feeding roller 6, which rotates in arrow direction B, and a feed table 7, the feeding roller 6 and feed table 7 together forming a nipping line 8 for the sliver 9.
The fibers of the continuously fed-in sliver 9, stuck fast at the nipping line 8, reach the opening roller 3 in the form of a fiber beard 10. As a result of the rotation of the feeding roller 6, individual fibers 11 are continuously released from the nipping connection at the nipping line 8 and picked up by the opening roller 3. The individual fibers 11 are forwarded by the opening roller 3 in rotation direction A to a fiber feed channel 4, where, due to the centrifugal forces exerted by the opening roller 3 and the prevailing suction in the fiber feed channel 4, the fibers 11 are released from the opening roller 3 and are transported through the fiber feed channel 4 to a spinning element (not shown).
As can be seen in FIGS. 2 and 3, the combing teeth 14 in circumferential direction of the opening roller 3 are so arranged one behind the other that they form coils 20, 21 which extend helically over the circumference of the ring mounting 13, covering substantially the entire axial width C. The opening roller 3 is somewhat wider than the ring mounting 13, as it comprises mounting elements (not shown) which, after assembly, lie on the base body 12 against the end wails of the ring mounting 13. Grooves 22 are formed between two neighboring helixes 20, 21.
The helixes 20 and 21 are distributed in zones 18 with combing-out effect and zones 19 without combing-out effect. Each zone 18 with combing-out effect comprises eight combing teeth 14, each with a short back 15, as well as the tooth tip 71 and the tooth face 72 of a combing tooth 16 with a long back 17. The long back 17 lies in the zone 19 without combing-out effect, the zone 19 following a zone 18 with combing-out effect. The area of the long back 17 of the combing tooth 16 has the form of a modified tooth projecting radially from the ring mounting 13, and thus forms the zone 19 without combing-out effect. The combing-out effect results from, among other factors, the incline of the tooth tips 71 and 76 of the combing teeth 14 and 16 in the rotation direction A of the opening roller 3.
The zones 18 with combing-out effect and the zones 19 without combing out effect are distributed evenly in circumferential direction of the opening roller 3. Each complete helix 20, 21 comprises six zones 18 with combing-out effect and six zones 19 without combing-out effect. The combing teeth 14 and the combing teeth 16 with the modified teeth 69 are connected integrally, so that a continuous, thin strip 70 extending in circumferential direction is formed which contains the contours of the combing teeth 14 and the combing teeth 16 integrally with the modified teeth 69.
As can be seen in particular in FIG. 3, the zones 18 with combing-out effect and the zones 19 without combing-out effect are distributed evenly over the entire axial width C of the ring mounting 13. The zones 18 with combing-out effect and the zones 19 without combing-out effect are each arranged along lines 66 which extend parallel to the axis 67.
Due to the even distribution of the zones 18 with combing-out effect and the zones 19 without combing-out effect, a regular combing out of the fibers 11 from the fiber beard 10 is effected, whereby the number of strokes carried out on the fibers 11 in the fiber beard 10 is reduced as a result of the zones 19 without combing-out effect.
As the grooves 22 between neighboring helixes 20 and 21 also include the areas of the zones 19 without combing-out effect, the transport of the released fibers 11 to the fiber feed channel 4 is guaranteed.
In FIG. 4, another distribution possibility of the zones 24 with combing-out effect and zones 25 without combing-out effect over the width C of a ring mounting 26 is shown, which differs from the arrangement in FIG. 2. The zones 25 without combing-out effect are arranged in the direction of width C of the ring mounting 26 within the lines 27, 28, the lines extending with a direction component in axial direction and in circumferential direction of the opening roller 3. The lines 27 and 28 are, for reasons of simplification, shown drawn straight, as though the ring mounting 26 does not take a curved course, but rather a straight one.
In the embodiment in FIG. 5, only teeth 29 with long backs 30 are shown on the ring mounting. The zones 68 without combing-out effect are formed here by the long backs 30, while the zones with combing-out effect are formed by the tooth tips 31 and the tooth faces 32 of the combing teeth 29.
In the embodiment shown in FIG. 6, a combing tooth 33 with a short back 34 and a combing tooth 35 with a long back 36 are arranged alternately in circumferential direction behind each other. The zones without combing-out effect are also formed here by the long backs 36.
In the embodiment shown in FIG. 7, after each group of five combing teeth 37 with short backs 38, a single combing tooth 39 with a long back 40 is arranged in circumferential direction. The long back 40 of the combing tooth 39 has the same direction of curvature as the opening roller 3, whereby the radius of curvature of the long back 40 is smaller than the radius of curvature of the opening roller 3.
In the embodiment shown in FIG. 8, a modified tooth 42, projecting radially from the opening roller 3, is provided after each group of four combing teeth 41, the modified teeth each forming a zone without combing-out effect. The modified teeth 42 have the contour of a segment of a circle whose curved circumferential edge 43 borders the modified tooth 42 in radial direction of the opening roller 3.
In the embodiment of FIG. 9, two radially projecting modified teeth 45, 46 are arranged in circumferential direction of the opening roller 3 after each group of four combing teeth 44, the modified teeth having the same contour as the modified teeth in FIG. 8 and forming together a zone without combing-out effect.
In the embodiment shown in FIG. 10, a radially projecting modified tooth 48 is arranged in circumferential direction of the opening roller 3 after each group of five combing teeth 47, the modified tooth being limited in its radial extension by an edge 49, curving in the opposite direction to the direction of curvature of the opening roller 3. The radially projecting modified tooth 48 forms a zone without combing-out effect.
In the embodiment shown in FIG. 11, zones 50 with combing-out effect and zones 51 without combing-out effect, or with reduced combing-out effect, are distributed evenly in circumferential direction on the opening roller 3. A zone 50 with combing-out effect each comprises eight combing teeth 52 with a short back 53 as well the tooth tip 73 and tooth face 74 of a combing tooth 75 with a long back 56. This long back 56 forms the edge of a modified tooth 58 projecting from the opening roller 3. The tooth tips 53, 73 are both inclined in circumferential direction of the opening roller 3, so that the tooth faces 55 and 74 form, together with the radial line R1, a face angle α.
The zone 51 comprises the radially projecting modified teeth 58, 59 and 60 and contains areas with combing-out effect and areas with reduced combing-out effect. The edges 56, 57 of the modified teeth 58, 59 have absolutely no combing-out effect. The teeth of the modified teeth 60 have a reduced combing-out effect. The tooth face 61 of each tooth 60 is not inclined in the sense of direction A of the opening roller 3, but rather extends in the direction of the radial line R2, so that the face angle is zero.
In the embodiment shown in FIG. 12, a radially projecting modified tooth 63 with short teeth 64 is arranged after each group of three combing teeth 62, whereby the modified tooth 63 forms a zone with reduced combing-out effect. The short teeth 64 differentiate from the combing teeth 62 in that the short teeth 64 have a shorter tooth face and a shorter tooth back, so that the tooth base is relatively near to the tooth tip. The short teeth 64 have a considerably reduced combing-out effect in comparison to the combing teeth 62. The lateral surfaces of the combing teeth 62 and of the radially projecting modified tooth 63 are provided with a surface structure in the form of grooves which extend in circumferential direction. The taking along of the combed-out fibers 11 from the sliver 9 is hereby improved.
Although the invention has been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example, and is not to be taken by way of limitation. The spirit and scope of the present invention are to be limited only by the terms of the appended claims.
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An opening roller for an open-end spinning device is provided with a fitting of combing teeth. The fitting comprises zones with reduced, or entirely without, combing-out effect. The zones with reduced or entirely without combing-out effect are so designed and arranged relative to the combing teeth on the fitting that the fibers are combed out evenly of the sliver. A careful treatment of the fibers without a variation in yarn evenness is hereby achieved.
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a yarn clamping device for underwinding yarns on spindles of a ring spinning or ring twisting machine wherein a clamping ring and at a distance therebelow a radially protruding collar are provided on the spindle under an underwinding crown; wherein an axially displaceable clamping sleeve is located between the clamping ring and the collar on the spindle; wherein the clamping sleeve can be displaced by means of an actuating device between a clamping position defined by the contact against the clamping ring and an open position defined by the contact against the collar for opening or closing a clamping cleft; and wherein the clamping sleeve is equipped with radially extending means for the operation of the actuating elements of the actuating device and with elements for fixing the position of the clamping sleeve at least in the closed position.
A similar kind of device is already known by publication EP 1 218 577 B1. The clamping sleeve is equipped with permanent magnets which, in order to secure the closed position, fix the clamping sleeve on the clamping ring below the underwinding crown. If the clamping cleft is to be opened, the clamping sleeve will move to the lower, open position by means of an actuating device which acts on a radially protruding collar of the clamping sleeve by means of actuating elements, thereby overcoming the magnetic forces. In the open position magnetic forces of the magnets integrated into the clamping sleeve will in turn become active and will hold the clamping sleeve on the lower collar of the spindle. The actuating device is not described in detail in publication EP 1 218 577 B1.
Common actuating devices for adjusting the clamping sleeve are described, among others, in publication EP 0 775 769 B1. Actuating means which act on radially protruding means of the clamping sleeve via levers and transport the clamping sleeve into the positions required by the functioning of the system are mounted on parts that are firmly fixed to the machine frame. These known devices share the feature that the actuating devices act on one side and/or eccentrically on the clamping sleeves. This eccentric action requires long guides of the clamping sleeves along the spindle axles. Therefore, a limitation of the spindle speed is quite often also required. Another disadvantage is the high amount of additionally required structural outlay for these devices, which is also shown by the devices described in the publications EP 587 526 A1 and DE 199 04 793 C1.
Publication EP 462 467 B1 also discloses an actuating device which uses a ring rail on its way to the underwinding position for moving the clamping sleeve from the closed position to the open position. For each spindle the ring rail is equipped in the region of each spindle on its lower side with a projecting part which presses on the radially protruding collar of the clamping sleeve when the ring rail is approaching the underwinding position. This action compresses an axially acting pressure spring which is called “retroactive element” to the maximum width of the clamping cleft, thus opening the clamping cleft for the insertion of the underwinding yarn spiral. Except during this described procedure, the spring constantly keeps the clamping sleeve in the closed position, which is also called “working position”. During the short opening of the clamping cleft the yarn end still held in the cleft is released and the new underwinding yarn spiral is inserted almost simultaneously. The spindles run at very low speed during this opening procedure, because the underwinding should show a yarn loop of less than 360°. Ejecting and removing the yarn ends from the clamping cleft overlaps to a certain extent with the application of the new underwinding yarn spiral and is therefore not reliable. Frequent machine standstills for cleaning are the result.
Publication DE 196 28 826 A1 describes a yarn clamping device with a clamping sleeve which slides vertically displaceably on the shaft of the spindle wharve. A pressure spring, which is supported on the lower side of the wharve collar, presses the front surface of the clamping sleeve upwards against the clamping ring and closes the clamping cleft. Between an upper ring-shaped surface inclined inwards and downwards on the clamping sleeve, there are ball-shaped centrifugal elements with a relatively small diameter of max. 3 mm, which are located in the clamping position with their upper vertex a short distance from the lower side of the clamping ring. The centrifugal elements are guided in radial grooves of the clamping ring which are open underneath.
When the cop spinning process is finished, the ring rail lowers. The yarn guided by the traveler of the spinning ring is inserted at slowly decreasing spindle speed, approx. 5000/min, into the clamping cleft which is to be kept open by the centrifugal elements. If the spindle falls below this speed, the spring will close the clamping cleft, because it has to generate the complete clamping force for the underwound yarn upon cop change.
During the following start of yarn spinning for the new bobbin or cop, the centrifugal elements guided on the clamping ring move outwards due to the rotation of the spindle. They only open the clamping cleft after having reached approx. 5000 spindle rpm and also only to a small extent.
Therefore, this device is highly disadvantageous. The pressure spring, which has to apply the complete clamping force for the underwindings in the state of highest extension, can be overcome by the centrifugal elements only at high speeds. This means that also the underwinding process has to take place at these high speeds. The large mass of spindles and drawing sections, however, does not allow a sudden standstill out of this speed range, which would be absolutely necessary for limiting the looping of the underwinding to 270° up to a max. of 360°.
The consequence is that at relatively low speed the underwinding yarn is deposited only in the wedge-shaped area in front of the already closed clamping cleft and thus it is not sufficiently clamped. This considerably disrupts cop change. The spinning of the new cop is not effected with the required reliability.
If, in contrary, the underwinding yarn is inserted at a speed of more than 5000/min and clamped in the clamping cleft, clearly more than one winding will be deposited in the clamping cleft and several spirals will regularly be wound on the clamping sleeve. Removing these additional spirals from the clamping cleft and from the clamping sleeve creates considerable problems. In most cases the start of winding the new tube is also hindered. Yarn breakages and losses of production are the result.
The publications DE 197 46 819 A1 and DE 198 07 740 A1 disclose devices for clamping the underwindings during the bobbin change and for releasing the underwindings to be removed. These devices dispense with a clamping sleeve which can be displaced by means of actuating elements. Instead of the clamping sleeve, this system uses an elastic O-Ring for clamping which, due to the centrifugal force, is supported at high spindle speeds on the inner side of a ring at a distance from the clamping surface on the spindle and thus opens the clamping cleft. Such a design is unsatisfactory because the underwinding threads can only be inserted into the wedge-shaped clamping cleft which is closed at low speeds. Also a specific control of the delivery speed during this phase does not lead to a satisfactory safety of the clamping procedure during cop change.
BRIEF SUMMARY OF THE INVENTION
The object of the present invention is to propose an actuating device for a yarn clamping device equipped with a clamping sleeve which allows the reliable removal of the yarn waste from the clamping cleft and the reliable and safe clamping of a new underwinding thread with a circumference angle smaller than 360° until the winding procedure for the newly placed tube has begun.
This object is achieved by a yarn clamping device for underwinding yarns on spindles of a ring spinning or ring twisting machine wherein a clamping ring and at a distance therebelow a radially protruding collar are provided on the spindle under an underwinding crown; wherein an axially displaceable clamping sleeve is located between the clamping ring and the collar on the spindle; wherein the clamping sleeve can be displaced by means of an actuating device between a clamping position defined by the contact against the clamping ring and an open position defined by the contact against the collar for opening or closing a clamping cleft; and wherein the clamping sleeve is equipped with outwardly radially protruding means for the operation of the actuating elements of the actuating device and with elements for fixing the position of the clamping sleeve at least in the clamping position and for the application of a clamping force; wherein the actuating elements and the radially protruding means are held together elastically on the clamping sleeve radially to the spindle axles via angular surfaces; and wherein the direction of action of the actuating elements relative to the clamping sleeve can be switched over in such a way that, depending on the programme of the spinning machine, with increasing RPM the open position and at decreasing RPM the clamping position can be activated.
The combined non-positive and partly positive clutch between the actuating elements and the clamping sleeve allows the forces of the clamping sleeve on the clamping ring resp. on the collar of the spindle during the opening procedure to be reliably overcome. The actuating elements release the additional fixing between clamping sleeve and clamping ring and push the clamping sleeve into the open position. Opening of the clamping cleft happens at an especially favourable moment, i.e. at the end of the first downwardly directed ring rail lift at a relatively low speed and it remains open during the complete cop spinning procedure. Throwing off of the yarn waste is done during a long period of time at high spindle speeds. In addition, this procedure is supported by repeated blowing and suction processes on the open clamping cleft by means of the conventional travelling cleaner.
During the preparation phase for the cop change, the underwinding thread can be inserted in the still open clamping cleft, which is completely free from yarn waste, at an especially low speed, e.g. lower than 2000/min. Once the underwinding is finished, the actuating element, after having changed the direction of action on the clamping sleeve and after having jumped downwards over the radially protruding elements of the clamping sleeve, pulls the clamping sleeve upwards into the clamping position. After having reached this position, the actuating elements again jump over the radially protruding elements of the clamping sleeve and the clamping force required for carrying out the cop change is taken over by the means for fixing the clamping sleeve in the clamping position.
The essence of the claimed invention consists of the fact that the underwinding thread is placed at low spindle speed into a clamping cleft which is reliably free from yarn waste and sufficiently open.
According to an especially useful design of the invention the actuating elements are located on the ring rail; the radially protruding means on the clamping sleeve and/or the actuating elements have radially effective angular surfaces in both relative directions of motion; and the effective movement of the ring rail for closing the clamping cleft is bigger than the maximum width of the clamping cleft. The ring rail is especially suitable for receiving the actuating elements, as they are directly involved in the formation of the underwinding thread. Only a modification of the cycle of motion is required.
According to a favourable design variant of the invention, the actuating elements of each spindle consist of a group of radially moveable, resilient actuating elements which are arranged around the spindle axle on the lower surface of the ring rail and which elastically cooperate with the radially protruding means of the clamping sleeve. This design of the actuating elements avoids a one-sided or eccentrical load on the spindles.
A simple design of the actuating elements is achieved by the fact that the angular surfaces are part of the actuating elements.
The object of this invention is also achieved in a surprisingly easy way by a yarn clamping device for underwinding yarns on spindles of a ring spinning or ring twisting machine, wherein on the spindle below an underwinding crown a clamping ring and at a distance therebelow a radially protruding collar are provided; wherein an axially displaceable clamping sleeve is located between the clamping ring and the collar on the spindle; wherein the clamping sleeve can be displaced by means of an actuating device between a clamping position defined by the contact against the clamping ring and an open position defined by the contact against the collar for opening or closing a clamping cleft; and wherein the clamping sleeve is equipped with radially extending means for the operation of the actuating elements of the actuating device and with elements for fixing the position of the clamping sleeve at least in the clamping position by applying a clamping force; wherein the yarn clamping device is characterized in that the actuating devices are located on the spindles; and the actuating elements consist of centrifugal elements which slide in guides which are radially oriented with respect to the spindle axle and participate in the rotation of the spindle; which cooperate with angular surfaces or conical ring surfaces on the spindle or on the clamping sleeve; and which act against spring elements which, on the one hand, are supported by the collar of the spindle and, on the other hand, press the clamping sleeve into the clamping position.
The combination of the centrifugal elements acting against the spring and the elements for fixing the clamping sleeve in the clamping position allows the use of a very weak spring as it does not have to provide the necessary clamping force for the cop change. The underwinding procedure can also be executed at very low speeds and with a reliably opened and cleaned clamping cleft. It is possible to limit the winding yarn to a circumference angle of less than 360° without abruptly stopping the machine.
According to an example of the invention, the guides of the centrifugal elements are located on the clamping sleeve and the angular surfaces or conical ring surface are located on the collar of the spindle.
According to another alternative design of the invention, the guides of the centrifugal elements are located on the collar of the spindle and the angular surfaces or the conical ring surface are located on the clamping sleeve. The advantage of this design is the very compact design and low risk of fouling. It is moreover advantageous when the elements for fixing the clamping sleeve and for applying a clamping force are permanent magnets which are integrated in the clamping sleeve.
In accordance with a preferred embodiment of the invention, the elements for fixing the position of the clamping sleeve and applying a clamping force in the clamping position or for fixing the position of the clamping sleeve in the open position are formed by radially acting spring push buttons in the shaft of the spindle in cooperation with fixing grooves on the inner surface of the clamping sleeve, whereby the fixing grooves have a mutual spacing in the axial direction that is at most equivalent to the width of the open clamping cleft.
The use of permanent magnets which are integrated in the clamping sleeve as elements for the fixing of the clamping sleeve and the application of a clamping force allows designing a structurally simple and functionally very reliable embodiment for the fixing of the clamping sleeve at least in the clamping position to be provided. The magnets produce a reliably high clamping force in the clamping position.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The invention shall be explained in more detail below with reference to some exemplary embodiments. The corresponding drawings show
FIG. 1 a cross section of the middle part of the spindle with its relation to the ring rail;
FIG. 2 the action of the clamping sleeve controlled by the ring rail during the cop building cycle in six successive phases a) to f);
FIG. 3 an embodiment with ball-shaped actuating elements;
FIG. 4 an embodiment in which the radially protruding means on the clamping sleeve consist of elastically supported balls;
FIG. 5 an embodiment in which radially resilient leaf springs are provided on the clamping sleeve;
FIG. 6 a schematic top view of the drawing according to FIG. 3 ;
FIG. 7 a variant in which the actuating elements are made of a sleeve of synthetic material, the surface lines of which are slotted from the free, lower end.
FIG. 8 a , b, c three positions of a variant (a) underwinding, b) clamping, c) spinning) in which the clamping sleeve is allocated mechanical elements for the fixing in the end positions;
FIG. 9 a , b, c three positions of another alternative of the invention in which the actuating elements are centrifugal elements which rotate together with the spindle;
FIG. 10 a, b two positions of a variant in which the centrifugal elements are ball-shaped and guided on parts of the collar of the spindle; and
FIG. 11 a successfully tested clamping device according to the principle of FIG. 10 a and FIG. 10 b in a view on the basis of FIG. 1 .
DESCRIPTION OF THE INVENTION
FIG. 1 shows the middle part of spindle 1 of a ring spinning machine in a simplified cross section drawing. The support (not shown) of spindle 1 firmly connected with the machine frame shows, starting from the bottom, wharve 14 . The sleeve guided thereabove on shaft 16 forms collar 13 , of which the upper fore-part limits the path of clamping sleeve 2 at the lower end. At the upper end, the path of the clamping sleeve 2 is limited by clamping ring 12 which is firmly connected to underwinding crown 11 and shaft 16 .
The lower end of tube 51 for cop 5 to be wound is placed on the top end of shaft 16 . Other upwardly extending guiding elements for the tube are not shown.
Clamping sleeve 2 is equipped with magnets 21 which can fix clamping sleeve 2 on clamping ring 12 in the clamping position A or on collar 13 in the open position B. The way in which this is done is described in more detail in publication EP 1 218 577 B1.
The position change of clamping sleeve 2 from the open position B to the clamping position A and vice versa requires in any case additional adjustment means which release the fixing in one position and move the clamping sleeve into the range of activity of the other fixing elements.
FIG. 1 shows clamping sleeve 2 in the open position B. In the area of clamping cleft C underwinding zone 15 is emphasized on the surface of shaft 16 .
Ring rail 3 in the phase of FIG. 1 is lowered in underwinding position. Traveller 32 moves on spin ring 31 at the level of clamping cleft C and underwinding zone 15 and forms the underwinding spirals with the thread. The underwinding encircles shaft 16 of spindle 1 by less than 360°.
In the bore on ring rail 3 , through which spindle 1 extends, actuating device 4 for each spindle 1 is inserted from below. Its holding ring 40 extends with its hook-shaped elements through said bores of ring rail 3 .
Leaf-like springs 411 adjoin the holding ring 40 towards the bottom; on their downwardly directed free end there are angular surfaces 412 , 413 directed inwards for the radially outwardly directed means resp. collar 22 of clamping sleeve 2 .
The functioning of ring rail 3 with actuating device 4 and clamping sleeve 2 is shown in FIG. 2 in several phases a) to f). Phase a) shows that a new sleeve 51 has just been placed. Spindle 1 is starting to rotate again. Ring rail 3 is lifted to form the first layer and tensions the yarn held in the closed clamping cleft C as far as the first upper winding of the first yarn layer of the new bobbin 5 .
In the following phase b) ring rail 3 is lowered to finish the first double yarn layer. It leads fixing element 43 which is firmly connected to it to a ball 222 (cf. FIG. 4 ) radially guided in clamping sleeve 2 . The angular surface 2221 effective on the surface of this ball 222 is caught by actuating element 43 and moves clamping sleeve 2 downwards into the area where the force of magnets 21 and the inherent mass of clamping sleeve 2 moves clamping sleeve 2 further into the open position B. Clamping cleft C is then open.
This state is also maintained in phases c) and d). The yarn waste within clamping cleft C is torn at high speed at underwinding crown 11 and thrown off. The yarn waste will be removed by means of a blowing and/or suction device (not shown). In fact, the whole cop winding cycle can be used for this procedure.
After the winding of cop 5 is finished, phase e), ring rail 3 lowers into the underwinding position. Traveller 32 of spin ring 31 leads yarn 6 around underwinding zone 15 into the still open clamping cleft C and forms underwinding 61 . Actuating element 43 overcomes, by means of the resistance of collar 13 in the open position of clamping sleeve 2 , the ball 222 , which is resilient in a radially inwards direction, of clamping sleeve 2 and positions itself below the resilient ball 222 .
As soon as underwinding 61 is finished, delivery section and spindles 1 are stopped. Ring rail 3 moves upwards again. Actuating element 43 positions itself on the lower angular surface 2222 of ball 222 and lifts clamping sleeve 2 by overcoming the magnetic force between clamping sleeve 2 and collar 13 . Clamping sleeve 2 moves into the clamping position A and fixes the underwindings 61 by the action of the magnets 21 in clamping cleft C.
Cop change can be carried out. When removing cop 5 the yarn is torn or cut between clamping cleft C and cop 5 . This process starts again with phase a) after cop change has been completed.
FIGS. 3 to 7 show other embodiments of the elastic actuating elements and radially protruding means on clamping sleeve 2 .
FIG. 3 and FIG. 6 show a clamping sleeve 2 with rigid collar 221 . Actuating element 42 has, on its holding ring 40 ′, radially directed bores 421 , which are tapered inwards. The taper forms a stopper for ball 422 . Annular spring 423 , which is guided in a circumferential groove of holding ring 40 ′, holds three of these balls 422 which are located at a mutual spacing of 120° elastically inwards on the mentioned stoppers. The parts of ball 422 protruding from the inner side of the bores 421 form the angular surfaces 412 ′ and 413 ′. This embodiment guarantees a high functional safety and allows a simple exchange of the balls 422 which are subject to wear.
In FIG. 4 , actuating element 43 is stably fixed to ring rail 3 . The radially resilient ball 222 is pressed from inside to outside to the stoppers by annular spring 23 . The characteristics of this design are similar to those as described in FIG. 3 with the limitation that the labour for exchanging the balls 222 is slightly higher.
The device as per FIG. 5 is similar to the one as per FIG. 4 . Also in this case the actuating element 43 is stable and has a rigid collar 431 directed to the inside. Actuating element 43 is firmly connected with ring rail 3 . The function of the ball 222 is carried out by an angularly bent leaf spring 251 which is fixed in a groove 25 of clamping sleeve 2 . The angular surfaces 2511 and 1512 are formed on leaf spring 251 . The vertex 2513 in between is very narrow and guarantees a safe movement of clamping sleeve 2 in all phases.
FIG. 7 shows another preferred embodiment. Clamping sleeve 2 has a fixed collar 221 ′. Actuating element 41 ′ is made in one piece as a sleeve and includes the functions and elements of the holding ring 40 and the springs 411 . Sleeve 41 ′ is preferably a part made from synthetic material. The section directed downwards which carries out the functions of spring 411 , is slotted along surface lines, so that the shell segments can spring individually. On their lower end, the shell segments form the angular surfaces 412 , 413 and vertex 414 . Depending on the characteristics of the synthetic material of sleeve 41 ′, two or more shell segments are formed as springs 411 on the circumference of sleeve 41 ′.
Apart from these described embodiments, additional advantageous alternatives are possible within the context of the present invention. For example, instead of the balls 222 or 422 also the spring push buttons known in specialist fields as “Novibraknöpfe” (Novibra buttons) can be used. In the following text, these parts will be called spring push buttons ( 17 ).
In the case of these spring push buttons, a unit consisting of three elements (sleeve/spring/bowl), instead of the balls, bowl-shaped calotte shell segments are pressed against the actuating element 43 ( FIG. 4 ) or against the collar 221 of clamping sleeve 2 by means of spiral springs.
Instead of balls or bowls made of steel, also other materials, e.g. synthetic materials, can be used.
Publication EP 1 218 577 B1 described that, by means of certain arrangements of magnets in clamping sleeve 2 and in collar 13 when twisting the clamping sleeve 2 with respect to the collar 13 , an axial shifting of clamping sleeve 2 will be achieved. In the described embodiment magnetic poles with different polarity and attracting action are located opposite to each other at closed clamping position within the clamping cleft. When the actuating device touches the collar 221 of clamping sleeve 2 , it brakes first of all the clamping sleeve 2 . Clamping sleeve 2 twists against spindle 1 . With this, the poles in the clamping cleft of same polarity are initially opposing one another and repelling each other. Clamping sleeve 2 is pushed downwards in the direction of open position B. At the same time poles of different polarity are approaching each other at the bottom between clamping sleeve 2 and collar 13 . These are attracting each other and support the movement of clamping sleeve 2 into the open position B. Afterwards the poles of different polarity stabilize the open position B.
If the ring rail 3 is brought into the underwinding position, the actuating element 41 jumps over collar 221 of clamping sleeve 2 . The underwinding yarn which has in the meantime been inserted is clamped into clamping cleft C at the next upward movement of ring rail 3 when spindles 1 and delivery section are stopped. Between clamping sleeve 2 and clamping ring 12 poles of different polarity approach each other. Thereby they initiate a turning of clamping sleeve 2 with respect to spindle 1 . Clamping sleeve 2 and clamping ring 12 realign themselves in circumferential direction. The necessary clamping force for the underwinding yarn spirals can be generated.
In this case, upon opening of clamping cleft C the actuating element 4 of ring rail 3 does not execute a direct adjusting motion between clamping position A and open position B, but only transmits a braking impulse which allows the magnets to change the position of the clamping sleeve 2 .
FIGS. 8 a , 8 b , 8 c show another alternative of the device of the invention. Instead of the magnets 21 described in relation to FIG. 1 , the already described spring push buttons 17 are used for fixing the clamping sleeve 2 ′ in the clamping position A resp. in the open position B. Spring push buttons 17 are radially inserted in the shafts 16 of spindle 1 . The ball segments of ball 171 protruding outwards or the protruding segments of the bowls or calotte shells (not shown) grip elastically into the fixing grooves 27 resp. 28 and fix the position of clamping sleeve 2 ′ in the clamping position A or in the open position B.
This kind of fixing of the clamping sleeve 2 ′ allows the use of so-called O-rings 26 in the clamping area. The hoop 261 which embraces the O-ring 26 externally and partly from the top allows, due to its shape and configuration, space for the radial extension of the elastic O-ring 26 so that it can additionally fix the underwinding spirals in the clamping position A as shown in FIG. 8 b . When the ring rail 3 reaches the underwinding position after cop winding, as shown in FIG. 8 a , the spring of the actuating element 41 jumps over the collar 221 of clamping sleeve 2 ′ and positions itself below collar 221 .
The spring push button 17 is located in the fixing groove 27 and still secures the open position B.
In the position according to FIG. 8 b the ring rail 3 has lifted itself into the position required for the cop change. The spring of actuating element 41 has firstly displaced the clamping sleeve 2 ′ into clamping position A. The spring push button 17 now secures the position of the clamping sleeve 2 ′ by locking it in fixing groove 28 .
When continuing to move upwards, the spring of actuating element 41 overcomes the collar 221 of clamping sleeve 2 ′ and leaves the area of movement of clamping sleeve 2 ′.
After having finished the first yarn layer, the ring rail 3 with the actuating element 41 hits the collar 221 from above and displaces the clamping sleeve 2 ′ into a position in which it is shifted into the open position by the spring push button 17 in cooperation with fixing groove 27 and is fixed there.
FIGS. 9 a , 9 b , 9 c show another solution for the object to be achieved according to this invention. As shown in FIG. 1 , an actuating bush 18 is mounted axially non-displaceably and torsionally rigid on spindle 1 in the area of the collar 13 . The upwardly directed walls overlap the lower area of the clamping sleeve 2 ″ on the outside and form an inwardly and downwardly directed angular surface 181 .
The radially protruding means 22 ′ of clamping sleeve 2 ″are equipped with radial guides in which the radially freely moving centrifugal elements 29 are inserted. The outer upper edge of these centrifugal elements 29 is in contact with the angular surface 181 when the spindle 1 is rotating.
There are magnets 21 ′ inserted, in clamping sleeve 2 ″, the poles of which are directed towards the clamping cleft C. They assist the clamping pressure when they are close to the clamping ring 12 . Clamping sleeve 2 ″ is supported with its lower end on spring elements 131 which, in turn, are supported in bores of the actuating bush 18 . These spring elements 131 keep clamping sleeve 2 ″, during standstill of the spindle at a low clamping pressure, in clamping position A. The magnets 21 ′ provide the necessary clamping force which allows the tearing off of the yarn as shown in FIG. 9 b.
The functioning of the device as per FIG. 9 is the following. When the spindle speed has lowered to approx. 2000 rpm, the traveller 32 leads the thread into the underwinding area. Clamping cleft C is open. It can take up the underwinding yarn in an exactly defined length without problems.
If the spindle is stopped, as shown in FIG. 9 b , the force generated by the centrifugal elements 29 on the angular surface 181 is reduced. The spring elements 131 displace clamping sleeve 2 ″ into clamping position A. The magnets 21 ′ provide the necessary clamping force. The cop change can take place. The yarn between cop and clamping cleft C is torn or cut.
As soon as the spinning process is started on the new cop, the spindle speed increases. The centrifugal elements 29 are pressed to the angular surfaces 181 and push clamping sleeve 2 ″ against the direction of action of spring 131 downwards into the open position B. Clamping sleeve 2 ″ remains in this position until the next cop change begins, starting with a decrease of the spindle speed. There is sufficient time left to throw off and remove the yarn waste from the open clamping cleft C.
The device according to FIGS. 10 a and 10 b shows an embodiment in which balls 134 are used as centrifugal elements. They are guided in bores 135 radially directed outwards and upwards in collar 13 ′ of spindle 1 .
The clamping sleeve 2 ′″ overlaps this part of the collar 13 ′ on the spindle and forms on the inside a conical ring surface 20 directed inwards and downwards. The upper part of clamping sleeve 2 ′″ is positively guided on the spindle and can freely move in axial direction between open position B and clamping position A. In this area of the clamping sleeve 2 ′″ magnets 21 ′ are arranged which work together with the clamping ring 12 of the spindle.
A pressure spring 132 is supported at the bottom on the collar 13 ′ of the spindle and at the top on the clamping sleeve 2 ″′. The spring is designed in such a way that it can push the clamping sleeve 2 ′ as far as clamping position A. The required clamping force for the underwound threads is mainly provided by the magnet 21 ′.
FIG. 10 a shows the device in clamping position A. During standstill of the spindles and at relatively low spindle speeds (below 5000/min), the balls 134 serving as centrifugal elements are not capable of opening the clamping cleft C, i.e. cannot overcome the adhesive force provided by the magnets 21 ′ and the force of pressure spring 132 . During the spinning process, at speeds above approx. 5000/min. the balls 134 can, assisted by the inherent weight of the clamping sleeve 2 ′″, firstly by overcoming the adhesive force of the magnets 21 ′ and against the action of the rather small spring 132 , move downwards. Clamping cleft C opens and clamping sleeve 2 ′″ assumes the open position B as shown in FIG. 10 b.
After having finished bobbin 5 , ring rail 3 is lowered into the underwinding position and the speed of spindles 1 is reduced to approx. 2000/min. At around this low speed the centrifugal force of the balls 134 can still safely overcome the low force of the pressure spring 132 and can reliably keep the clamping cleft C open. At this speed the underwinding yarn can be produced in a manner limited to less than 360°.
This low speed also makes it possible to further slow down the spindle and the delivery speed of the drafting system in an appropriate time almost synchronously to zero; without increasing the underwinding yarn to an unacceptable extent.
Due to the decreasing centrifugal forces of the balls 134 , the spring 132 can guide the clamping sleeve 2 ″′ into clamping position A again. When the clamping cleft is closing, the magnet 21 ′ generates the main portion of the clamping force needed for an error-free cop change.
The magnets 21 ′ should be e.g. designed in such a way that the holding force exerted by them at almost closed clamping cleft C is higher than the difference of the pressure force of the spring elements 132 between open position B and clamping position A.
FIG. 11 shows a clamping device built according to the principle of FIGS. 10 a and 10 b in a view analogue to FIG. 1 .
Instead of the springs 132 a single spring 132 ′ takes over the movement of the clamping sleeve 2 ″″ into clamping position A. The simple construction design of clamping sleeve 2 ″″ and the hidden actuating elements, consisting of collar 13 ′, ball-shaped centrifugal elements 134 , ring surface 20 and the spring 132 ″, can be clearly seen.
LIST OF REFERENCE NUMERALS
1 Spindle
10 Spindle axle
11 Underwinding crown
12 Clamping ring
13 , 13 ′, 13 ″ Collar
131 Spring element
132 , 132 ′ Spring/spring element
134 Ball/centrifugal element
135 Ball guide
14 Wharve
15 Underwinding zone
16 Shaft
17 Spring push button
171 Ball
172 Spring
18 Actuating bus
181 Angular surface
2 , 2 ′, 2 ″, 2 ′″, 2 ″″ Clamping sleeve
20 Ring area, conical
21 , 21 ′ Magnets
22 Radially protruding means
221 , 221 ′ Collar
222 Ball
2221 Angular surface
2222 Angular surface
23 Annular spring
24 Bore
25 Groove
251 Leaf spring
2511 Angular surface
2512 Angular surface
2513 Vertex
26 O-ring
261 Hoop
27 Fixing groove (open position)
28 Fixing groove (clamping position)
29 Centrifugal elements
3 Ring rail
31 Spin ring
32 Traveller
4 Actuating device
40 , 40 ′ Holding ring
41 Actuating element
41 ′ Actuating element, sleeve
411 Spring
412 , 412 ′ Angular surface
413 , 413 ′ Angular surface
414 Vertex
42 Actuating element
421 Bore
422 Ball
423 Annular spring
43 , 43 ′ Actuating element
431 , 431 ′ Collar, inner side
5 Cop
51 Tube
52 First layer
6 Yarn
61 Underwinding
A Clamping position
B Open position
C Clamping cleft
N North pole
S South pole
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The invention relates to a thread clamping device for lower winding threads on spindles of a ring spinning frame or ring twisting frame. A clamping sleeve is provided between a clamping ring and a radially protruding flange on the spindle which can be axially displaced between a clamping position, which is defined by the position on the clamping ring, and an open position. The clamping sleeve is associated with an actuation device for the axial displacement thereof, which co-operates with radially extending means on the clamping sleeve. The clamping sleeves are associated with elements for fixing the position thereof at least in the clamping position. The aim of the invention is to introduce lower windings into the clamping gap and to improve the removal thereof from the clamping gap. As a result, the actuation elements and/or the radially protruding means are maintained on the clamping sleeve in a radially, elastically touching manner in relation to each spindle axis and are provided with rising sloping surfaces which are radially effective in both relative directions of movement.
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RELATED APPLICATIONS
This Application claims priority from co-pending U.S. Provisional Application Ser. No. 60/511,672 filed Oct. 17, 2003, the contents of which are incorporated herein by reference.
FIELD
The present disclosure teaches techniques related to an architecture for efficiently delivering compressed test data to a circuit and to receive compressed results from the testing.
BACKGROUND
1. References
The following papers provide useful background information, for which they are incorporated herein by reference in their entirety, and are selectively referred to in the remainder of this disclosure by their accompanying reference symbols in square brackets (i.e., [JaS'03] for the paper by A. Jas et al):
[ITRS'01] International technology roadmap for semiconductors, 2001 edition (http://public.itrs.net)
[TestKompress] TestKompress, Mentor Graphics, http://www.mentor.com
[SoCBIST] SoCBIST, Synopsys, http://www.synopsys.com
[VirtualScan] VirtualScan, SynTest, http://www.syntest.com
[Jas'03] A. Jas, J. Ghosh-Dastidar, Mom-Eng Ng, N. A. Touba, “An efficient test vector compression scheme using selective Huffman coding”, in IEEE Trans. Computer-Aided Design, Vol. 22, No. 6, June 2003
[Jas'98] A. Jas, N. A. Touba, “Test vector decompression via cyclical scan chains and its application to testing core-based designs”, in Proc. International Test Conference, pp. 458-464, 1998
[Chandra'03] A. Chandra, K. Chakrabarty, “Test data compression and test resource partitioning for system-on-a-chip using frequency-directed run-length codes”, in IEEE Trans. on Computers, Vol. 52, No. 8, August 2003
[Chandra'01] A. Chandra, K. Chakrabarty, “System-on-a-chip test compression and decompression architectures based on golomb codes”, in IEEE Trans. Computer-Aided Design, Vol. 20, pp. 355-368, March 2001
[Chandra'02] A. Chandra, K. Chakrabarty, “Test data compression and decompression based on internal scan chains and Golomb coding”, in IEEE Trans. Computer-Aided Design, Vol. 21, pp. 715-722, June 2002
[Golomb'66] S. W. Golomb, “Run-length encoding,” in IEEE Trans. Inform. Theory, vol. IT-12, pp. 399-401, December 1966
[Huff'52] D. A. Huffman, “A Method for the construction of mini-mum redundancy codes”, in Proc. IRE, vol. 40, 1952, pp. 1098-1101.
[Wolff'02] F. G. Wolff, C. Papachristou, “Multiscan-based test compression and hardware decompression using LZ77”, in Proc. International Test Conference, pp. 331-339, 2002
[Li'03] L. Li, K. Chakrabarty, “Test data compression using dictionaries with fixed length indices”, in Proc. VLSI Test Symposium, pp. 219-224, 2003
[Koenemann'91] B. Koenemann, “LFSR-coded test patterns for scan designs”, in Proc. European Test Conference, pp. 237-242, 1991
[Rajski'02] J. Rajski, M. Kassab, N. Mukherjee, R. Thompson, K. Tsai, A. Hertwig, N. Tamarapalli, G. Mrugalski, G. Eide, J. Qian, “Embedded deterministic test for low cost manufacturing test”, in Proc. International Test Conference, pp. 301-310, 2002
[Rajski'03] G. Mrugalski, J. Rajski, J. Tyszer, “High speed ring generators and compactors of test data”, in Proc. IEEE VLSI Test Symposium, pp. 57-62, 2003
[Rajski'00] J. Rajski, N. Tamarapalli, J. Tyszer, “Automated synthesis of phase shifters for built-in self-test applications”, in IEEE Trans. on Computer-Aided Design, Vol. 19, pp. 1175-1188, October 2000
[Krishna'98] C. Krishna, A. Jas, N. A. Touba, “Test vector encoding using partial LFSR reseeding”, in Proc. International Test Conference, pp. 885-893, 2001
[Rajski'98] J. Rajski, J. Tyszer, N. Zacharia, “Test data decompression for multiple scan designs with boundary scan”, in IEEE Trans. on Computers, Vol. 47, pp. 1188-1200, 1998
[Wohl'03] P. Wohl, J. A. Waicukauski, S. Patel, M. B. Amin, “Efficient compression and application of deterministic patterns in a Logic BIST architecture”, in Proc. Design Automation Conference, pp. 566-569, 2003
[Balakrishnan'03] K. J. Balakrishnan, N. A. Touba, “Deterministic test vector decompression in software using linear operations”, in Proc. VLSI Test Symposium, pp. 225-231, 2003
[Chak'93] S. T. Chakradhar, V. D. Agrawal and S. G. Roth-Weiler, “A transitive closure algorithm for test generation”, IEEE Transactions on Computer-Aided Design of Integrated Circuits and Systems, Vol. 12, No. 7, pp. 1015-1028, July 1993.
[Hwang'02] S. Hwang, J. A. Abraham, “Optimal BIST using an embedded microprocessor”, in Proc. International Test Conference, pp. 736-745, 2002
[Miron] M. Abramovici, M. A. Breuer, A. D. Friedman, Digital systems testing and testable design, Computer science press, New York, N.Y. 10010
[Xtensa] Xtensa microprocessor, Tensilica Inc. (http://www.tensilica.com)
[ARC] ARCtangent processor, Arc International (http://www.arc.com)
2. Overview
Test cost per chip is increasing and threatens the ability to cost-effectively design and manufacture larger and larger ICs [ITRS'01]. A major percentage of the test cost comes from the capital required for the automatic test equipment (ATE). Different approaches for reducing ATE cost have been explored, which include
Lowering the time spent by the ATE per chip by reducing the test application time. Avoiding reloading of the ATE memory by decreasing the test set size Exploiting support from on-chip test HW and using inexpensive ATE Storing compressed data in the ATE memory that can be de-compressed on-chip before application.
The last approach, also referred to as test data compression, has matured in recent years, and is a useful technique for reducing rising test costs, and the explosion in the volume of data that has to be transported between the ATE and the chip under test. In test data compression, test patterns are compressed offline (during test generation) and the compressed data is stored on the tester. The tester applies this data to the chip under test and on-chip decompression hardware helps to recover the original test patterns from the compressed data.
For test responses, on-chip circuitry compresses the patterns, and the compressed response data is sent to the tester, which compares the compressed responses with the golden (correct) responses. Existing work in the field of test data compression [Jas'03, Jas'98, Chandra'01, Chandra'03, Wolff'02, Li'03, Rajski'02] explores the use of different compression/decompression algorithms and techniques to reduce test set size and test application time for a given circuit. Commercial tools that are capable of providing a test compression solution for a wide range of circuits include: Embedded Deterministic Test or Test-Kompress™ [TestKompress], SoCBIST™ [SoCBIST], and VirtualScan™ [VirtualScan].
Several approaches for compressing test data [Jas'98, Jas'03, Chandra'01, Chandra'02, Chandra'03, Wolff'02, Li'03] are based on existing compression schemes (statistical encoding, dictionary based methods, etc). Test data compression based on statistical encoding techniques like Huffman, Golomb and run-length encoding are presented in [Jas'03, Chandra'03, Chandra'02, Chandra'01, Jas'98]. While huffman coding encodes fixed length words in test data into variable length code words, run-length coding encodes variable length words into fixed length code words. Golomb coding encodes a variable length word to a variable length code word. The extent of compression that can be achieved using the above-mentioned statistical techniques also depends on the distribution of fixed/variable length words in the test data. Input data statistics play an important role in deciding the compression ratio.
Compression ratio can be improved by increasing the frequency of occurrence of selected words is by using a cyclical scan register [Jas'98]. But a major drawback with the above approach is the need for the cyclical scan register to be as long as the scan chain itself. Hence, there is a 100% hardware overhead in terms of the number of memory elements. The use of boundary scan or scan chains in other cores, not under test, as cyclical scan register reduces the hardware overhead [Jas'98]. But, this may involve significant routing overhead. Moreover, existence of boundary scan or scan chains in other cores matching the length of each scan chain in a given core is not guaranteed.
Techniques have been proposed in [Chandra'01, Chandra'02, Chandra'03] where the test difference vector is evaluated with respect to the circuit response and is compressed using golomb codes. Although, this results in a lower hardware overhead, they require an additional feedback to the ATE during decompression.
Dictionary-based test compression schemes were presented in [Wolff'02, Li'03]. These methods select strings of symbols to create a dictionary, and then encode them into equal-size code words using the dictionary. The dictionary stores the strings, and it may be either static or dynamic. The compression algorithm LZ77 is based on a dynamic dictionary and uses part of the previously seen input stream (window) as dictionary [Wolff'02]. In general, increasing the window size increases the compression ratio, which in turn implies the need for increased memory re-sources. An important step in constructing the static dictionary is to select the entries in the dictionary. This involves identifying “compatible” words that can be represented with the same dictionary entry. This is similar to the clique-partitioning problem [Li'03]. The words are mapped to the nodes of the graph and two nodes are connected if the corresponding words are “compatible”.
Other methods [Rajski'98, Krishna'98, Wohl'02] for com-pressing test data use a linear feedback shift register (LFSR) to encode multiple test patterns into a single LFSR seed. In order to avoid any reduction in fault coverage, very large sized LFSR's (256-400 bits) [Wohl'02] are used to encode the test vectors of moderately sized circuits. Another approach called embedded deterministic test (EDT) [Rajski'02] obtains spatial compression by using a modified LFSR followed by a phase shifter. The phase shifter enables the use of a reasonable sized LFSR (24-32 bits) to feed a large number of scan chains. All the above techniques exploit the fact that the test cubes frequently feature a large number of unspecified positions. Hence, the compression scheme interacts with the ATPG algorithm to maximize compression. Recent work [Hwang'02] explores the use of an embedded microprocessor for executing the linear operations of a LFSR. The decompression speed is further improved by using “word-based” linear operations in the software implementations of the LFSR, which expands the compressed test data into the corresponding deterministic test vectors [Balakrishnan'03].
Related technologies for test data compression do not best exploit the hierarchical structure of modern integrated circuits, or Systems-on-chip (System LSI). For example, related technologies do not re-use the hardware for test decompression across different on-chip components or cores. Further, they do not allow for a composition of multiple, different compression algorithms for a single circuit. Finally, current test compression technologies do not provide a solution that is truly scalable across the needs of a wide range of circuits.
SUMMARY
It will be significantly advantageous to overcome problems noted above. There is provided an integrated circuit comprising at least one system level decompressor and at least a first hardware block associated with a core level decompressor. The system level decompressor is capable of performing system level decompression of received compressed test data to form partially decompressed test data. The core level decompressor being capable of performing core level decompression of the partially decompressed test data.
In a specific enhancement, the integrated circuit comprised a second hardware block, wherein a core level decompression for the first hardware block is based on a scheme different from a core level decompression for the second hardware block.
In another specific enhancement a subset of core level decompression is implemented in hardware.
In another specific enhancement, a subset of core level decompression is implemented in software.
In another specific enhancement a subset of system level decompression is implemented in hardware.
In another specific enhancement, a subset of system level decompression is implemented in software.
In still another specific enhancement, a subset of system level decompression is performed off-chip.
In still another specific enhancement, the circuit further comprises a communication circuit that enables communication between the system level decompressor and first hardware block.
In still another specific enhancement, the circuit further comprises a specialized test access mechanism for test data.
More specifically, the test access mechanism is a test bus.
More specifically, a processor used to perform core level decompression is enhanced to comprise at least one custom instruction adapted to accelerate a software implementation of the core level decompression.
More specifically, a processor used to perform system level decompression is enhanced to comprise at least one custom instruction adapted to accelerate a software implementation of the core level decompression.
In yet another specific enhancement, the circuit further comprises, at least one memory wherein test data is stored in the said memory.
In still another specific enhancement, decompression is performed by a parallel operation on multiple processors.
In another specific enhancement, core level decompression for the first hardware block is performed in parallel with core level decompression for a second hardware block.
In another specific enhancement, system level decompression and core level decompression are performed in a pipelined manner.
Another aspect of the disclosed teachings is a method of testing comprising loading compressed data from a tester to an integrated circuit. A system level decompression is performed on the compressed data to form a partially decompressed data. The partially decompressed data is transmitted through a communication circuit to at least a first hardware block. Core level decompression is performed on the partially compressed data to generate uncompressed data. Testing is performed using the uncompressed data.
Still another aspect of the disclosed teachings is a method of performing testing comprising receiving results of applying test vectors to at least a first hardware block in an integrated circuit. Core level compression of the results is performed at the hardware block to form partially compressed results. The partially compressed results are transmitted through a communication circuit. System level compression is performed on the partially compressed results.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosed teachings will become more apparent by describing in detail examples and embodiments thereof with reference to the attached drawings in which:
FIG. 1 is an exemplary implementation of a test architecture embodying some aspects of the disclosed teachings.
FIG. 2 provides a comparison of two-level compression schemes for different example scan configurations.
FIG. 3 provides additional comparative data for a single level and two-level compression schemes.
FIG. 4 shows a pipelined implementation of a multi-level decompression scheme.
FIG. 5 shows Table 1 depicting comparative test data volume statistics for an SOC with a homogenous and heterogeneous compression schemes.
FIG. 6 shows Table 2 depicting hardware overhead and processor cycles for different HW/SW partitioning choices.
FIG. 7 shows Table 3 depicting improvement in test application time using customized instructions.
DETAILED DESCRIPTION
Synopsis and Advantages
This disclosure teaches a general-purpose system-level architecture to support the delivery of compressed test data to different components in a complex heterogeneous integrated circuit, for example a system-on-chip (SOC). It should be noted that some of the examples discuss an SOC. However, the techniques are valid for any integrated circuit. This architecture is general enough to support any compression scheme used today for a given core or component, or any new compression scheme that will be developed in the future. The following attributes are desirable for any such architecture:
FLEXIBILITY: Since different components of complex chips may have different test strategies or compression strategies, it should be flexible enough to support a wide range of test compression schemes.
HARDWARE REUSE: The hardware overheads of test data decompression can be significant, especially in SOCs with a large number of cores, and when strong or “heavy-duty” compression algorithms are used in order to obtain a high level of compression. It is desirable to reuse the SOC's constituent components for the purpose of compressed test data delivery, whenever possible.
HIGH COMPRESSION RATIOS: The hardware architecture should facilitate the use of compression schemes that obtain high compression ratios. It is desirable that the compression scheme be customized to the requirements of each core.
LOW TEST APPLICATION TIME (TAT): While the use of test data compression in itself results in an improvement in test application time, the speed with which data can be decompressed and delivered to each component on-chip can significantly affect the extent of TAT savings.
AT-SPEED TEST APPLICATION: SOCs fabricated in current and future technologies will require at-speed testing in order to detect speed related defects. It is desirable that the test compression architecture allows for at-speed delivery of test patterns to each component of the chip.
SCALABILITY: A general-purpose test architecture is used in a wide range of ICs, with vastly varying constraints such as cost and performance. It is desirable that any system-level test architecture allows for tradeoffs between hardware overhead and other metrics such as compression ratio or test application time.
The disclosed architecture addresses aspects of the above requirements by exploiting the fact that modern SOCs contain a significant amount of mission logic that can serve fairly general-purpose functions, and hence, can be adapted for test decompression and delivery. For example, SOCs contain programmable processors, which are general purpose computing platforms, and can hence be used for performing any computation such as test decompression.
Similarly, the on-chip communication architecture (buses or interconnect networks) forms a general-purpose interconnection fabric, which can be exploited to transport test data between components on chip. The system memory offers a re-usable medium for storage or buffering of compressed and decompressed test data.
A wide range of test decompression schemes can be efficiently implemented with the help of on-chip programmable processors. Further, communication architecture interfaces (e.g., bus interfaces) of different components can be enhanced to act as a specialized test wrapper that implements decompression-specific functionality. The flexibility of the proposed architecture can be exploited in several ways to benefit test decompression and delivery:
High compression ratios can be obtained by
Using a component-specific compression scheme without excessive hardware overhead. For example, some cores may use an ATPG-assisted compression technique such as embedded deterministic test (EDT), while other cores may have pre-defined test sets, which are compressed using a data coding based approach such as Huffman encoding. It should be noted that a core is a hardware block within the integrated circuit. Using “high-effort” or “heavy-duty” compression schemes sometimes require prohibitive overheads if decompression is implemented in hardware. However, these schemes are implemented at virtually no cost when on-chip programmable processors are used for de-compression. For example, feasibility of using high-quality compression schemes such as LZ77 for test data decompression is discussed. Using multi-level or hierarchical compression schemes. The decompressor that directly feeds test data (e.g., scan patterns) to the component under test needs to have a simple timing interface and output data at a fairly constant rate in order to avoid the use of complex clock or data control and handshaking circuitry. While various test compression schemes that have been proposed in the past satisfy this requirement, in doing so they leave significant compression opportunities “on the table”. Use of a two-level decompression scheme, wherein a first level of “heavy-duty” general-purpose de-compression is performed, followed by a second level of test decompression which is able to “stream” data to the on-chip components at the desired constant rate, results in significantly higher compression efficiency.
Test application time can be improved in the proposed architecture by
Partitioning the compression functionality between the programmable processor and the test wrapper of each component. This affects both the “computation” time required to execute the decompression algorithm, and the on-chip communication time required to transport data from the processor to the component under test. Customizing the processor to more efficiently perform decompression. The customizations could include enhancing the instruction set to add custom instructions that implement computation-intensive steps of the decompression algorithm, or a separate co-processor that per-forms decompression.
The proposed architecture using components from various industrial designs, as well as the ISCAS89 bench-marks are evaluated. Various experiments have been performed to demonstrate the benefits of the proposed architecture in test data volume reduction, hardware overhead, and test application time.
Examples Illustrating Concepts Underlying the Disclosed Teachings
FIG. 1 shows an exemplary architecture that embodies aspects of the disclosed teachings. In order to maximize the compression of test vectors for any of the IP cores 1 - 4 , the architecture exploits a two-level test compression scheme. At the core level, the compression schemes for some IP cores may be predefined (e.g., IP cores 1 and 2 in the figure), while other IP cores may be associated with predefined test sets or allow for the definition of a suitable compression scheme (e.g., IP cores 3 and 4 in the figure). Both statistical encoding techniques (Huffman, run-length, Golomb) and LFSR based schemes (EDT, D-BIST) are suitable at this level. In Section IV.B.1, it will be seen that the diverse test characteristics of the different IP cores warrant the use of heterogeneous compression schemes at the core level.
Further compression can be achieved on top of the core-level compression schemes by using a second level of compression. As discussed further below, the use of strong compression schemes such as LZ77 at the system level will result in higher compression ratios for several IP cores. In addition, exploiting the on-chip processor and system memory for decompression will allow for the efficient deployment of the SW implementations of system-level de-compression schemes that are otherwise hard to implement in hardware. System-level decompression can also be used to implement de-compression functionality that is reused across several cores.
For example, schemes such as D-BIST require the use of PRPGs that are 250-500 bits long, along with equally long shadow registers. In such a case, the system-level compression scheme can efficiently implement the PRPG functionality used across several cores resulting in significant hardware savings (e.g., IP core 3 has the decompression functionality completely implemented in SW while IP core 4 shows partitioning of decompression functionality). The trade-offs associated with the partitioning of test decompression functionalities are discussed studied in Section IV.B.3.
From a test application time standpoint, the on-chip programmable processor used to perform system-level decompression can be enhanced using special custom instructions that accelerate the SW implementations of the system level decompression schemes. This is shown in the figure, wherein both the PRPG functionality and LZW decompression programs are instrumented to directly use specialized custom instructions. These customizations are discussed further in Section IV.B.4.
Before proceeding to study the various aspects of the system-level decompression architecture, the experimental setup used is described. It should be noted that the experimental setup is merely illustrative and is used to demonstrate the efficacy of the disclosed teachings.
System-level benchmarks: The example SOCs considered in the experiments consisted of an Xtensa processor from Tensilica, system memory and various cores (ISCAS'89 benchmarks as well as industrial designs). The Xtensa processor is a five-pipeline stage, embedded RISC processor. Full scan versions of each core were considered, with single or multiple scan chains inside them.
Test generation and compression: The test vectors for the cores were generated using the ATPG tool TRAN [Chak'93]. Dynamic compaction was turned “on” during test vector generation in order to obtain a minimum sized test set and to get a realistic evaluation of the compression algorithms. The main compression schemes used in this work are Huffman, EDT and LZ77. C implementations of Huffman and LZ77 schemes were used to generate the corresponding compressed test vectors. Compressed test vectors in the case of EDT have to be generated during ATPG itself.
Test generation in [Rajski'02] proceeds by iterating through the following steps (a) using combinational ATPG to determine the test vector values in the different scan chain flip-flops and circuit primary inputs, (b) using a linear solver to determine the vectors at the inputs of the EDT decompression hardware (injectors) corresponding to the values in (a). An alternative methodology is used to generate the compressed test vectors in EDT. The EDT decompression hardware (ring generator+phase shifter) is unrolled as many times as the maximum length of scan chains in a given core.
This allows establishment of a relationship between the output of each flip-flop and inputs (injectors) to the ring generator over different time-frames. This association is converted into a set of XOR gates. Hence, the new input list of this modified circuit consists of the inputs to the ring generator over as many time-frames as the maximum length of scan chains in the given circuit. The regular inputs in the given circuit are also assumed to be part of a scan chain. Since all circuits considered are full-scan, the input to each flip-flop is converted into a primary output. Hence, the modified circuit does not contain any sequential elements. Combinational test generation plus dynamic compaction is now performed on the modified circuit to obtain the compressed test vectors.
Decompression: C implementations of the Huffman, LZ77 and EDT decompression algorithms were designed. In addition, Verilog RTL implementations of Huffman [Jas'03] and EDT de-compression schemes were also developed. The hardware overhead of the decompression hardware is obtained by synthesizing it using the SYNOPSYS design compiler. The libraries used for synthesis are standard.sidb and gtech.db.
Simulation: The binary memory image of the test program performing system-level decompression and test vector delivery was generated by first cross-compiling the C implementation of the algorithm using Xtensa's cross-compilation flow. RTL simulation of the processor, bus and the bus interfaces of different cores enhanced with core-specific decompression hardware with the binary memory image loaded into the system memory was performed using the simulator MODELSIM.
Processor Customization: The Xtensa processor, being an extensible processor, allows for augmentation of its basic instruction set with custom instructions. The customized instructions, used to reduce the test application time and hardware overhead, are written in Tensilica Instruction Extension (TIE) language and instrumented in the C descriptions of the decompression SW. The Xtensa instruction set simulator is used to evaluate the speedup achieved from using custom instructions. The RTL description of the customized processor is generated using the Xtensa processor generator.
1. Heterogeneous Compression
Different IP cores on a SOC have different test requirements. Some cores are associated with predefined test sets. ATPG-assisted compression schemes like EDT do not yield good compression ratios for such predefined test sets. This is due to the inherent correlation in the output vector/vectors of a LFSR. Also, compression ratios vary for a given compression scheme based on the distribution of user-defined symbols/words in the test sets of different cores. Hence, for a given SOC, selecting core specific compression schemes can maximize the net compression ratio. The following example illustrates this concept.
Example 1: Consider an example SOC with 5 different cores. The cores (s13207, s15850, s35932, s38417, s38584) are taken from the ISCAS'89 benchmark suite. In order to model the fact that IP cores are associated with pre-existing test sets, it is assumed that test sets for the cores s15850 and s38417 are predefined. Three different compression schemes (Huffman, EDT and LZ77) are used and the effectiveness of choosing a single compression scheme for all the IP cores is evaluated. Table 1, shown in FIG. 5 , reports the results, wherein the column labeled “original # of bits” indicates the distribution of uncompressed test data volume for all the five cores. When Huffman and LZ77 compression algorithms are employed for all the cores, significant compression is achieved overall (41% and 55%, respectively). If EDT is the compression algorithm of choice for all the cores, the test sets for all the cores except s15850 and s38417 can be compressed (EDT is ATPG-assisted), resulting in 53% net compression. Table 1 reports the test data volume statistics for the individual cores in the different cases and highlights the best case compression scheme for each core. Clearly, the highest net compression can be obtained by choosing a heterogeneous compression scheme, wherein the best compression scheme is chosen for each core (LZ77 for cores s15850, s35932 and s38417, and, EDT for cores s13207 and s38584) resulting in 72% compression.
2. Multi-Level Test Compression
In this section, use of a combination of system-level and core-level compression schemes that enable the generation of highly compressed test data is discussed. How such a multi-level decompression can be efficiently performed on an SOC is also discussed.
a) Achieving Better Compression
Conventional test data compression schemes [Rajski'02, Jas'03, Chandra'03] do not fully exploit the opportunities for compression. A large percentage of the test data of a given circuit comprises of unspecified\don't care bits [Rajski'02]. These bits can be set in such a way so that the compression ratio is maximized [Jas'03]. The compressed data still contains a large number of repeated codes and hence further compression can be achieved by using a second level “heavy-duty” compression scheme like LZW, LZ77 etc. These compression schemes are referred to as “heavy-duty” because the compression and decompression stages require significant memory resources to maximize compression. Both LZW and LZ77 are dictionary-based compression schemes and bigger dictionaries lead to comparable or higher compression ratios. For example, gzip, which uses a variant of the LZ77 compression scheme, uses a 258 byte long window buffer and a 32 KB long lookahead buffer for compression and decompression. Using a hardware implementation of the “heavy-duty” decompression algorithms for each core in the SOC would result in an unrealistic hardware overhead.
By exploiting the on-chip processor and the system memory, the disclosed architecture (for example, FIG. 1 ) naturally supports such a multi-level decompression scheme. The “heavy-duty” decompression scheme can be efficiently implemented in software on the processor while the core-level decompression schemes like EDT, Huffman etc. can be implemented in hardware and integrated with the test wrapper. Such a multi-level compression/decompression scheme leads to higher compression ratios compared to single core-specific compression schemes. Also, the hardware overhead is comparable or marginally greater than the other approaches.
Example 2: FIG. 2 shows the test set size for a particular core (s13207) before and after compression for different multi-level compression strategies and for different scan chain configurations. The first-level or local compression schemes are core-specific (EDT or Huffman). The second-level or “heavy-duty” decompression scheme is based on the LZ77 compression/decompression algorithm. The straight lines in FIG. 2 represent the sizes of the uncompressed test set, test set compressed using Huffman encoding alone and test set compressed using Huffman encoding followed by LZ77 compression scheme. Huffman encoding and the two-level Huffman−LZ77 compression schemes give the same compression ratio for different scan chain configurations as the compression is performed for a fixed test set obtained by performing test generation on the given full scan circuit. Huffman+LZ77 compression scheme yields a compression ratio of 78% as compared to the 57% compression ratio obtained using Huffman encoding alone. The two curved lines in FIG. 2 represent the size of the compressed test set using EDT and EDT followed by LZ77 compression scheme.
In embedded deterministic test (EDT), longer scan chains imply greater linear dependence in the inputs to a particular scan chain, hence resulting in an increased number of test vectors. This is clearly observed in FIG. 2 , where initially the number of bits obtained by EDT is greater than the uncompressed test set size, but as the number of scan chains is increased, the compression ratio improves. When the number of scan-chains is 4, the compression ratios obtained by using EDT and EDT+LZ77 are around 57% and 78% respectively. If the number of scan chains is increased to 32, then both EDT and EDT+LZ77 compression schemes yield a compression ratio of 92%. For longer scan chain configurations, increasing the number of injectors reduces this dependence but results in lower spatial compression. In this experiment the number of injectors is taken to be ‘1’ for all the scan chain configurations.
Example 3: FIG. 3 presents the compression ratios obtained using the two-level compression schemes for the different cores in Example 1.
b) Decompression and Delivery
Since the test data usually contains long strings of identical bits, the compressed data obtained from the first level compression scheme (EDT or Huffman) also contains strings of identical codes. Dictionary based schemes like LZ77 encode such strings into small dictionary indices. This is also due to the large sizes of sliding buffer and lookahead buffer. During the second-level or “heavy-duty” decompression, the encoded symbols or indices get decoded into a large number symbols or input bits to the first-level or “core-specific” decompression scheme. These are decoded serially and fed to the scan chains.
This scenario presents an opportunity for pipelining the decompression scheme on the processor and the decompression schemes on different cores. FIG. 4 shows such a case where decompression on the processor is almost three times as fast as decompression on cores 1 , 2 and 3 . Hence, by the time a core finishes decoding the input symbols, feeding the scan-chains and compacting the test responses, the processor can decode the input from the system memory for two other cores.
3. Flexible Partitioning
A variety of options are available for implementing the multi-level decompression scheme. The “heavy-duty” decompression is implemented in software using the embedded processor, as other-wise a hardware implementation will require unreasonable memory and computational resources. However, the core-level decompression algorithms can be either implemented in HW/SW. Furthermore, the decompression functionality can be partitioned between the processor (SW) and the test wrapper (HW). For example, in the case of DBIST [Wolff'02], the LFSR can be either implemented in hardware or in software. On the other hand, in the case of EDT, either both the ring generator and the phase shifter can be implemented in HW/SW or the ring generator can be implemented in hardware and the phase shifter can be implemented in software.
The choice of partitioning of the decompression functionality decides the workload of processor and test wrapper as well as the communication requirements between the processor and the test wrapper. Hence, the hardware overhead for decompression and the test application time depends on the decompression algorithm and the choice of partitioning. Hence, for each core, a different partitioning scheme may be optimal depending on the circuit statistics and the decompression algorithm.
Example 4: Table 2 (shown in FIG. 6 ) shows the hardware overhead and the number of processor cycles taken by the decompression algorithm for different partitioning (or implementation) choices of the algorithm on an example core (s5378). The results depicted represent the EDT decompression scheme. The hardware overheads for different cases were obtained by synthesizing the test wrapper (HW part of the decompression algorithm) using the Synopsys generic libraries (standard.sldb, gtech.db) and the processor cycles were obtained from RTL simulation (using Modelsim's simulation tool) of the processor along with the test wrapper.
Three different configurations are considered. In case I, both the ring generator and phase shifter are implemented in HW. In case II, the ring generator is implemented in SW whereas the phase shifter is implemented in hardware. Finally, Case III has SW implementations for the ring generator and phase shifter.
The performances of the three cases are analyzed below.
In case I, the processor needs to transfer only the ring generator inputs to the core's test wrapper. In case II, for each single bit input to the processor, the entire LFSR state needs to be transmitted from the processor to the test wrapper. Hence, the communication period per input bit to the ring generator increases. On the other hand, the hardware overhead comes down as the LFSR is efficiently implemented in SW using custom bit-level instructions, as explained in the next section. The HW overhead reported includes the additional overhead required for the custom instruction. In case III, the communication period increases compared to case II provided the size of the phase shifter is bigger than the length of ring generator. In this case the size of the phase shifter is comparable to that of the ring generator. Hence, the test application times, for both cases, are comparable. However, there is a reduction in the hardware overhead as the XOR operations are efficiently integrated with the custom instructions used in case II.
The above example illustrates the tradeoffs between test application time and hardware overheads for the EDT decompression scheme. Moving the functionality to the embedded microprocessor increases the test application time but decreases the hardware over-head. Hence, the partitioning of the decompression functionality should be done based on the limits of hardware overhead and test application time for each core and the entire SOC.
4. Processor Customization
Programmable processor may be quite inefficient in performing some decompression algorithms. For example, EDT [Rajski'02] and DBIST [Wolff'02] have a large number of bit-level operations, which can be performed much faster on application specific hard-ware than on a programmable processor. However, modern processors (Xtensa from Tensilica [Xtensa] and ARCtangent from ARC [ARC]) often feature the option to customize the processor by adding application specific instructions, or coprocessor units, to efficiently perform selected computations. A large number of compression schemes [Koenemann'91, Rajski'02, Wolff'02] use LFSRs for test vector decompression.
In the example implementations discussed herein, a regular C implementation of a 64-bit LFSR is used. A custom instruction is introduced to improve its performance. Using the custom instruction does not change the functionality of the decompression algorithm. Custom instructions are defined using the Ten-silica Instruction Extension (TIE) language. The user-register semantics is used to map a user-defined state to a user-register file. The registers can be as wide as 32 bits. Hence, the new state of the LFSR can be obtained by doing some bit manipulations on the initial state of the LFSR and the coefficient vector, defined by the positions of the XOR taps (or the characteristic polynomial). Note that the custom instruction can handle any 64 bit LFSR. Since the coefficient vector (or primitive polynomial) and the initial state are inputs to the customized instruction, the same instruction can be used for different cores using LFSRs based on different primitive polynomials.
Table 3 (shown if FIG. 7 ) shows the improvement in test application time achieved due to the introduction of custom instructions. The results were obtained using the Xtensa instruction set simulator. Each of the LFSR implementations was simulated for 20 successive LFSR states. The LZW decompression algorithm was simulated using the compressed test set of the ISCAS benchmark s9234. As the size of the LFSR is increased, the time taken by the regular C implementation of the LFSR increases. In fact, when the size of the LFSR is increased from 32-bit to 64-bit, the time taken by the regular implementation doubles. On the other hand, the time taken by the implementation using customized instructions remains the same for all the three cases. This clearly indicates the improvement that can be achieved in test application time by using instructions tailored to the decompression algorithm.
Other modifications and variations to the invention will be apparent to those skilled in the art from the foregoing disclosure and teachings. Thus, while only certain embodiments of the invention have been specifically described herein, it will be apparent that numerous modifications may be made thereto without departing from the spirit and scope of the invention.
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An integrated circuit comprising at least one system level decompressor and at least a first hardware block associated with a core level decompressor. The system level decompressor is capable of performing system level decompression of received compressed test data to form partially decompressed test data. The core level decompressor being capable of performing core level decompression of the partially decompressed test data.
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FIELD OF THE INVENTION
The present invention relates to authenticating a series of images on a receiver such as a series of postal stamps.
BACKGROUND OF THE INVENTION
Heretofore images of high quality have been produced by thermal printers. In a typical thermal printer an image is formed in three passes. First a dye donor having color such as yellow is placed in dye transfer relationship with a receiver and then the dye donor is heated in a pattern corresponding to the yellow portion of an image to be completed. Thereafter, cyan and magenta portions of the image are formed in a similar fashion. The completed color image on the receiver is continuous tone and in many cases can rival photographic quality.
In one type of thermal printer which prints colored images, a donor contains a repeating series of spaced frames of different colored heat transferable dyes. The donor is disposed between a receiver, such as coated paper, and a print head formed of, for example, a plurality of individual heating resistors. When a particular heating resistor is energized, it produces heat and causes dye from the donor to transfer to the receiver. The density or darkness of the printed color dye is a function of the energy delivered from the heating element to the donor.
Thermal dye transfer printers offer the advantage of true "continuous tone" dye density transfer. This result is obtained by varying the energy applied to each heating element, yielding a variable dye density image pixel in the receiver.
Thermally printed images are used in a number of different applications. In one of those applications, so-called "sticker prints" are made on a receiver and arranged so that they can be peeled off and individually pasted onto another surface. However, these stickers are not used in situations which require that they be "authentic". By use of the term "authentic" is meant that the image can indicate to a viewer or a reader with a high degree of certainty that the image has not been counterfeited.
SUMMARY OF THE INVENTION
It is an object of the present invention to authenticate images formed in a receiver.
This object is achieved in a method of forming authentic user viewable images on a receiver to which a series of viewable images such as postal stamps are adapted to be transferred, comprising the steps of:
a) providing a receiver; and
b) forming a series of authentic user viewable marks on the receiver prior to transfer of the series of images onto such receiver.
An advantage of the present invention is that it effectively authenticates images preventing counterfeiting, misuse or fraud.
A feature of the present invention is that authenticating marks are formed in the receiver prior to forming a series of images. The marks are formed which authenticate images and these marks can be in the form of a bar code, an official seal, alphanumeric data or encoded digitized information.
It is an important feature of the present invention that marks are formed which provide marks in the support of an image receiving structure of the receiver. These marks can either be viewable under ambient lighting conditions which can include holograms or not viewable under such conditions. In the latter case, the marks can be formed of fluorescent materials which fluoresce under certain lighting conditions. A further feature of the invention is that the marks can be in the form of silver impregnated threads or magnetic strip material or in an encoded form that requires a device such as a bar code reader to scan the images and decode the authenticating marks. The marks can form water marks.
Another feature of the invention is that the marks can be embossed.
Another feature of the present invention is that it facilitates the design of images to be authenticated such as postage stamps, travelers checks, checks and other types of official documents.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a thermal printing apparatus which makes colorant images on a receiver in accordance with the present invention;
FIG. 2 is an exploded cross-sectional view showing various layers of a receiver in accordance with the present invention;
FIG. 3 shows a series of images and marks which authenticate such images in a receiver of FIG. 2;
FIG. 4 is an exploded view of an embodiment of a receiver in accordance with the present invention;
FIG. 5 is an exploded view of another embodiment of a receiver in accordance with the present invention;
FIG. 6 is a view similar to that of FIG. 5 but showing the use of a magnetic strip which contains authenticating information;
FIG. 7 shows a series of marks which provide water marks in accordance with the present invention; and
FIG. 8 show a series of embossed authenticating marks.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 shows a thermal printer apparatus 10 which employs a receiver 12 and a colorant donor element 14 in the form of a web. Receiver 12, in the form of a sheet is serially fed from a tray 16 to a print position by a conventional sheet feeding mechanism, not shown. As used herein the term "colorant" can include dyes, pigments or inks which can be transferred from the colorant donor element 14 to a receiver 12.
Now referring to FIG. 2, receiver 12 includes an image receiving structure 50 which is formed on a support 56. The support 56 can be formed of paper or plastic such as polyethylene terephthalate or polyethylene napthalate. Alternatively, it can be in the form of a web. In this embodiment an adhesive layer 54 is provided on the back surface of the support 56. A peelable protective release layer 59 is provided over the adhesive layer 54 until it is to be used for securing the image receiving structure 50 to a surface. This type of construction is particularly suitable when a series of images 90 and the authentic user viewable marks 70 need to be peeled apart for use, e.g., postal stamps. The image receiving structure 50 includes in sequence three layers, the support 56, a barrier layer 58 and the colorant receiving layer 60. At the time of manufacture of the colorant receiving layer 60 authentic user viewable marks 70 are formed on the colorant receiving layer 60 which authenticate images to be formed. These marks can be in the form of a bar code, an official seal, alphanumeric data or encoded digitized information. In operation, a platen 18 is moved into print position by an actuator 20 pressing the receiver 12 against the colorant donor element 14. Actuators are well known in the field and can be provided by a mechanical linkage, solenoid, and small piston arrangement or the like. The colorant donor element 14 includes a series of colorant patches (not shown). These colorant patches can be yellow, cyan and magenta and they are sequentially moved into image transferring relationship with the colorant donor element 14. The result of this process are images 90 formed on the receiver 12.
The colorant donor element 14 is driven along a path from a supply roller 24 onto a take-up roller 26 by a drive mechanism 28 coupled to the take-up roller 26. The drive mechanism 28 includes a stepper motor which incrementally advances and stops the colorant donor element 14 relative to the receiver 12.
A control unit 30 having a microcomputer converts digital signals corresponding to the desired image from a computer 32 to analog signals and sends them as appropriate to the optical system 38 which modulates the laser beam produced by a laser light source 34 and focuses the laser light onto the colorant donor element 14. The laser light source 34 illuminates the colorant donor element 14 and heats such colorant donor element 14 to cause the transfer of colorant to the receiving layer 60 of the image receiving structure 50. This process is repeated until an image 90 is formed on each of the image receiving structures 50. During the final pass a protective layer 62 is then formed on the color receiving layer 60. Alternatively, a plurality of dye donor resistive elements (not shown) which are in contact with the colorant donor element 14. When a dye donor resistive elements is energized it is heated which causes dye to transfer from the colorant donor element 14 to the receiver 12 in a pattern to provide the colored image. For a more complete description of this type of thermal printing apparatus reference is made to commonly assigned U.S. Pat. No. RE 33,260.
Turning now to FIG. 3 which shows the output of the printing process which is a series of authentic user viewable marks 70 and an image 90 such as postal stamps. It is desirable that the authentic user viewable marks 70 on the receiver 12 be highly accurate so that they may not be counterfeited. As is well known in the art the receiver 12 in a web form can be run through a gravure process. For that purpose the authentic user viewable marks 70 are created in the receiver 12, when the receiver 12 is in a web form by using a gravure process. The authentic user viewable marks 70 are formed with a high level of detail so that they are difficult to duplicate. The authentic user viewable marks 70 have a high level of detail so that when an image 90 is formed during the thermal printing process, the authentic user viewable marks 70 will be visible indicating to a viewer or reader of the receiver 12 that the images are authentic. The gravure process is capable of creating authentic user viewable marks 70 of very high resolution, well beyond the capabilities of most common printers. The gravure process is an intaglio process. It uses a depressed or sunken surface for the authentic user viewable marks 70. The authentic user viewable marks 70 include cells or welds etched into a copper cylinder and the unetched surface of the cylinder represents the non-printing areas. The cylinder rotates in a bath of ink. Gravure printing is considered excellent for printing highly detailed marks or pictures that create the authentic user viewable marks 70. High cylinder making expense usually limits gravure for long runs. Different types of inks may be used for depositing the authentic user viewable marks 70 by the gravure process as noted later on the receiver 12 which can be used in the thermal printer apparatus 10 of FIG. 1.
At the time of manufacture of the receiver 12 authentic user viewable marks 70 can also be formed on the support 56, as shown in FIG. 4.
The colorants used to form the authentic user viewable marks in the receiver 12 can be inks, dyes or pigments. Inks used in gravure printing are generally solvent based having fluid properties that allow them to fill the wells of the engraved cylinders or plates without spreading outside of these wells, yet are drawn out when contacted by the substrate. The binder solvent used in the formulation is such that the inks dry by evaporation and have good adhesion to the substrate. These inks are well known in the art and are described in detail in the Graphic Arts Manual, Arno Press, Musarts Publishing Corp., New York, N.Y., 1980; specifically in the chapters titled "Inks in Common Use", Theodore Lustig, Sun Chemicals Corp. and Introduction to Printing Inks, Gary G. Winters, Inmont Corporation.
The marks can be formed of fluorescent materials which fluoresce under certain lighting conditions. When the colorants are inks or dyes of the type that fluoresce and are invisible to the unaided eye as described in commonly assigned U.S. Pat. Nos. 5,752,152; 5,772,250; 5,768,674 and U.S. patent aplication Ser. Nos. 08/598,785; 08/837,931; 08/873,959; the disclosures of which are incorporated by reference. The colorants can be for example comprised of inks or dyes that can be seen using infrared light with a wave length between 10 -6 meters and 10 -3 meters, or colorants comprised of inks or dyes that can be seen using ultraviolet light with a wave length between 10 -8 meters and 10 -7 meters. Alternatively, the marks can be formed from dye from a material which disappears under non-ambient lighting conditions. Various combinations of colorant marks and embossed marks with the colorants formed of different materials will suggest themselves to those skilled in the art.
Turning now to FIG. 5 which shows the receiver 12 with an authenticating silver impregnated thread 92 in the support 56 of the receiver 12.
Turning now to FIG. 6 which shows the receiver 12 with an authenticating magnetic strip material 98 in the support 56 of the receiver 12. The magnetic material for example can be iron oxide and the authenticating marks are encoded in the magnetic material as magnetic pulses which can be read and decoded using magnetic read/write heads. The magnetic strip can also be formed from a plastic mixture which further includes a substantially uniform distribution of magnetic particles, as described for example, in the Kodak Product Brochure titled "Inherent Intelligence with the New Magnetic Card System from Kodak", 1995.
Turning now to FIG. 7 which shows the receiver 12 with the authentic user viewable marks forming an authenticating type seal in the support 56 of the receiver 12. The authentic user viewable marks can be in the form of water marks 100 that appear under special lighting conditions such as when the receiver is help up to a light source.
Turning now to FIG. 8 which shows the receiver 12 with the authentic user viewable marks embossed into the support 56 of the receiver 12 forming a tactile indicia 110 as the means authenticating the image.
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 spirit and scope of the invention.
______________________________________PARTS LIST______________________________________10 thermal printer apparatus12 receiver14 colorant donor element16 tray18 platen20 actuator24 supply roller26 take-up roller28 drive mechanism30 control unit32 computer34 laser light source38 optical system50 image receiving structure54 adhesive layer56 support58 barrier layer59 peelable protective release layer60 colorant receiving layer62 protective layer70 viewable marks90 images98 strip material110 tactile indicia______________________________________
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A method of forming authentic user viewable images on a receiver to which a series of viewable images such as postal stamps are adapted to be transferred including providing a receiver, and forming a series of authentic user viewable marks on the receiver prior to transfer of the series of images onto such receiver.
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The United States Government has rights in this invention pursuant to Contract No. W-7405-ENG-48 between the United States Department of Energy and the University of California for the operation of Lawrence Livermore National Laboratory.
TECHNICAL FIELD
The present invention relates to efficient methods for the preparation of 7-hydroxy-1,2,3,4-tetrahydroquinoline which is an intermediate useful in the economic manufacture of laser dyes.
BACKGROUND OF THE INVENTION
Large scale production of rhodamine class laser dyes depends upon the cost of the synthesis of these dyes. The high cost of intermediates can make large scale production of the laser dyes commercially impracticable.
SUMMARY OF THE INVENTION
The present invention provides for the efficient, cost-effective preparation of 7-hydroxy-1,2,3,4-tetrahydroquinoline which is an intermediate useful in the preparation of a class of dyes which lase at wavelengths between 540 and 570 nm.
The present invention further provides for the preparation of a class of laser dyes which exhibit lasing efficiency and photochemical stability for extended periods of operation from relatively inexpensive materials.
In general, the present invention is directed to efficient method for the preparation of the intermediate 7-hydroxy-1,2,3,4-tetrahydroquinoline, and to the use of this intermediate to prepare dyes of the general formula: ##STR1## wherein R 1 , R 2 and R 3 are each individually hydrogen or a linear alkyl or fluoroalkyl group of 1 to 10 carbon atoms.
These and other objects and advantages of the invention will be apparent in the description of the specific embodiments.
DETAILED DESCRIPTION OF THE INVENTION
I. Synthesis of 7-Hydroxy-1,2,3,4-Tetrahydroquinoline
A. m-Aminoohenol/Boron Hydride Method
Chart 1 shows the synthesis of 7-hydroxy-1,2,3,4-tetrahydroquinoline from m-amino phenol. ##STR2##
The acylation of m-aminophenol 1 to form the amide 2 can be performed in water with bicarbonate as base with little loss in yield and thereby avoiding expensive organic solvents.
The cyclization of the amide 2 to obtain the lactam 3 can be conducted in the presence of aluminum chloride, but this results in the formation of significant amounts of the undesired 5-hydroxy isomer. The use of a eutectic of aluminum chloride, sodium chloride and potassium chloride in the cyclization reaction reduces the formation of the undesired isomer, but leads to a noticeable exotherm and potential foaming.
The lactam group 3 is reduced to give the quinoline 4 with borane-methyl sulfide complex in toluene. The quinoline product 4 may be isolated as the maleate complex which is somewhat easier to crystallize than the free base.
EXAMPLE 1--3-Chloro-3'-hydroxypropionanilide
To a mixture of 21.82 g (0.2 mol) of m-aminophenol, 16.8 (0.2 mol) of sodium bicarbonate, 0.5 g of tetrabutylammonium hydrogen sulfate and 300 ml of water stirred under nitrogen and cooled in an ice bath to 4° C. was added dropwise 19.1 ml (25.4 g, 0.2 mol) of 3-choropropionyl chloride during 0.5 hour. The temperature held at 5° C. and the reaction mixture foamed. The slurry was stirred for a further 1.5 hr in the ice bath. The solid was collected, washed with water and dried to give 32 3 g (81%) of product as a white solid, melting point 132°-136.5° C.
EXAMPLE 2--7-Hydroxy-3,4-dihydrocarbostyril
A mixture of 10 g (50 mmol) of 3-chloro-3'-hydroxypropionanilide 2 and 26.67 g (200 mmol) of powdered aluminum chloride was put in an oil bath at 130° C. with a magnetic stirrer. The temperature was raised to 160° C. In about 10 min the reaction mixture liquified and foamed. The temperature was held at 145° to 160° C. Thin layer chromatography of the mixture at 1 hr 10 min showed there was no amide left. After 1 hr 40 min total of heating, 50 ml of water was cautiously added. Hydrogen chloride was given off and the reaction mixture boiled. Another 25 ml of water was added and the mixture stirred overnight. The precipitated product was collected and rinsed with water to give 7.35 g (90%) of off-white powder, melting point 217°-220° C. Recrystallization to isolate the desired isomer is needed.
EXAMPLE 3--7-Hydroxy-3,4-dihydrocarbostyril
A mixture of 20 g of potassium chloride, 20 g of sodium chloride and 160 g of aluminum chloride in a 500 ml flask with mechanical stirrer, condenser and thermometer was melted in an oil bath at 160° C. To it was added 40 g (0.2 mol) of 3-chloro-3'-hydroxy propionanilide 2 in portion during 25 min. There was an exotherm and the oil bath was removed. The reaction mixture foamed badly. The oil bath was slowly replaced and reaction was continued for 1.5 hr after the addition was complete until the foaming stopped. A little of the mixture was lost out the condenser. The mixture was allowed to cool to ca. 110 ° C. and then poured onto 1.2 kg of ice. The product was collected, washed with water and dried in the oven to give 28.76 g (88%), melting point 224°-228° C. (trace of fast spot on thin layer chromatography.) Re-crystallization from 700 ml of water gave 23.66 g (72%) of product, melting point 233°-237° C. (thin layer chromatography 10% MeOH/CH 2 Cl 2 single spot).
EXAMPLE 4--7-Hydroxy-1,2,3,4-tetrahydroquinoline
To a suspension of 9.79 g (60 mmol) of 7-hydroxy-3,4-dihydrocarbostyril in 40 ml of toluene in a 250 ml 3-necked flask provided with magnetic stirrer, condenser with nitrogen connection and a rubber septum was added 60 ml of 2M boranemethylsulfide complex in toluene. A heating mantle was put on. In 15 min the mixture was foaming badly, its temperature was 90°, and material was going out the condenser. The mantle was removed. After 10 min it was replaced with less heat. After 20 min the internal temperature was 90° C. and the mixture was foaming. It was then held at 90°-104° C. for 1 hr 50 min. At 1 hr 30 min thin layer chromatography showed that no starting material was present. To this was added 25 ml of methanol dropwise during 20 min. It was reconcentrated in vacuo. The residue was treated with methanol and reconcentrated twice. The 12 g of residue was crystallized from water to give 8.19 g (91%) of crude product, melting point 87°-91° C., with foaming.
EXAMPLE 5--7-Hydroxy-1,2,3,4-tetrahydroquinoline
To a suspension of 9.79 g (60 mmol) of 7-hydroxy-3,4-dihydrocarbostyril in 40 ml of toluene in a 250 ml 3-necked flask provided with magnetic stirrer, condenser with nitrogen connection and a rubber septum was added 60 ml of 2M boranemethylsulfide complex in toluene. A heating mantle was put on. The temperature was raised during 20 min to 85° C. An exotherm occurred and the mantle was temporarily removed. The temperature was then held at ca. 100° C. for 3 hr. The reaction was cooled and some flocculent material was filtered off. The filtrate was concentrated in vacuo, allowed to stand overnight and then reconcentrated with methanol to 8.76 g of dark oil. It did not crystalize with hexane so it was dissolved in 25 ml of methanol and 6.96 g of maleic acid was added. The acid dissolved and the maleate complex crystallized out. The complex was filtered off after cooling overnight in the refrigerator to give 8.096 g (51%) of maleate, melting point 141°-143° C. The filtrate was concentrated in vacuo to 8.49 g of brown oil. The oil was cooled overnight in the refrigerator with 10 ml of acetonitrile. The solid formed was collected to give 2.17 g (14%) of maleate, melting point 137-°140° C. The two crops were combined.
B. Tetrahydroquinoline Nitration Method
Chart 2 shows the preparation of 7-hydroxy-1,2,3,4-tetrahydroquinoline from tetrahydroquinoline. The first two steps from 5 to 6 and from 6 to 7 are generally described in the literature. See, M. Kulka, R.H.F. Manske, "The Nitration of Some Quinoline derivatives," Can.J.Chem. 1952, 30, 720, and J.v. Braun, A. Grabowski, M. Rawicz, Ber. 1913, 46, 3169, respectively. Nitration of 5 occurs mainly in the 7-position to give 6 as shown. The crude yield of nitroquinolines is close to quantitative, but after recrystallization about 50% of the 7-isomer 6 is obtained in a fairly pure state.
Hydrazine catalyzed with Raney nickel reduces the nitro group to an amino group quantitatively. The amine 7 is quite sensitive to air.
The amino group can be hydrolyzed to give 7-hydroxy-1,2,3,4-tetrahydroquinoline in the presence of a strong aqueous acid and at a temperature of from about 140° to 180° C. A preferred temperature is 165°±5° C. The reaction can occur at atmospheric pressure. In a preferred embodiment, the amino group is hydrolyzed off with strong aqueous acid such as phosphoric, sulfuric, methanesulfonic, trifluoromethanesulfonic, and hydrobromic acids at a temperature from about 140° C. to 180° C., under atmospheric or higher pressure. 7-Hydroxy-1,2,3,4-tetrahydroquinoline 4 is obtained in 70% yield after recrystallization. ##STR3##
EXAMPLE 6--7-Nitro-1,2,3,4-tetrahydroquinoline
To 75 ml of 96.6% sulfuric acid cooled in a salt-ice bath was added dropwise 25 ml (0.2 mol) of 2,3,4-tetrahydroquinoline. After 30 min concomitant addition of 9.5 ml (0.2 mol) of 90% nitric acid in 40 ml of sulfuric acid was started at such a rate that the temperature remained at 5°-10° C. The addition of the quinoline was finished in 50 min. The addition of the nitric acid was finished in 30 min. The tetrahydroquinoline forms lumps which are slow to dissolve. The reaction mixture was stirred in the ice bath for 3 hr and then poured onto 1.4 kg of ice. The solution was neutralized to pH.8 with 255 g of sodium carbonate. The precipitate was collected, washed with water and allowed to stand in the hood overnight to give 44 g of crude product. This material was combined with 36 g from a similar experiment and recrystallized from ca. 200 ml of methanol to give 35 g (49%) of dark orange solid, melting point 60°-63° C. compared to literature reports of 62°-63° C.
EXAMPLE 7--7-Amino-1,2,3,4-tetrahydroquinoline
A 1 l round-bottomed flask fitted with thermometer, magnetic stirrer, addition funnel, and condenser with nitrogen inlet was charged under nitrogen with 26.73 g (0.15 mol) of 7-nitro-1,2,3,4-tetrahydroquinoline 6, 150 ml of methanol and 3.7 g of Raney nickel slurry rinsed with methanol. Addition of a solution of 16.5 ml (0.33 mol) of hydrazine hydrate in 15 ml of methanol to the stirred mixture was started. The reaction mixture was warmed to start the reaction after about one-third of the hydrazine solution had been added. Addition of the hydrazine took 45 min. Then the reaction mixture was heated under reflux to complete the reduction. The catalyst was filtered off through Celite and washed with methanol. The filtrate was concentrated in vacuo and reconcentrated twice with toluene to remove water. The residue was crystallized from hexane to give 21.92 g of product as a black solid.
EXAMPLE 8--7-Hydroxy-1,2,3,4-tetrahydroquinoline
A 300 ml Parr bomb was charged with 120 g of 70% phosphoric acid and 12 g. (81 mmol) of 7-amino-1,2,3,4-tetrahydroquinoline 7. It was stirred and heated at 160° C. for 20 hours. A pressure of ca. 55 lb developed. The cooled contents were rinsed into a 600 ml beaker with 150 ml of water and neutralized to pH 6 with 64 g of sodium carbonate. The precipitate was collected, rinsed with water and dried to give 11.88 g (98%) of crude product, melting point 83°-87° C. Recrystallization from 50 ml of toluene with 1 g of charcoal gave 8.36 g (69%) of tan solid, melting point 90°-92° C. Material which has been purified by filtration through silica gel has a melting point range of 90°-96° C.
While this embodiment has been described with respect to constant volume conditions and the use of phosphoric acid, it will be apparent to those skilled in the art that the reaction can be conducted in other strong aqueous acids, under ambient pressure conditions at temperatures between 140° to 180° C. The strong aqueous acid can be selected from the group consisting of phosphoric, sulfuric, methanesulfonic, trifluoromethane sulfonic, hydrobromic acids, and mixtures thereof.
II. Syntheses of Laser Dyes Utilizing 7-Hydroxy-1,2,3,4-Tetrahydroquinoline
A Laser Dye 1,11-Bis(2,2,2-trifluoroethyl)-1,2,3,4,8,9,10,11-octahydro-6-(2-methoxycarbonylphenyl)-dipyrido[3,2-b:2',3'-i]xanthylium perchlorate
The efficient synthesis of 7-hydroxy-1,2,3,4-tetrahydroquinoline enables the synthesis of a laser dye having the following structure: ##STR4##
The aminophenol precursor to this dye was made by alkylation of 7-hydroxy-1,2,3,4-tetrahydroquinoline. Trifluoroethyl tosylate was the alkylating agent for preparing 1-trifluoroethyl-1,2,3,4-tetrahydro-7-hyroxyquinoline, which was converted with phthalic anhydride to the rhodamine 1,11-bis(2,2,2-trifluoroethyl)-1,2,3,4,8,9,10,11-octahydro-6-(2-carboxyphenyl)-dipyrido[3,2-b:2',3'-i]xanthylium perchlorate in 85% phosphoric acid at 170° C. (structure 8), which in turn was converted to the methyl ester (structure 9). ##STR5##
EXAMPLE 9--Purification of 7-hydroxy-1,2,3,4-tetrahydroquinoline
A mixture of 80 g of crude 7-hydroxy-1,2,3,4-tetrahydroquinoline and 300 ml of methylene chloride was filtered to remove a fine precipitate. The filtrate was chromatographed on 800 ml of silica gel in methylene chloride. Elution was with methylene chloride containing increasing amounts of ethyl acetate. Those fractions eluted with 10-15% of ethyl acetate were concentrated to give 38 g of pure material (thin layer chromatography 50% ethyl acetate/hexane on silica gel). There was about 19 g of fairly impure material in fractions before and after these fractions.
EXAMPLE 10--Alkylation of 7-hydroxy-1,2,3,4-tetrahydroquinoline with trifluoroethyl tosylate
A mixture of 24 g (0.16 mol) of 7-hydroxy-1,2,3,4-tetrahydroquinoline, and 50 g (0.197 mol) of 2,2,2-trifluoroethyl p-toluenesulfonate was stirred under nitrogen in an oil bath at 180°-190° C. for four hours. The cooled mixture was partitioned between 200 ml of methylene chloride and 200 ml of water. The aqueous phase was adjusted to pH 7 by the addition of solid sodium carbonate. The organic phase was separated. The aqueous phase which contained solid was washed with 100 ml of methylene chloride. The organic phases were combined, washed with 100 ml of water and dried over sodium sulfate. Some black tar separated. The mixture was filtered and concentrated in vacuo to leave 64.83 g of dark oil. This was dissolved in methylene chloride and filtered through 400 ml of silica gel in a 600 ml coarse sintered glass funnel. Fractions of 200 ml were collected. The first two contained 33 g of unreacted tosylate. The next five contained 11.34 g (31%, more typically 20%) of product as a pink solid. Ethyl acetate (400 ml) eluted 5.23 of dark oil which thin layer chromatography showed to contain some unreacted tetra-hydroqinoline. An analytical sample of the product was prepared by recrystallization from hexane with charcoal to give long white needles, melting point 106°-108° C. Analysis calculated for C 11 H 12 F 3 NO: C,57.14; H, 5.23; N, 6.06. Found: C, 56.99; H, 5.18; N, 602.
EXAMPLE 11--Synthesis of 1,11-bis(2,2,2-trifluoroethyl)-1,2,3,4,8,9,10,11-octahydro-6-(2-carboxyphenyl)-dipyrido[3,2-b:2',3'-i]xanthyliumhydroxyde, inner salt (rhodamine structure 8)
A mixture of 9.25 g (40 mmol) of 1-(2,2,2-trifluoroethyl)-1,2,3,4-tetrahydro-7-hydroxyquinoline and 8.89 g (60 mmol) of phthalic anhydride in a 250 ml round bottom flask was stirred and heated in an oil bath at 170° C. under nitrogen for 3 hours. The mixture gradually thickened. It was then removed from the bath and allowed to cool slightly. To it Was added 9.25 g (40 mmol) of 1-(2,2,2-trifluoroethyl)-1,2,3,4-tetrahydro-7-hydroxyquinoline and 30 ml of 85% phosphoric acid. It was then heated in the 170°-173° C. oil bath for 4.5 hrs. It was again allowed to cool slightly and 70 ml of methanol was added dropwise to the hot reaction mixture. It was allowed to reflux for 5 minutes and then transferred to an Erlenmeyer flask. To it was added with stirring 200 ml of water in portions. A red-gold solid precipitated. The mixture was cooled in the refrigerator overnight. The solid was collected, washed with water (two 10 ml portions) and dried four hours at water pump vacuum at 100° C. to give 25.93 g of brownish solid.
EXAMPLE 12-Esterification of 1,11-bis(2,2,2-trifluoroethyl)-1,2,3,4,8,9,10,11-octahydro-6-(2-carboxyphenyl)-dipyrido[3,2-b:2',3'-i]xanthyliumhydroxide, inner salt to form 1,11-bis(2,2,2-trifluoroethyl)-1,2,3,4,8,9,10,11-octahydro-6-(2-methoxycarbonylphenyl)-dipyrido[3,2-b:2',3'-i]xanmthylium perchlorate (rhodamine structure 9)
To 4 g (6 mmol) of the rhodamine 8 dissolved in 50 ml of methanol was added carefully 4 ml of trifluoromethanesulfonic acid. The mixture was stirred and heated under reflux in a nitrogen atmosphere for 48 hours. It was concentrated in vacuo to about 13.5 g and the residue was treated with 35 ml of saturated sodium bicarbonate solution in portions until the pH was about 6. A gum separated out. This gum gradually solidified on scratching with the addition of a little ethyl acetate. The red solid that formed was collected and allowed to dry overnight to give 4.35 g of crude triflate.
To a solution of this triflate in 25 ml of methanol was added 1 ml of 70% perchloric acid. This mixture was seeded, scratched and cooled in the refrigerator for one hour. The solid was collected, rinsed with 50% aqueous methanol and air-dried overnight to give 3.09 g (76%) of crude perchlorate. For analysis this material was recrystallized four times form 50% aqueous methanol to give red prisms with a green sheen, melting point 254°-257° C. Analysis calculated for C 31 H 27 ClF 6 N 2 O 7 : C, 54.04; H, 3.95; N, 4.07. Found: C, 54.10; H, 3.98; N, 4.01.
B. Laser Dye 1,11-Bis(3,3,3-trifluoropropyl)-1,2,3,4,8,9,10,11-octahydro-6-(2-methoxycarbonylphenyl)-dipyrido[3,2-b:2',3'-i]xanthylium trifluoromethanesulfonate
The efficient synthesis of 7-hydroxy-1,2,3,4-tetrahydroquinoline enables the synthesis of a laser dye having the following structure. ##STR6##
1-Trifluoropropyl-1,2,3,4-tetrahydroquinoline was made from trifluorochloropropane and the 7-hydroxy-1,2,3,4-tetrahydroquinoline in aqueous sodium acetate in a stirred pressure reactor at about 150° C. and 200psi. In this case, the rhodamine 1,11-bis(3,3,3-trifluoropropyl)-1,2,3,4,8,9,10,11-octahydro-6-(2-carboxyphenyl)-dipyrido[3,2-b:2',3'-i]xanthylium trifluoromethanesulfonate (rhodamine structure 10) was prepared in refluxing o-dichlorobenzene separating the water generated in the reaction by a trap and in turn was converted to the methyl ester (rhodamine structure 11). ##STR7##
EXAMPLE 13--Alkylation of 7-hydroxy-1,2,3,4-tetrahydroquinoline with trifluorochloropropane
A mixture of 7-hydroxy-1,2,3,4-tetrahydroquinoline 22.4 g (0.15 mol), anhydrous sodium acetate 18.4 g (0.225 mol), water 112 ml and trifluorochloropropane 29.8 g (22.8 ml, 0.225 mol) were placed in a Parr 300 ml pressure reactor. The reactor was cooled to 5° C., stirred, purged with nitrogen for six minutes and closed. It was stirred rapidly and heated to 150° C.(±5° C.) for 18 hours when the pressure dropped from 202 psi to 76 psi. It was allowed to cool to room temperature, whilst stirring, then to 5° C. and the excess pressure was released. It was warmed to 40° C., the reactor opened, and the mixture was poured into a 500 ml separatory funnel and was washed in with toluene (100 ml plus 30 ml). A pale orange heavy oil was extracted into the toluene whereas the rejected aqueous phase had a pH of 4 to 5. It was washed with 10% aqueous sodium carbonate, water, dried (sodium sulfate), filtered, evaporated to dryness and then on a vacuum pump at 3 mm at room temperature for three hours. 27.3 g (74% crude yield) of a brown gum was obtained that crystallized after standing two days in a 5° C. refrigerator under a nitrogen atmosphere. Thin layer chromatography on silica, developing with ethyl acetate/n-hexane (1:1, v:v), showed mainly the required product R f 0.75 and starting material (5 to 10%) R f 0.30.
This material was used directly in the next dye preparation step. It could be recrystallized from n-hexane but was still contaminated with the 7-hydroxy-1,2,3,4-tetrahydroquinoline starting material. For purification 9.2 g was chromatographed on a Woelm silica column (160 ml of silica powder), eluting with dichloromethane. The first 200 ml coming off just before a yellow ring, contained two faster running impurities on the ethyl acetate/n-hexane thin-layer detection chromatogram, and was rejected. The next four 50 ml samples, on evaporation gave 3.3 g, 1.5 g, 0.6 g and 0.2 g respectively of light-brown clear gum, which crystallized overnight and which was collected as product. 0.8 g was further purified by recrystallization from 150 ml of n-hexane to give pale-brown, translucent plates, melting point 72.5°-73.0° C.
Analysis calculated for C 12 H 14 F 3 NO: C, 58.77; H, 5.75; N, 5.71. Found: C, 59.18; H, 5.83; N, 5.70%.
EXAMPLE 14--Synthesis of 1,11-bis(3,3,3-trifluoropropyl)-1,2,3,4,8,9,10,11-octahydro-6-(2-carboxyphenyl)-dipyrido[3,2-b:2',3'-i]xanthylium hydroxide, inner salt (rhodamine structure 10)
1-Trifluoropropyl-1,2,3,4-tetrahydro-7-hydroxyquinoline 27.2 g (0.11 mol) was dissolved and washed into a 250 ml, round-bottomed, single-neck flask with o-dichlorobenzene (50 ml+33 ml). Phthalic anhydride 12.3 g (0.083 mol, 1.5 mole equivalents to 2 mole equivalents of the base), two pieces of bumping stone and a magnetic stirring bead were added. The mixture was stirred and brought to reflux when some frothing occurred and the deep red color of the rhodamine appeared. The refluxing was continued for 3.5 hr and 2.0 ml of water from the reaction was collected in a trap. The mixture was allowed to cool whilst stirring when some dye precipitated, and the flask was stored at 5° C. for two days. A fine solid was filtered off and sucked dry (18.2 g wet weight), which was stirred and boiled with 10% sodium hydroxide 200 ml for half an hour, and the suspension was allowed to cool. Filtration in a wide-necked funnel gave a deep red-brown solid and a light orange filtrate. After the solid was washed with water, the filtration was slow and the filtrate was deep red. The water washing was continued until the filtrate was colorless, when the solid was sucked dry and was dried several days in the fume hood, the solid yielded 13.6 g (41%). This was analyzed directly as a zwitterion, melting point 300° C., decomp.
Analysis calculated for C 32 H 28 F 6 N 2 O 3 : C, 63.78; H, 4.68; N, 4.65. Found for a sample dried at 60° C. at 1 mm for two hours: C, 63.90, H, 4.68; N, 4.57%.
The material was sparingly soluble in methanol giving a red solution and orange-red fluorescence, and would not dissolve sufficiently in methanol, water, ethanol or their mixtures to permit convenient recrystallization. Thin layer chromatography on alumina gave a single, strongly fluorescent spot, R f 0.2 eluting with isopropanol, or R f 0.8 eluting with methanol. A careful comparison with the rhodamine dye obtained directly from 7-hydroxy-1,2,3,4-tetrahydroquinoline showed no contamination. The yield of the above reaction varied up to 45%, whereas using the chromatographed base and 2 mole equivalents of phthalic anhydride with two mole equivalents of the base increased it to 66%.
EXAMPLE 15--Esterification of 1,11-bis(3,3,3-trifluoropropyl)-1,2,3,4,8,9,10,11-octahydro-6-(2-carboxyphenyl)-dipyrido[3,2-b:2',3'-i]xanthylium hydroxide, inner salt to form 1,11-bis(3,3,3-trifluoropropyl)-1,2,3,4,8,9,10,11-octahydro-6-(2-methoxycarbonylphenyl)-dipyrido[3,2-b:2',3'-i]xanthylium trifluoromethanesulfonate (rhodamine structure 11)
A 3% (v/v) solution of trifluoromethanesulfonic acid in anhydrous methanol was made by dripping 10 ml of anhydrous acid into 330 ml with stirring over five minutes. The rhodamine 10, 20.1 g (0.03 mol), was transferred and washed into a 250 ml round-bottomed, three necked flask fitted with stirrer and an efficient reflux condenser having a loose cotton-wool plug by means of 167 ml of the trifluoromethanesulfonic acid solution (66% excess). The mixture was refluxed and stirred for 94 hours and the esterfication was monitored by thin-layer chromatography on fresh alumina eluting with methanol-rhodamine 10 Rf 0.85, rhodamine 11 Rf 0.7. Warm (60° C.) water 42 ml was added steadily to the stirred mixture which was brought to reflux and stirred for 7 minutes before filtering hot. On cooling crystals of the 1,11-bis(3,3,3-trifluoropropyl)-1,2,3,4,8,9,10,11-octahydro-6-(2-methoxycarbonylphenyl)-dipyrido[3,2-b:2',3'-i]xanthylium trifluoromethanesulfonate appeared and the flask was stored at 5° C. overnight. The material was filtered off, was washed twice with cold methanol/water (1:1, v:v), was sucked dry and was dried in the hood for three days--22.1 g (86%). Recrystallization of 5 g from 100 ml of methanol/water (2:1, v:v) gave 4.2 g of dark green needles with golden metallic sheen, mp. 236.5°-237° C.
Analysis calculated for C 34 H 31 F 9 N 2 O 6 S: C, 53.26; H, 4.08; N, 3.65; S, 4.18. Found: C, 53.64; H, 4.06; N, 3.69; S, 4.23.
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Methods for the efficient preparation of 7-hydroxy-1,2,3,4-tetrahydroquinoline include a first method in which the acylation of m-aminophenol obtains a lactam which is reduced to give the desired quinoline and a second method in which tetrahydroquinoline is nitrated and hydrogenated and then hydrolyzed to obtain the desire quinoline. 7-hydroxy-1,2,3,4-tetrahydroquinoline is used in the efficient synthesis of four lasing dyes of the rhodamine class.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to road surface marking tape materials for use on roadway pavements so as to provide a traffic regulating indicium thereon, such as traffic lane dividing lines, road lane edges defining lines and so on. More particularly, this invention relates to prefabricated tape material having wear-resisting properties, and principally (as far as the invention is concerned) anti-skid properties, provided by the fact that the material has a smooth highly wear resisting planar surface layer and a plurality of hard crystalline particles at least some of which include an upper portion extending outwardly from the upper face of said layer to impart good anti-skid properties to said face for vehicle traffic safety. The tape material concerned with the invention being also of the kind designed to be applied on and secured to the roadway pavement by means of lower "primer" layer best suitable for its anchorage with the pavement.
2. Description of the Prior Art
This art is a well known and worked one and several improvements had been made thereto. A number of Patents had been issued to the present applicant thereabout. Reference is herein made to the U.S. Pat. Nos. 3,872,843 and 3,935,365 for more complete acknowledgement of such prior art and of the problems concerned therewith.
One important problem descends from the most desirable anti-skid property of the material. The upper surface of the tape in service is firmly engaged by the vehicle wheel treads and therefore powerful thrusts occur to be applied tangentially on the said surface (the term "tangentially" refers to the wheel tread where contacting the said surface, that is directed in the plane defined by said surface), extremely powerful forces can be for example originated by a heavy and/or fastly traveling vehicle engaged in an emergency braking or by the centrifugal force during a curve. These thrusts tend to displace the tape in the direction of the force, that is cause the tape material to "slide" on the road pavement, detaching said tape from said pavement.
On the other hand such powerful thrusts are applied on the tape surface at a rather small surface area thereof, that is at the wheel tread-tape surface interface. Now, the tape material is secured to the (generally bitumen based) roadway pavement by means of an essentially plastic composition, even if the primer layer comprises completely hardened bituminous components. The resistance to said tendency of horizontally displacing the tape, under said thrusts, can provided at the tape material-road pavement interface (more properly, interlayer) at a very greater interfacial area.
In the practical service of said road marking tapes, as known to those skilled in the art, a tangentially applied powerful thrust can cause and frequently causes a localized damage to the tape material, which locally flakes off and wrinkles up, and sometimes is torn apart.
Complemental problems concern the desirable provision of tape material of small overall thickness (both for economy reasons and for limiting its overall height or protrusion from the actual road pavement surface) and the difficult and hard and fatiguing operation of removing, when necessary, a properly applied and secured marking tape from the road pavement, for example when the location of the marking is to be modified.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a new and improved tape material which is not subject to the above and other objections. In other words, it is an object of this invention to properly and satisfyingly solve the above and other problems.
More specifically, it is an object of this invention to provide a new and improved road surface marking tape material, which when applied and in service on a roadway pavement, has a multi-layer structure including a lower primer layer firmly secured to said pavement at a large interfacial area (such as that defined by the entire width by a substantial length of the tape), an upper traffic wear resisting and anti-skid layer the upper face of which can effectively frictionally engage the vehicles' wheel treads and transfer the tangentially applied thrusts, localized in relatively small interfacial areas, to the tape structure, and an essentially pliable but inextensible and tensionally resistant intermediate layer so connected to the said adjacent lower and upper primer and respectively anti-skid layers that the said localizedly applied thrusts are evenly distributed and transferred over a many times greater area in the said lower layer and concurrently of the roadway pavement surface.
Essentially, the road marking multi-layer tape material of the invention is therefore characterized by comprising, between a lower primer contacting and connected to the roadway pavement, and an upper layer having an anti-skid upper surface designed to be contacted and frictionally and tangentially engaged by the wheel treads of the vehicles, a relatively thin and pliable, but inextensible and tensionally resistant intermediate layer intimately and connected to both said upper and lower layers adjacent thereto at the entire interfacial area therebetween.
According to an embodiment of the invention, the said intermediate layer consists of a film of highly tensionally resistant polymeric resin. Preferably, said intermediate layer consists of a polyester film from 0.02 to 0.3 mm thick.
According to another embodiment of the invention, the said intermediate layer consists of a highly tension resistant resin impregnated non-woven fibrous structure. Preferably, said fibrous structure is impregnated at its portions adjacent to the upper and respectively to the lower layer by the same compounds comprised in said layers.
The said non-woven structure consists of fibers made of any suitable fiber forming synthetic composition capable of providing essentially inextensible and highly tensionally resistant fiber, such as polyester. The same structure can also be made of glass fibers. In such occurrence, the fibrous structure can be suitably impregnated with a synthetic rubbery or elastomeric composition for minimizing the brittleness of the fibers.
According to a complemental advantageous feature of the invention, the new tape material of the invention can be easily removed from the road pavement to the extent necessary for obliterating the marking, by inserting and displacing a heated blade at the level of the lower (or of intermediate layer, when made of heat meltable material) for separating the marking forming upper layer from the roadway pavement contacting lower or primer layer. The said upper layer can be recovered for subsequent application and use.
These and other features and advantages of the invention will be made best apparent from the following detailed description of preferred embodiments thereof, reference being made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat diagrammatical, fragmentary, partly sectional perspective view of a tape material according to the invention, applied on and secured to a roadway pavement;
FIG. 2 is an exploded view of the components of the material of FIG. 1, the intermediate layer forming component being shown to illustrate two alternative embodiments thereof;
FIG. 3 is a diagrammatical side view and partly a sectional view of a mechanism adapted for removing the material from the roadway pavement;
FIG. 4 is a sectional view illustrating a combination of certain components of the structure, before and after the assembling thereof;
FIG. 4A is a view similar of that of the righthand part of FIG. 4 and illustrates a modified combination; and
FIGS. 5, 6, 7 and 8 are views similar to that of FIG. 4 and illustrate further modified combinations, including thermoplastic components preferably comprising bituminous and/or epoxy-bituminous components.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In its broadest aspect, the tape material according to the invention comprises the combination and the arrangement of components as shown in FIG. 1. When properly laid on and secured to the surface of a roadway pavement generally indicated at T, by means of a "primer layer" (this term is of current use in the art, as being conventionally referred to a layer which is formed on the pavement surface, preparatory to laying the tape material thereon) of substantially bituminous nature, the road surface marking material has an upper face 16 which defines the sign. Said lower or primer layer is generally indicated at P.
Such upper face 16 is embodied by an upper layer S p having a high resistance to wear and formed by a highly resistant polymer, such as a polyester or a polyamide resin, and preferably of a polyurethane resin, and consists of a layer of thickness preferably comprised between 0.4 and 1.0 mm. This upper face 16 is made "anti-skid" by embedding into said layer hard particle, preferably crystals or microcrystals of a substance having a hardness at least of and preferably greater than 6 on the Mohs' Hardness Scale, such as of quartz, aluminum silicofluoride, aluminum sesquioxide and preferably carborundum. Some partially protruding particles are diagrammatically shown and indicated at 20 in FIGS. 1 and 2.
The upper layer can be also provided, according to the art, with light retroreflective elements, generally spheroidal, part of which are also shown and indicated at 22.
According to the invention, the said upper layer S p and the said lower or primer layer P are interconnected by an intermediate layer which is pliable (for best adaptation of the tape material to the road pavement T unevenness, and for admitting the winding of the material into coils or bobbins, for storage and/or transportation), essentially inextensible and having a great resistance to tension. Such intermediate layer can comprise a sheet of suitable substance, such as indicated at 24, or comprise a non-woven fibrous structure, as indicated at 24' in the righthand portion of FIG. 2.
The described multi-layer structure comprises in at least one of its layers thermoplastic components. This provision can be made use of for easily detaching the tape from the road pavement by making use of a simple apparatus such as illustrated in FIG. 3, and generally indicated at 30. Such apparatus comprises a truck which can be displaced in direction A along the tape to be removed. The frame structure 32 of said truck supports a blade-like tool 34 positioned for engagement and lengthwise insertion into and below the tape material, at a level intermediate its upper mayer (generally indicated at S in FIG. 3, for simplicity) and the lower pavement engaging face of the primer layer P.
The blade tool 34 is heated for example by a burner 36 and the upper layer portion of the detached tape material can be pull up along a sloping support 40 by a recovery bobbin 42. Said upper layer portion, generally indicated at S s , thus recovered, can be further made use of. This provide a substantial saving because the upper layer S p is as a matter of fact the most costly component of the product, in particular when provided with a substantial amount of corundum crystals and/or of retroreflective elements. The apparatus is complemented by the provision of a fuel source, such as a bottle 38 containing liquified gas and, is desired, with a source of power, such as an internal combustion engine, for driving the truck and/or rotating the mandrel about which the bobbin 42 is wound.
Various arrangement and interactions of the layers in a multi-layer structure in which the intermediate layer comprises a non-woven fibrous impregnated structure will be now briefly described with reference to FIGS. 4 to 8 inclusive. Such arrangements comprise preferably but not exclusively a fibrous structure formed with glass fibers.
It has been found that binder agents consisting of bituminous or epoxy-bituminous compounds are well compatible with and intimately penetrate into such fibrous structures. Upon juxtaposition of a layer S p of resinous substance, such as polyurethane, on a fibrous layer, another substantial interpenetration occurs. This greatly improved the bond between the various layers.
Further, the fibrous intermediate layer is generally preliminarily impregnated preparatory to the layer juxtaposition, and the various still liquid or viscous and not yet set compounds either forming the upper layer and/or the lower layer and impregnating the intermediate viscous layer intermix at the layers' interfaces and thereabout for further improving the bond and the structural even if heterogeneous unitarity of the multi-layer structure.
Thus, as diagrammatically shown in FIG. 4, the juxtaposition of the components of the upper layer S p and of the intermediate non-woven layer Snt yields to forming of a mixed (and possibly a chemically interreacted) interlayer Sp+Snt improving the bond. FIG. 4A diagrammatically indicates that the upper layer S p can be preliminarily formed as a calendered sheet and then coupled to the fibrous layer under pressure and vulcanization process.
The diagram of FIG. 5 visualized the interlocation of a sheet F of a flexibilizing and/or waterproofing agent between the upper layer forming component S p and the non-woven structure Snt. In the compound product (lefthand part of the FIGURE) a plurality of interlayers is therefore formed, such as generally indicate at Sp+F and F+Snt. Correspondingly, as indicated in the diagram of FIG. 6, an interlayer of crossed impregnation P+Snt can be formed between the impregnated fibrous layer Snt and the primer layer P. FIG. 7 depicts the formation of two interlayers Sp+snt and F+P resulting from the interposition of the said flexibilizing and/or waterproofing agent F between the non-woven layer and the primer layer P. FIG. 8 finally illustrates a deep intercrossed impregnation which involves nearly the entire thickness of the fibrous layer Snt, by part of both the compounds of the upper layer S p and the primer layer P. The substances and compounds adapted for providing such interrelations will be commented in the following Examples.
EXAMPLE 1
This Example refers to the manufacture of a multi-layer tape material including an intermediate layer 34 consisting of a resinous film from 0.03 to 0.3 millimeters thick. This material corresponds to the combination shown in the lefthand portion of FIG. 2. In this structure it is critical that the layer S p will be intimately and firmly bonded to the intermediate film. Assuming that such film is made of a polyester resin, the wear resisting upper layer can be made of a polyester composition as follows (in percent by weight):
______________________________________Polyester resin (such as "Dynapol S 206", by Dynamit Nobel A.G.) 56 %Methylethylketone 34 %Titanium dioxide 10 %______________________________________
EXAMPLE 2
This Example refers to forming a primer layer well adapted to provide a firm bond with an intermediate layer as above, by a two-component (A and B) composition, as follows (in parts by weight):
______________________________________Component "A"Solid oxidized bitumen parts 17Epoxy Tar (tar for epoxy resins) parts 10Synthetic rubber (such as "R.T.V. Rubber", by Polysar Canada) parts 24Colloidal silica (such as "Aerosil") parts 2Epoxy resin (such as "Araldite 250", by Ciba) parts 42Component "B"Solid 40/50 bitumen parts 17Epoxy Tar parts 15Cresylic Acid parts 5Polyamide resin (such as "Versamid 140") parts 36Kaolin parts 27Accelerator for the Epoxy Resin of Component "A" (such as "D.M.P. 30") parts 2______________________________________
The following Examples refer more specifically to the manufacture of tape material comprising a fibrous intermediate layer.
In general, the said fibrous intermediate layer comprises a non-woven fabric of weight comprised between 50 and 250 g/sq. meter, which is impregnated and subject to uniform pressure, by calendering for example, for providing a structure preferably of thickness less than one millimeter; a thickness comprised between 0.3 and 0.6 mm is preferred, so that the coupling of the upper layer (which includes abrasive and retroreflective elements) and on the intermediate layer forms a multi-layer of thickness generally slightly above one millimeter. This feature is advantageous in view of the cost, pliableness and light weight of the material to be laid on a prepared primer layer.
The impregnation of the fibrous structure is preferably made by making use of impregnating compound having, when completely set, a substantial resiliency. These compounds comprise preferably but not critically epoxy resins, epoxy-urethane resins epoxy-nitrile resins, polyester resins and, more preferably, combinations of epoxy resins and of synthetic in particular nitrile rubbers. The impregnating compound, added to suitable accelerator agents, is applied as a solution and heat processed, when the impregnation has been completed, to provide a stable waterproof and highly resistant structure.
EXAMPLE 3
A non-woven fabric of polyester fibers, weight 75 g/sq. meter and resisting 10 kg/cm (perpendicularly to the force) is impregnated up to weight of 160 g/sq.m with the following composition (parts by weight):
______________________________________Nitrile rubber (such as "Chemigum N 600" by Goodyear) 100Epoxy resin (such as "Epon 828", by Shell) 100Zinc oxide 5Stearic acid 1Sulphur 3.5Accelerator (DMP 30) 1.5Accelerator (benzotiacyldisulphate) 1.5Titanium dioxide 7.5______________________________________
This composition is soluted into a solvent consisting of 250 parts of methylethylketone peroxide and 250 parts of toluene, and subjected to a 10' treatment at 160° C. The thus impregnated and processed fibrous structure resists to tension of 20 kg/cm and has excellent waterproof and water resistant properties.
EXAMPLE 4
For the bonding of a structure obtained according to the above Example 3 with a polyurethane upper layer, the surface of said structure can be treated with a mordanting composition consisting of (parts by weight):
______________________________________Epoxy resin (such as "Epon 828" by Shell) 70Polybutadiene, orButyl rubber (such as "Polysar" Canada) 30Polyamide (such as "Versamin 125", by Schering) 40Titanium dioxide 35Dibasic lead phthalate 5Solvent (toluene) 320______________________________________
EXAMPLE 5
The twin layer structure comprising the intermediate layer of Example 3 can be secured to the roadway pavement upon applying and doctoring of the pavement surface a primer layer consisting of (parts by weight):
______________________________________Butyl rubber (such as "Polysar Butyl 301") 100Oxidized bitumen 15Zinc oxide 5Stearic acid 2Extra-fine clay ("China Clay") 15Zinc diethylditiocarbammate 3.5Dibenzylamine 2Sulphur 2Solvent (such as "Solvesso 100") 25______________________________________
EXAMPLE 6
The multi-layer prefabricated tape material can be provided with a compatible primer layer preliminarily applied (such as by calendering) and secured to the face of the intermediate layer, opposite to the upper layer.
Such preliminarily applied primer layer can be made by the use of the following composition (in part by weight):
______________________________________Butyl rubber (as above 100Oxidized bitumen 65Extra-fine clay (as above) 25Hydrocarbonic resin (such as "Piccopale 100") 20Liquid coumarone resin (such as liquid "Cumar", by Allied) 20Carbon black 25Anthracene oil, or tar 20______________________________________
EXAMPLE 7
This Example is a modification of Example 3 and refers to a composition particularly adapted for providing a laminated or calendered sheet of the impregnating material, such as indicated at F in FIGS. 5 to 7, for example. Such composition comprises, in parts by weight:
______________________________________Epoxy resin (such as "Epon 828", by Shell) 70Bromine modified butadiene rubber, capable tocross-link at ambient temperature (such as"Polysar RTV") 30Polyamide (such as "Versamid 125", by Shering) 40Titanium dioxide 50Dibasic lead phthalate 5Toluene 180Isopropyl alcohol 120______________________________________
The impregnated structure is heated for 10' at 160° C.
EXAMPLE 8
The use of fiberglass for producing the fibrous structure of the interlayer is preferably combined with the use of an essentially resilient compound for forming the upper layer S p of FIGS. 4 to 8, such as a polyurethane resin, for minimizing the brittleness of the glass; and forming a deeply compenetrated layer system. The upper layer can be made extremely thin. The advantageous provision of the flexibilizing (and waterproofing) interlayer forming component F (interlayer Sp+F, and F+Snt, and also F+P, FIGS. 5 to 7) can be provided by making use of the following composition, in parts by weight:
______________________________________Polyethylene chlorosulphonate (such as "Hypalon", by DuPont) 400Titanium dioxide 250Baryte 150Kaolin clay 150Polyester resin (such as "Neoxil") 50______________________________________
The thus flexibilized and/or waterproofed structures can be various formed and arranged, as examplified in FIGS. 5 to 7.
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An improved multi-layer surface marking tape material for use on roadway pavements so as to provide a traffic regulating indicium thereon, and having an anti-skid and wear-resisting upper layer and a lower primer layer for connecting the material to said pavement, the new multi-layer tape material comprising further an intermediate relatively thin, pliable, essentially inextensible and tensionally resistant intermediate layer compatible with and intimately connected to both said layers for distributing and transferring over a large primer layer-roadway pavement interfacial area horizontally directed stresses tangentially applied to said anti-skid upper layer at localized upper layer-vehicle wheel treads interfacial areas.
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FIELD OF THE INVENTION
This invention relates to a SAW (surface acoustic wave) device including a plurality of SAW elements or including at least one SAW element and a semiconductor IC (integrated circuit) provided on a single substrate, and more particularly to an arrangement for acoustically isolate or separate the SAW elements from each other or to from other electronic circuits.
BACKGROUND OF THE INVENTION
Recent progress in the art of SAW devices provides a complex SAW filter assembly with a number of SAW filters formed on a single substrate and an RF monolithic integrated circuit (IC) assembly with a SAW device and a semiconductor IC placed on a single substrate.
However, no effective proposal has been made to acoustically isolate the respective filters from each other in the complex SAW filter assembly or acoustically separate the SAW device from the semiconductor IC in the RF monolithic IC assembly.
Prior art systems can simply reduce interference between SAW elements or between a SAW device and a semiconductor IC by arranging SAW filters so that SAW propagation paths do not cross with each other, or alternatively by interposing sound absorbing material to attenuate surface acoustic waves as shown in FIG. 5 wherein sound absorbing material 3 is imbedded in a piezoelectric substrate 1 to isolate a SAW device having a pair of comb-shaped electrodes 2 from other similar SAW devices.
The specific placement of SAW elements in the prior art to isolate the SAW propagation paths thereof unduly reduces the number of SAW filters which can be incorporated on a substrate. The use of sound absorbing material requires a high precision to properly place the material in a limited space or to maintain a uniform shape and amount of the material, and therefore causes non-uniformity in finished products.
OBJECT OF THE INVENTION
It is therefore an object of the invention to provide a unique arrangement for a complex SAW filter assembly or an RF monolithic IC assembly which establishes an effective acoustic isolation or separation between SAW filters or between a SAW device and a semiconductor IC.
SUMMARY OF THE INVENTION
The most generic feature of the invention is the use of a metal electrode provided on a substrate of a complex SAW filter assembly or on an RF monolithic IC assembly, which electrode surrounds each SAW elements in the assembly so as to isolate them from each other. Between the electrode and the semiconductor substrate is applied a bias voltage with a value selected to forcibly invert the polarity of the semiconductor surface.
According to a more advantageous feature of the invention, the surface of the semiconductor substrate may be covered by an insulating layer of SiO 2 or Si 3 N 4 , for example. Each edge of the metal opposed to the SAW element advantageously defines an irregular margin so as to irregularly reflect an incident surface acoustic wave.
Comb-shaped electrodes in each SAW element are connected to external electrodes or to other electronic circuits on a common substrate by metal strips straddling the metal electrode via the insulating layer.
The portion where the metal electrode is provided has a so-called monolithic MIS (metal/insulator/semiconductor) structure. A surface acoustic wave, when propagating through the monolithic MIS structure, largely changes its propagation loss in response to a bias voltage applied between the metal and the semiconductor. The propagation loss and the bias voltage have relationships shown in FIG. 6 where the temperature is a parameter. FIG. 6 shows that the propagation loss remarkably increases and reaches 100 dB/cm in a limited voltage range. This means that in this voltage range a surface acoustic wave substantially disappears after a short distance propagation.
The voltage range inviting the rapid degradation of a surface acoustic wave corresponds to a voltage value which forcibly inverts the polarity of the surface of the semiconductor (the interface between the piezoelectric layer and the semiconductor). FIG. 7 is a graph showing the result of comparison of the C-V characteristic (capacitance-to-voltage characteristic) at curve b and the propagation loss at curve a. The drawing shows that the propagation loss suddenly increases when the polarity of the semiconductor surface is forcibly inverted (in the left hand range of a dotted line).
As discussed, since a bias voltage of a value forcibly inverting the polarity of the semiconductor surface significantly prevents surface acoustic waves from interfering each other, the invention can prevents acoustic interference between adjacent SAW filters or between a SAW device and a semiconductor IC.
The invention will be better understood from the description given below, referring to some preferred embodiments illustrated in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a complex SAW filter assembly having an arrangement of the invention;
FIG. 2 is a perspective view of an RF monolithic IC having an arrangement of SAW elements according to the invention;
FIG. 3 is a plan view of a complex SAW filter assembly having a more specific arrangement of the invention;
FIG. 4 is a fragmentary perspective view of the assembly of FIG. 1 or FIG. 2 which shows how to connect a comb-shaped electrode to an external electrode or to a semiconductor IC;
FIG. 5 is a plan view of a prior art arrangement of a SAW device;
FIG. 6 is a graph showing the relationship between the propagation loss and a bias voltage; and
FIG. 7 is a graph showing the relationship between the propagation loss and the capacitance-to-voltage characteristic (high frequency capacitance to bias voltage).
DETAILED DESCRIPTION
FIG. 1 shows a complex SAW (surface acoustic wave) filter assembly having an arrangement of the invention. A piezoelectric layer 5 is provided on one surface of a semiconductor substrate 4, and they make a piezoelectric substrate 1. On the other surface of the semiconductor 4 is formed a bottom electrode 6 connected to earth. A plurality of (four in the drawing) SAW filters F 1 through F 4 each including two comb-shaped electrodes 2 are provided on an upper surface of the piezoelectric layer 5 opposite to the semiconductor 4. The respective filters F 1 to F 4 are surrounded and isolated by a metal electrode 7. A bias voltage V B is applied between the metal 7 and the bottom electrode 6.
FIG. 2 shows an RF monolithic IC (integrated circuit) assembly having an arrangement according to the invention. A semiconductor substrate 4 is provided on one surface thereof with an insulating layer 8 on which a piezoelectric layer 5 is selectively provided. The portion including the piezoelectric layer 5 is a SAW device segment 9 whereas the portion with the insulator 8 exposed is a semiconductor IC segment 10. The SAW device segment 9 includes a plurality of SAW elements each having two bomb-shaped electrodes 2. The individual SAW elements are surrounded and isolated by a metal electrode 7. A bias voltage is applied between the metal 7 and a bottom electrode 6 provided on the bottom surface of the semiconductor 4 and connected to earth. The semiconductor IC segment 10 includes different electronic circuits I 1 through I 3 .
In the assemblies of FIG. 1 and FIG. 2, the metal 7 may be made of the same material as that of the comb-shaped electrodes 2 or electrodes of the semiconductor IC's. Also, the metal 7 may be formed at the same time and by the same method (etching) as the comb-shaped electrodes 2 and semiconductor IC electrodes are made. Each edge of the metal 7 opposed to the filter need not be straight as shown in FIGS. 1 and 2 but may define an irregular margine with the filter as shown in FIG. 3 to decrease the effect of reflection of a surface acoustic wave by the edge.
The use of the metal 7 requires a specific arrangement for connecting the comb-shaped electrodes 2 to external electrodes or to electrodes of the semiconductor IC's, although a conventional wire bonding may be employed. The invention specifically proposes a multi-layer wiring as shown in FIG. 4 wherein an insulating layer 11 is provided on the metal 7, and a wiring metal 12 is provided on the insulator 11 to electrically connect the comb-shaped electrode 2 to an external electrode or to an electrode 13 of a semiconductor IC.
The arrangement of the invention may be used not only in the SAW filter assembly or RF monolithic IC assembly as illustrated but also in a delay line oscillator, convolver or SAW change transfer device.
As described, since the invention uses the metal electrode which can be formed in the same process and step as the comb-shaped electrodes are formed, it maintains uniform configuration and position of the metal electrode and hence maintains a uniform property of finished products as compared to the prior art arrangement using the sound absorbing material. In comparison with another prior art arrangement which reserves a great distance between individual SAW elements to isolate the SAW propagation paths thereof, while the prior art imposes a limitation in the number of elements provided in a given area of a substrate, the invention arrangement can incorporate more elements in a substrate with the same area.
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A surface acoustic wave device includes a plurality of surface acoustic wave elements provided on a piezoelectric substrate. The device further includes a metal electrode provided on the piezoelectric substrate between and around the respective elements, and a bias voltage is supplied to the metal electrode to cause local attenuation.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention pertains generally to the field of lens fabrication and more particularly to the removal of a lens from a lens retaining block.
[0003] 2. Description of Prior Art
[0004] The fabrication of lenses includes processing steps to generate both the surfaces of the lenses so as to impart specific optical properties to the lens, and also to accomplish the peripheral alteration, or edging, of the lenses. The first step in altering a lens is typically the generation of a surface on a partially finished lens blank. The second step in processing the lens is normally the peripheral alteration of the shape of the surfaced lens. The lens blanks and surfaced lenses may be, for example, spherical, cylindrical, optical flats, aspherical, or of multiple focal lengths. Once the lenses have been finished they may be put to a variety of uses such as spectacle lenses, camera lenses, or lenses used in instrumentation.
[0005] Edging the lens to obtain a desired shape involves a series of steps. Typically the optical center and, optionally the cylinder axis, of the lens is located and marked on a face. In those instances when the lens to be edged contains an asymmetric surface it is necessary that the optical center and cylinder axis of the lens be located and marked. Next, the lens is attached to a lens block by some type of holding mechanism, such as an adhesive, so that the optical center, and optionally the cylinder axis, of the lens are aligned with the center point and cylinder axis of the block. The desired peripheral shape is then imparted to the lens. During edging the temperature of the lens rises. The lens is often exposed to the steady flow of a coolant in order to prevent the lens from cracking.
[0006] Some means must be provided to attach the lens blank to the edging block with a bond that will not fail during alteration yet is possible to break once alteration is complete. In practice, the lens may be removed from the block by a variety of methods. For example, the lens may be pried from the block. However, this method has the disadvantage that the lens is often chipped, scratched, or otherwise damaged by the act of prying. This method can be facilitated by immersing the lens and block in hot water for a short period of time. However, some plastic lens materials cannot withstand such temperatures.
[0007] Another method of lens removal is the use of a fluid that is forced against the surface of a blocking pad that is adhered to the lens, thereby reducing the force holding the pad to the lens or block. Approximately two atmospheres of fluid gauge pressure are sufficient to reduce the holding force such that the lens may be easily separated from the block. The fluid used to achieve removal should comprise a gas or liquid that is nontoxic and which will be inert with respect to the lens block, the blocking pad, and the lens. Representative examples of useful gases for pneumatic lens removal include air, nitrogen, carbon dioxide, helium, and fluorocarbon gases. Representative examples of useful liquids for hydraulic lens removal include water, hydraulic oils, mineral oils and fluorocarbon liquids.
[0008] Another method of lens removal employs a tab that is pulled in the direction of the plane of the blocking pad so as to cause a reduction in the thickness of the pad and a progressive disengagement of the pad from the interface between lens and block. Removal may also be accomplished by placing the combination of lens, blocking pad and block into a cavity of the mounting block and then rotating the lens and the block in opposite directions with respect to each other, thereby causing them to separate. A specially designed hand tool may also be provided to accomplish this same result. The tool is not as wide as the mounting block and facilitates removal by making it easier to grasp the edge of the lens.
[0009] The latter method of lens removal is disclosed in U.S. Pat. No. 3,962,833 entitled METHOD FOR THE ALTERATION OF A LENS AND AN ADHESIVE LENS BLOCKING PAD USED THEREIN, issued to Johnson on Jun. 15, 1976: The problem repeatedly grasp pliers or a similar tool to remove the lens. Some level of skill is required to perform the lens removal operation rapidly while avoiding damage to the lens. After a period of time in such an occupation, the operator is likely to suffer various forms of fatigue and injury including, for example, carpal tunnel syndrome.
[0010] A final issue to be faced when removing a lens from an edging block is the relatively recent development and use of hydrophobic and oleo phobic coatings, which cause the surface of coated lens to have a relatively low coefficient of friction. The relatively slick frictionless lens surface required the development of adhesive pads having relatively greater adhesion which caused the aforementioned methods of lens removal to be generally less effective. In particular, the conventional methods of lens deblocking resulted in crazing, pitting or other scarring and damage to the lens, or additional treatment step to remove adhesive residue from the lens.
SUMMARY OF THE INVENTION
[0011] The current invention is an improved apparatus and method for the removal of a lens from an edging block. The present invention retains the blocked lens by means of a collet chuck or clamp. The blocked lens resides on a pad which supports the lens on the edging block while protecting the lens from abrasion or damage from the block itself. A pair of opposed slidable lens clamps or arms are pneumatically advanced to grip the blocked lens along portions of the lens edge. Once the lens is secured by the lens clamp, the collet chuck is rotated approximately forty five degrees, thereby breaking the bond between the lens and the edging block. The lens clamps may then be retracted away from the lens edges and the lens may be manually removed from the pad.
[0012] The surface area of the combined edging block and pad is typically on the order of fifty percent of the total lens surface area. Thus when the lens is freed from the pad by the twisting motion of the collet, the lens is still sufficiently supported by the pad, which itself still rests on the edging block, to prevent the lens from falling off of the pedestal formed by the collet. After the lens is removed, the pad may be lifted from the edging block and then the edging block may be removed from the collet.
[0013] In a preferred embodiment of the invention, the device includes a pair of collet chucks or clamps spaced apart along a line that is substantially parallel to a line formed by the gripping edges of the lens clamps. In this embodiment, a blocked lens is placed on each collet and both lenses are gripped simultaneously by the opposed jaws of the lens clamps. The collets are rotated simultaneously by means of a manually operated switch, thereby freeing each lens from its respective pad. When the lens clamps are retracted, each lens may be easily lifted from its respective pad. These and other advantages of the present invention will become apparent by referring to the accompanying drawings and the detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of an automated edged lens deblocking system constructed according to the principles of the present invention;
[0015] FIG. 2 is a perspective view of one of the many various types of edging block that may be utilized by the system depicted in FIG. 1 ;
[0016] FIG. 3 is a first perspective view of an edging block and pad mounted on a lens as utilized by the system depicted in FIG. 2 ;
[0017] FIG. 4 is a second perspective view of an edging block and pad mounted on a lens as utilized by the system depicted in FIG. 1 ;
[0018] FIG. 5 is a perspective view of two lenses mounted on a pad and edging block while being retained by the deblocking system depicted in FIG. 1 ;
[0019] FIG. 6 is a perspective view of the automated edged lens deblocking system depicted in FIG. 1 with the chassis cover removed;
[0020] FIG. 7 is a sectional view taken along line 7 - 7 of FIG. 6 ;
[0021] FIG. 8 is a perspective view of the collet depicted in FIG. 1 ;
[0022] FIG. 9 is a top plan view of the collet illustrated in FIG. 1 ;
[0023] FIG. 10 is an exploded perspective view of the automated edged lens deblocking system depicted in FIG. 1 ;
[0024] FIG. 11 is a top plan view of the automated edged lens deblocking system depicted with edging blocks and lenses mounted on the collets in an undamped position;
[0025] FIG. 12 is a top plan view of the automated edged lens deblocking system depicted with edging blocks and lenses mounted on the collets in a clamped position;
[0026] FIG. 13 is a top plan view of the automated edged lens deblocking system depicted with edging blocks and lenses mounted on the collets after the collets have been rotated from a first position to a second position;
[0027] FIG. 14 is a top plan view of the automated edged lens deblocking system depicted with edging blocks mounted on the collets after the lenses have been removed; and
[0028] FIG. 15 is a bottom perspective view of the automated edged lens deblocking system depicted in FIG. 6 with some components removed for clarity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Referring to FIG. 1 , an automated edged lens deblocking system constructed according to the principles of the present invention is shown generally at 1 . The deblocking system 1 includes a protective cabinet 2 typically composed of a durable metal or plastic material. The top surface 9 of the cabinet 2 is formed to include a generally rectangular aperture or slot 3 above which a pair of opposed arms 4 and 5 are slidably mounted by means of supports 6 and 7 . The supports 6 and 7 permit movement of the arms 4 and 5 in the directions generally indicated by arrow 8 . The top surface 9 also includes an opening or first circular aperture 10 which permits access to a first collet or edging block clamp 11 . A second circular aperture 12 is located in a symmetrical position opposite the rectangular aperture 3 . The circular aperture 12 permits access to a second collet or edging block clamp 13 .
[0030] As best seen in FIGS. 8 and 9 , each edging block clamp, such as first edging block clamp 11 , includes three distinct, separable regions or jaws 31 , 32 and 33 . Each region includes a series of inclined, angular and substantially planar surfaces, such as surfaces 34 , 35 , 36 and 37 , with each surface joining adjacent surfaces along a line, such as lines 38 , 39 and 40 . Each region 31 - 33 also includes a substantially circular aperture or bore, such as bores 41 , 42 and 43 , for example. A ridge 44 extends across the floor 45 of jaw 32 , while a collinear ridge 46 extends along the floor 47 of jaw 33 . Each of the features of the edging block clamp 11 facilitates the ability of the clamp to mate with or grip an edging block 22 as depicted in FIG. 2 . Additionally, the collet 10 is textured with a Carbinite high friction coating to facilitate gripping of the collet by the clamp 11 . The Carbinite coating is available from Carbinite Metal Coatings, 508 Pittsburgh Road, Butler, Pennsylvania 16002.
[0031] In a preferred embodiment the system 1 is pneumatically powered with air being introduced at inlet 14 of regulator assembly 17 , which also includes a regulating valve 15 , an air filter 18 and an air pressure indicator 16 . Several controls are accessible to the operator of the system 1 , including a first toggle switch 19 that causes the edging block clamps 11 and 13 to grip or release an edging block that may be placed upon them by moving jaws 31 - 33 in the directions indicated by the arrows 48 , 49 and 50 , respectively.
[0032] As seen in FIG. 2 , the edging block 22 includes a series of inclined surfaces, such as surfaces 23 , 24 , 25 and 26 , for example. Additionally the block 22 includes a diametric groove 27 which broadens to a keyway 30 at one end. The block 22 also contains a pair of substantially circular indentations 28 and 29 . At least some of the features such as the surfaces 23 - 26 , the groove 27 , the keyway 30 , the indentation 28 and indentation 29 are adapted to mate with and be gripped either by or within an edging block clamp, such as damp 11 , when the block 22 is placed on the clamp 11 and toggle switch 19 is activated. In particular, the groove 27 is adapted to fit within and be retained by the ridges 44 and 46 . The operator of system 1 also has access to a second toggle switch 20 that causes the opposed arms 4 and 5 to move in one of the directions indicated by arrow 8 . A button 21 causes the edging block damps 11 and 13 to rotate about a longitudinal axis.
[0033] Referring also to FIGS. 3 and 4 , the adherence and securing of a lens 51 to the block 22 can be better appreciated. An adhesive pad 52 , having an adhesive material on each side, is affixed to the undersurface 53 of the block 22 . The bottom surface 58 of the adhesive pad 52 is affixed to the bottom side 54 of the lens 51 . The pad 52 includes a tab 57 which aids an operator in manually affixing and removing the pad as necessary. Due to the transparent nature of the lens 51 , the pad 52 and block 22 are directly visible through the lens when viewed through the top or outer lens surface 56 . The entire perimeter or edge 55 of the lens 51 remains completely accessible after the pad 52 is affixed to both the lens 51 and the block 22 . The pad 52 is affixed in preparation for any of numerous types of machining or treating operations to be performed on the edge 55 of the lens during manufacture. Once the machining and treatment operations are complete, the problem remains of safely removing the adhesive pad 52 from both the lens 51 and the block 22 .
[0034] As best seen in FIG. 5 , a block 22 is mounted on each of the edging block clamps 11 and 13 , each block 22 supporting a pad 52 . The opposed arms 4 and 5 of the deblocking system 1 are movable in the direction of arrow 8 , and by actuating switch 20 the operator is able to urge both arms to simultaneously move toward the nearest edge 55 of the lens 51 . A urethane cushion 59 is affixed to the inner surface 60 of each arm 4 and 5 to provided a firm grip on the lens 51 without damaging the edge 55 .
[0035] Referring also to FIGS. 6 , 7 and 10 , the internal construction and function of the system 1 may be better understood. The internal components of the system 1 are supported by a base plate 61 which may be composed of any rigid material Mounted on the base plate 61 is a collet closer 62 which activates the collet jaws or clamp 11 , while oppositely mounted collet closer 63 operates clamp 13 . Also mounted on the base plate 61 is a support block 64 which itself supports a clamp 65 , the block 64 and damp 65 defining a path for feather shafts 66 and 67 .
[0036] A pillow block 71 is affixed to a slide rail 75 . Feather shafts 66 and 67 pass through a pillow block 71 and permit the assembly of the pillow block 71 and the slide rail 75 to move longitudinally along the feather shafts 66 and 67 . A shaft end support block 72 is mounted so as to serve as a stop for the pillow block 71 and includes shaft passageways 73 and 74 . Mounted on the slide rail 75 is an air cylinder 76 which receives pressurized air, via toggle valves 19 and 20 , from the pressure regulator assemblies 17 and 68 affixed to the base plate 61 by means of a regulator mounting plate 69 which is also supported by standoff 70 . The air cylinder 76 is linked to an arm pusher 77 , the arm pusher being affixed to the arm 5 along indentation 79 . A guide rail 78 constrains movement of the arm pusher 77 along a line that is parallel to the shafts 66 and 67 as well as the rectangular aperture 3 , thereby causing the arm 5 to be urged longitudinally along a line defined by the path of the guide rail 78 whenever the air cylinder 76 is energized.
[0037] In a preferred embodiment the air cylinder or pneumatic piston 76 is a Bimba FS-091.25 air cylinder including a rod 87 having a 1.25 inch stroke length and which is marketed by the Bimba Manufacturing Company located in Monee, Ill. A second air cylinder 80 is mounted on a second pillow block 81 , the second pillow block 81 also being slidably mounted on shafts 66 and 67 . The second air cylinder 80 including rod 86 is coupled to the arm 4 such that operation of the first toggle valve 19 causes each air cylinder 76 and 80 to simultaneously advance the arms 4 and 5 , respectively, toward the opposing arm and thereby grip the tens 51 between the opposed arms 4 and 5 . The cylinders 76 and 80 exert substantially horizontal and substantially equal forces, with variations in the amount of individual force extended by each individual cylinder being balanced mote precisely by the independent motion of each cylinder 76 and 80 which are slidably mounted on the pillow blocks 71 and 81 respectively. The pressurized air used to operate the air cylinders 76 and 80 enters the toggle valve 19 via connection 84 , the actual air hoses employed being omitted from the figures for the sake of clarity.
[0038] Once the lens 51 is firmly secured between the arms 4 and 5 , an additional air cylinder 82 is employed to impart a twisting motion to the edging block damps 11 and 13 . In a preferred embodiment, the edging block damps 11 and 13 are mounted on rotary bases 83 and 89 , respectively. As best seen in FIG. 15 , the additional air cylinder 82 is mounted on the bottom surface 85 of the base plate 61 by means of a riser 86 . The button 21 is connected to an air valve 90 which is in fluid communication with the additional air cylinder 82 , the actual interconnecting hoses being omitted for clarity. The air cylinder 82 is connected to a cam push block 91 which is formed to include two orifices 92 and 93 . Each orifice is associated with an individual collet closer, with only the collet closer 63 being shown for the sake of clarity.
[0039] The collet closer 63 is rotatably secured to the base plate 61 by means of a bearing washer 94 and a shim 95 , both of which surround a spindle 96 . A cam arm 98 is rigidly secured around the spindle 96 between the shim 95 and a cap 97 . Extending from an end region of the cam arm is a shaft 99 that is rotatably retained within the orifice 93 . Activating the push button 21 causes the cam push block 91 to advance in the direction of arrow 100 until the block 91 is pre vented from further motion in the direction of arrow 100 by the presence of the stop block 101 . The motion of the cam push block 91 causes shaft 99 to also move in the direction of arrow 100 and thereby cause the collet closer 63 to rotate generally in the direction of arrow 102 .
[0040] Referring also to FIGS. 11 , 12 , 13 and 14 , the operation of the system 1 can be better understood. FIG. 11 depicts the system 1 in an initial position when the lenses 51 , having been previously processed while secured to the edging blocks 22 , are placed onto the block clamps 11 and 13 . The toggle switch 20 is then moved from the first position shown in FIG. 11 to the second position shown in FIG. 12 , the switch 20 causing the block damps 11 and 13 to security grip the edging blocks 22 . The toggle switch 19 is then moved from the position shown in FIG. 11 to the position shown in FIG. 12 , thereby causing the arms 4 and 5 to move toward the opposing arm as well as the nearest edge of the nearest lens 51 . The arms 4 and 5 self center, that is, stop at a location which causes the fens 51 to be securely gripped regardless of the exact shape and position of each tens 51 , because each arm 4 and 5 is moved into position by the action of the air cylinders 80 and 76 , respectively, which are free to travel with their respective pillow blocks 81 and 71 , respectively, until the force exerted by each cylinder 60 and 76 on the arms 4 and 5 is substantially equal, regardless of the specific position of each cylinder.
[0041] The push button 21 is then pressed causing the cam push block 91 to impart rotation to the block clamps 11 and 13 , thereby creating the geometry depicted in FIG. 13 . The groove 27 can be seen to have rotated through an approximately forty five degree angle. The effect of this rotational displacement is to break the adhesive bond between the adhesive pad 52 and the lens 51 while leaving the lens 51 still securely gripped between the arms 4 and 5 . FIG. 14 depicts the orientation of the groove 27 after the push button 21 has been released.
[0042] By returning the toggle switch 19 to the position shown in FIG. 14 , the arms 4 and 5 will be withdrawn from the lenses 51 . Since the adhesive bond between the edging blocks 22 and the adhesive pad 52 has been broken, each tens 51 can be lifted from the edging block 22 and the adhesive pad manually removed from the lens by means of the tab 57 . The toggle switch 20 is then returned to the position shown in FIG. 14 in order to allow the removal of the edging blocks 22 from the block clamps 11 and 13 .
[0043] The foregoing improvements embodied in the present invention are by way of example only. Those skilled in the materials processing field will appreciate that the foregoing features may be modified as appropriate for various specific applications without departing from the scope of the claims. For example, the item to be loosened due to the twisting motion of the block clamps 11 and 13 may be some device or element other than a lens 51 . Further, the bond that is broken between the edging blocks 22 and die pad 52 may be some linkage other wan an adhesive, such as a mechanical, electrical or residual magnetic attraction or force.
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A lens deblocking system ( 1 ) used for removing a lens ( 51 ) from an edging block ( 22 ). The system ( 1 ) includes opposed movable arms ( 4, 5 ) that are constrained to travel longitudinally within an aperture ( 3 ) so as to grip a lens ( 51 ) that is adhesively secured to an edging block by a pad ( 52 ). The edging block ( 22 ) is held within a clamp ( 11 ) that resides on a collet closer ( 63 ) which may be rotated by activating an air cylinder ( 82 ). A cam push block ( 91 ) is linked to file cylinder ( 82 ) as well as a cam arm ( 98 ) that is attached to a spindle ( 96 ) extending from the collet closer ( 63 ). In response to the movement of the push block ( 91 ) a rotational motion is imparted to the damp ( 11 ) via the cam arm ( 98 ). The rotation of the clamp ( 11 ) occurs while the tens ( 51 ) is still constrained against rotational movement between the movable arms ( 4, 5 ) thereby physically breaking the bond between the pad ( 52 ) arid the clamp ( 11 ) and permitting subsequent manual removal of the pad ( 52 ) from the lens ( 51 ).
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RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 11/043,091, filed Jan. 27, 2005, the disclosure of which is incorporated by reference herein.
[0002] This application is related to “Replacement Solvents Having Improved Properties and Methods of Using the Same” filed on even date, which serial number is not yet assigned but is referenced by attorney docket number 029211.55582D2 by attorneys for Applicants.
GOVERNMENT INTEREST
[0003] This invention disclosed herein was made with funding from the United States Air Force, pursuant to Contract Number F04611-01-C-0025. The United States Government may have certain rights under this invention.
BACKGROUND OF THE INVENTION
[0004] Chlorofluorocarbons (CFC's) are widely used solvents for precision cleaning of parts and components due to their superior physical and chemical properties, especially their solvency for contaminating materials such as oils, greases, resin fluxes, particulates, and other contaminates. One solvent commonly used in many applications is CFC-113 (1,1,2-trichloro-1,2,2-trifluoroethane). These solvents are used to clean and/or degrease components or systems related to, but not limited to, oxygen handling systems, refrigeration equipments or heat pumps, electronics, implantable prosthetic devices, and optical equipment. In addition, these solvents have been used as a means to measure residue remaining is a system. For example, in Air Force launch vehicle applications involving liquid or gaseous oxygen systems, CFC-113 was the solvent of choice used to detect and quantify the amount of hydrocarbon and fluorocarbon residues in these systems, since the presence of those contaminants can be catastrophic. A further application of these solvents is for foam blowing and polymer coating.
[0005] CFC-113 has many favorable characteristics such as low toxicity; non-flammability; and stability. Furthermore, CFC-113 is not classified as an air-polluting volatile organic compounds (VOC's) by environmental regulators, is practically odorless, and has a high worker exposure threshold value, eliminating the need for costly air circulation or dilution precautions. These benefits also came at a low price (less than 1% of total manufacturing costs in 1988). Coupled with the growth of the electronics industry, and concerns over worker safety due to toxic chemical exposure and hazardous waste disposal resulting from the use of VOC's, the desirable characteristics led to the widespread use of CFC-113.
[0006] With the rise of electronic equipment during the 1970s, the need to properly clean these contaminant sensitive parts became very important and the solvent, 1,1,2-trichloro-1,2,2-trifluoroethane (CFC-113), was found to be an excellent and versatile solvent. Being able to dissolve an unusually large array of contaminants (greases, oils, etc) and having excellent physical characteristics, CFC-113 became the ‘solvent-of-choice’ for electronics cleaning and it's use spread to other applications—especially military. Specifically, CFC-113 was used to remove solder flux from small spaces between electronic components so as to ensure adhesion of coatings, and prevent corrosion and electromigration of ions. Even more favorable were the non-aggressive properties of CFC-113 towards most polymers and coatings and its use permitted a wide use of plastics and other solvent-sensitive materials in the manufacture of electronic components. By 1986, the removal of solder flux from printed circuit board assemblies accounted for close to half of worldwide CFC-113 consumption. A significant portion of the remaining half was utilized by the military and in particular, aviation.
[0007] The use of CFC-113, however, is restricted due to the Montreal Protocol due to its ability to react and deplete atmospheric ozone. By the Mid 1980s, problems regarding the ozone became apparent and the primary culprits were certain halogenated hydrocarbons including CFC-113. In 1987, twenty-four nations agreed in principle to control ozone-depleting substances (ODS), such as CFC-113. Although this solvent had become critical to the electronics industry, the importance of protecting the earth's ozone layer weighed heavier. Thus, non-toxic and non-ozone depleting replacement solvents became a priority for electronics manufacturers and the military. Various CFC-113 substitutes have emerged and often rely on solvents such as n-propyl bromide and dichloroethylene, which are flammable and not as desirable as CFC-113.
[0008] Refrigeration systems also require periodic flushing to remove contaminants. A contaminated refrigeration system may have drastically reduced performance resulting from compressor failure, for example. The materials and contaminants in these systems differ from other applications and therefore solvents must be optimized accordingly. For example, a flushing solvent must be compatible with the elastomers and metals in typical systems, while at the same time have the solvency properties to remove oils, acids, and decomposition products of the oils and refrigerants. Some of the currently used flushing solvents include terpenes (e.g., d-limonene), n-propyl bromide, pentafluorobutane, HCFC-141b, and HCFC-225 ca/cb.
[0009] Selection for CFC replacements typically involves two steps. First, commercially available materials with limited impact on the environment are selected; these are termed next-generation replacements. These next-generation replacements are interim and do not have all the desired properties of an ideal replacement (e.g. they are not as effective solvents or have non-zero ozone depletion potentials, or ODP). The second step is to evaluate the so-called second-generation replacements that are not commercially available, but are only available in research quantities or by custom synthesis, and have properties that are not known. Evaluation and manipulation (e.g. by mixing) of these candidate second generation solvents will result in second generation replacements that meet or exceed the next generation solvents' overall performance since all critical properties required of the solvent are accounted for.
[0010] Many factors are important when selecting CFC second-generation replacement solvents. Some of the critical performance properties for a second-generation CFC replacements include: cleaning effectiveness or solvency, volatility (e.g., Boiling point), compatibility with materials to be cleaned (e.g. metals, elastomers and systems), toxicity (e.g., LC50, LD50, cardiac sensitization, mutagenicity, skin irritation), environmental persistence (e.g., ozone depletion potential (ODP), global warming potential (GWP), tropospheric lifetime (TLT), biodegradability), flammability (e.g., autogenous ignition temperature (AIT), flash point), cost and availability.
[0011] The solvency of the replacement should be comparable to CFC so the primary factor of performance is not compromised. The volatility and materials compatibility of the replacement solvent should be similar to the CFC so there is minimal impact on existing cleaning systems by switching solvents. Hazardous risks such as flammability, toxicity, and environmental impact are also critical since every manufacturer will be required to eliminate hazardous solvents in the near future.
[0012] The solvency performance of the candidate replacements can be quantified through the solubility parameter of the compounds. The hazard potential of the candidate replacements can be characterized using toxicity information such as lethal doses (LD), lethal concentrations (LC) or threshold limit values (TLV), and flammability information. Environmental properties can be analyzed through ozone depletion potential (ODP), global warming potential (GWP), and tropospheric lifetime (TLT). For a discussion of these parameters and their measurements or calculations, see e.g. U.S. Pat. No. 6,300,378, to Tapscott. Volatility can be assessed using the normal boiling point (nBP) of the solvent. If all of these properties and others can be experimentally measured or modeled, one could identify and test non-hazardous “drop-in” replacement solvents to replace hazardous solvents. The following paragraphs discuss the relevance of these performance parameters.
Cleaning Effectiveness or Solvency
[0013] The solubility parameter is a very important measure of the cleaning effectiveness of a solvent in dissolving and removing another material. In general, these parameters provide an easy numerical method of rapidly predicting the extent of interaction between materials, particularly liquids. Compounds with similar solubility parameters are known by those skilled in the art to have similar solvency properties. For example, CFC-113 has a solubility parameter or about 7.5 which is within the range where a solvent will dissolve both hydrocarbon and fluorocarbon greases. This is a fairly unique solubility parameter and is a major part of what makes CFC-113 such an excellent solvent. It also makes the substitution for CFC-113 rather difficult.
[0014] A quantitative method for comparing the relative solubility of different materials is through the use of solubility parameters. This concept of expressing solubility is based on the idea that the solution of one material in another is a spontaneous process, and that it can be stated in terms of the free energy of mixing as shown below:
[0000] Δ G=ΔH+TΔS, (1)
[0000] where ΔG is the free energy of mixing, ΔH is the enthalpy of mixing, and ΔS is the entropy of mixing. The controlling term for a spontaneous process (where ΔG is negative) is the enthalpy of mixing, which can be expressed in terms of x 1 and x 2 , the mole fraction of the components, V 1 and V 2 , the molar volumes, and a 1 and a 2 , the interaction constants.
[0015] The expressions for the enthalpy and entropy of mixing are given below:
[0000]
Δ
H
m
=
x
1
x
2
V
1
V
2
x
1
V
1
+
x
2
V
2
[
a
1
V
1
-
a
2
V
2
]
2
(
2
)
Δ
S
m
=
R
[
x
1
ln
x
1
+
x
2
ln
x
2
]
(
3
)
[0016] The cohesive energy of a mole of a liquid mixture can be stated as
[0000]
Δ
E
m
=
(
x
1
V
1
+
x
2
V
2
)
[
(
Δ
E
1
v
V
1
)
1
/
2
-
(
Δ
E
2
v
V
2
)
1
/
2
]
2
φ
1
φ
2
,
(
4
)
[0000] where ΔE ν is the energy of vaporization and φ 1 and φ 2 are volume fractions. The enthalpy of mixing can be rewritten as
[0000]
Δ
H
m
=
V
T
[
(
Δ
E
1
v
V
1
)
1
/
2
-
(
Δ
E
2
v
V
2
)
1
/
2
]
2
φ
1
φ
2
,
(
5
)
[0000] where the term ΔE ν /V, the energy of vaporization per unit volume, is a measure of the internal pressure.
[0017] This term is called the solubility parameter, 8, and is defined below:
[0000]
δ
=
(
Δ
E
v
V
)
1
/
2
=
(
Δ
H
v
-
RT
V
)
1
/
2
=
a
1
/
2
V
,
(
6
)
[0000] where ΔH ν is the latent heat of vaporization. (The units of the solubility parameter are typically expressed in (cal/cm 3 ) 1/2 ).
[0018] Therefore, the free energy of mixing is given by:
[0000] Δ G=V[δ 1 −δ 2 ]φ 1 φ 2 +RT[x 1 ln x 1 +x 2 ln x 2 ] (7)
[0000] and solution should occur as δ 1 approaches δ 2 .
[0019] The above expression shows that the solubility parameter of a compound can be calculated directly from the latent heat of vaporization and the molar volume of the compound if these are available. Regardless of the method of determination, solubility parameters are useful in comparing the solvency of compounds because solvents with similar solubility parameters are known by those skilled in the art to have similar solvency properties.
[0020] For reference, the solubility parameter in (cal/cm 3 ) 1/2 for some common compounds are: water, 23.37; acetone, 9.646; ethyl alcohol, 12.779; HFC-134a, 8.067; propane, 6.404; hexane, 7.284; benzene, 9.142; isopropyl alcohol, 11.450; and d-limonene, 8.243.
Volatility
[0021] The volatility of a replacement solvent can be described in terms of properties such as the normal boiling point (nBP). An effective solvent replacement must be volatile enough to evaporate, but should not flash off of surfaces since the solvent must reside on the contaminants long enough to dissolve them. An nBP around 40° C. or higher is generally acceptable for cleaning applications.
Compatibility
[0022] Material and system compatibility is another requirement for a second-generation solvent. The solvent must be compatible with metals such as aluminum, copper, carbon steel and stainless steel, as well as elastomers. The solvent should not degrade or corrode surfaces in the system being cleaned. The solvent also needs to be compatible with the particular system application. For example, a solvent to be used for cleaning oxygen handling system must be compatible with liquid and gaseous oxygen. In this case, tests such as ASTM G86 for ignition sensitivity to mechanical impact must be considered.
Flammability: Autoignition, Flashpoint
[0023] Whether a solvent is suitable as cleaning solvents for systems (e.g., oxygen handling systems) is partially dependent upon its flammability, which sometimes is quantified by the autogenous ignition temperatures (AIT). AIT provides a measure of the material's relative ease of ignition and indicates the approximate temperature at which a material could be expected to spontaneously ignite in high-pressure oxygen. This test is typically performed per ASTM Method G72. A rating system has been established by the NASA White Sands Test Facility and Wright-Patterson Air Force Base. By this system, compounds are classified as A (not recommended, AIT<250° F.), B (caution when used, 250° F.<AIT<400° F.), and C (recommended, AIT>400° F.).
[0024] Another aspect of the flammability determination is the flashpoint of the solvent. The flashpoint is the temperature at which a liquid gives off vapor sufficient to form an ignitable mixture with air (oxygen) near the surface of the liquid. The ideal replacement solvent should not have a flashpoint below or at its boiling point. This insures a wide range of conditions whereby the solvent can be safely used.
Environmental Persistence
[0025] The environmental persistence of a solvent is also very important. Parameters such as the ozone depletion potential (ODP), global warming potential (GWP), and tropospheric lifetime (TLT) are measures of this attribute. ODP and GWP give the relative ability by weight of a chemical to deplete stratospheric ozone and to contribute to global warming, respectively. Values for ODP, GWP and TLT are calculated based on an earth surface release and then reported relative to a reference compound (typically CFC-11 for ODP and CFC-11 or carbon dioxide for GWP). Generally, the ODP should be less than 0.02, and the GWP and TLT should be minimized, preferably lower than the solvent being replaced.
[0026] The biochemical oxygen demand (BOD) is also another measure of persistence typically in groundwater, lakes, and other bodies of water.
Toxicity
[0027] Toxicity is yet another factor which must be considered when selecting second-generation replacement solvents. Parameters such as the lethal dose 50 (LD50), lethal concentration 50 (LC50), cardiac sensitization, skin irritation, and mutagenicity (e.g., via the Ames test) can be used as measures. LDn or LCn abbreviation, where n is the percent lethality, is used for the dose of a toxicant lethal to n % of a test population. For instance, at LD50, 50% of the recipients of that particular toxic dose would die. Cardiac sensitization is a measure of the ability of a compound to cause cardiac arrhythmia under stress. Generally, it is desired to minimize these parameters and select compounds that have lower values than the solvent that is being replaced.
Review of Prior Art
[0028] The CFC-113 replacements known in prior art do not address all of the required second-generation solvent properties. CFC-113 replacements and solvents that address ozone depletion have been introduced and are disclosed in e.g. U.S. Pat. Nos. 5,035,828, 6,402,857, 6,297,308, and 6,020,298. Various solvents and solvent mixtures are disclosed which have low ODPs. These replacement solvents, however, do not possess all of the desired properties of CFC-113 such as flammability, toxicity, oxygen compatibility and cleaning effectiveness.
[0029] In U.S. Pat. No. 5,035,828, HCFC-234 is combined with an aliphatic alcohol or cyclohexane, but this mixture is easily flammable. U.S. Pat. No. 6,402,857 utilizes n-propyl bromide with other organic constituents, which are also flammable and have a significant adverse impact on ozone. U.S. Pat. No. 6,020,298 utilizes hydrofluoropolyethers, and U.S. Pat. No. 6,297,308 utilizes halogenated ethers and hydrocarbons with a surfactant. While these solvents appear to avoid damage to the ozone layer, the perfluorinated compounds contained therein are known to be potent greenhouse gases. In addition, perfluorinated and fluorinated (no chlorine) solvents are undesirable as they can have widely varying solubility properties and different interactions with organic residues when compared to CFC-113.
[0030] U.S. Pat. No. 6,103,684 teaches the use of azeotrope-like mixtures comprised of 1-bromopropane with non-halogenated alcohols and alkanes, as well as halogenated alkanes and fluorinated ethers. The ODP for 1-bromopropane is stated as being between 0.002 and 0.03, classifying it as a Class II Ozone Depleting Substance. The flammability limits of 1-bromopropane are 2.7-9.2% in air, with an auto-ignition temperature of 490° C. In addition, the solubility parameter of 1-bromopropane is also 8.839, too high to effectively dissolve many greases and oils. Furthermore, the alcohols and alkanes of this invention are also flammable.
[0031] In U.S. Pat. No. 6,048,832, the inventors disclose the use of 1-bromopropane with 4-methoxy-1,1,1,2,2,3,3,4,4-nonafluorobutane (an ether) and at least one other non-halogenated organic compound. As in U.S. Pat. No. 6,103,684, the use of 1-bromopropane is questionable due to its high ODP, flammability, and undesirable solubility parameter. The other components, such as ethanol and 2-propanol, also have high solubility parameters of about 11-13, thereby decreasing the usefulness of these mixtures for a broad spectrum of contaminants as will be taught by the present invention.
[0032] Solvents that meet the environmental restrictions and are non-flammable are disclosed in U.S. Pat. Nos. 6,300,378 and 5,759,430 and in Tapscott & Mather, 2000, Tropodegradable fluorocarbon replacements for ozone-depleting and global-warming chemicals. J. Fluorine Chemistry 101:209-213. Compounds disclosed therein are generally non-flammable and/or non-ozone depleting, as they are “tropodegradable fluorocarbons,” defined as compounds having structural weaknesses to ensure rapid decay in the troposphere. When this class of compounds is exposed to sunlight (photolysis) or chemical radicals (e.g. hydroxyls) in the atmosphere, they decay into forms that do not damage the ozone layer nor contribute to the greenhouse effect. The structural weaknesses can take such forms as hydrogen being present on the molecule, a carbon-carbon double bond that is vulnerable to reactions, an ether bond, or a bromine atom being present for easy degradation. These structural vulnerabilities render the molecules unstable, and within a fairly short period of time, they break down and are no longer part of the atmosphere. These references, however, fail to teach solvents with optimized solubility parameters, together with desirable toxicity, and material compatibility. Specifically, these references do not suggest any advantages of using chlorine-containing ethers.
[0033] U.S. Pat. No. 5,273,592 discloses partially fluorinated ethers having a tertiary structure for solvent cleaning. The benefits of combining partially fluorinated ethers with hydrofluorochloro-ethers (HFCE's) or hydrobromochlorofluoro-alkenes (HBCFA's) for solvent applications are not suggested.
[0034] U.S. Pat. No. 4,999,127 teaches an azeotropic mixture of CHF 2 —CClF-O—CHF 2 , trans-1,2-dichloroethylene, and methanol. Some components of this mixture are toxic and flammable, and hence, not desirable as a safe second generation solvent replacement.
[0035] In short, the prior art has taught replacements to CFC's which only partially meet the requirements of a second generation solvent. There is thus a need for second generation replacement solvents that possess all required performance parameters.
SUMMARY OF THE INVENTION
[0036] This invention provides second generation solvents that possess all important performance properties, including:
1) Cleaning effectiveness or solvency; 2) Volatility (Boiling point); 3) Compatibility (metals, elastomers, systems); 4) Toxicity (e.g., LC 50 , LD 50 , cardiac sensitization, skin irritation, mutagenicity); 5) Environmental persistence (e.g., Ozone depletion potential (ODP), Global warming potential (GWP), Tropospheric lifetime (TLT), Biodegradability); 6) Flammability (e.g., Autogenous ignition temperature (AIT), Flash point); 7) Cost & availability.
[0044] We have discovered that mixtures of certain halogenated compounds can meet or exceed the performance properties of CFC's, and in particular, CFC-113. These solvent mixtures comprise two or more compounds selected from hydrofluorochloro-ethers (HFCE's), hydrobromochlorofluoro-alkenes (HBCFA's), hydrofluoro-ethers (HFE's), and halogenated alkanes, alcohols, diones, acetates, ketones (e.g., butanones, pentanones), esters (e.g., propanoates), anhydrides, cycloalkanes (cycloparaffins), cycloalkenes (cycloolefins), heterocyclics (e.g., furans), and aromatics. Many of these compounds have been ignored in the past based on an incomplete evaluation and assumption of generalities pertaining to performance properties. Our approach to identifying these optimal solvent mixtures utilized quantitative structure property relations (QSPR's) and a complex ranking scheme to objectively and completely evaluate numerous potential candidates and numerous properties required to meet the performance of CFC solvents. Many of the compounds and mixtures discovered through this process are novel and have not been considered in the prior art.
[0045] The mixtures taught by this invention comprise compounds which are non-flammable as measured by flashpoint and AIT testing, have ODP's of less than about 0.02, and have solubility parameters within about 10% of CFC-113. The boiling points of these components and mixtures are also greater than about 40° C. to make them useful in most solvent applications, with toxicities less than or similar to CFC-113. We have also found that these components and mixtures are compatible with most elastomers and metals.
[0046] One object of the present invention is to teach CFC solvent replacements comprising at least two tropodegradable components that act collectively to: meet or exceed the cleaning effectiveness or solvency of the CFC targeted for replacement; have ODP values less than about 0.02; have boiling points greater than about 40° C.; have toxicities less than or similar to the CFC targeted for replacement; have no flash point up to their boiling point; have autogenous ignition temperature classifications of B or C, and be compatible with common elastomers and metals.
[0047] The present invention further discloses that certain brominated compounds can be included in solvent mixtures to affect solvency properties so as to perform similar to or better than the CFC targeted for replacement. These brominated compounds are known to offer reductions in flammability, but we have discovered surprisingly that they also offer effective CFC solvency enhancement when combined with other compounds.
[0048] It has also been surprising discovered that mixtures of certain compounds can effectively increase the solvency range for certain common contaminants (e.g., hydrocarbon and fluorocarbon greases, oils, decomposition products) when compared to the CFCs targeted for replacement.
[0049] In another aspect, this invention shows that compounds that have generally been used as anesthetics are excellent solvents which possess minimal or well-characterized toxicity.
[0050] Yet another object of this invention is to teach the use of second generation solvent mixtures to clean and/or degrease components or systems related to, but not limited to, oxygen handling systems, refrigeration systems or heat pumps, electronics, implantable prosthetic devices, and optical equipments.
[0051] In a preferred embodiment, solvent mixtures of the present invention are compatible with liquid oxygen handling systems, especially with regard to ignition sensitivity to mechanical impact in liquid oxygen.
[0052] A related object of this invention is to teach alternative CFC compositions suitable for foam blowing and applying coatings.
[0053] An additional object of this invention is to teach the general methods by which second generation solvents can be specified to replace not only CFC's, but also future compounds which will be banned from use such as hydrochlorofluorocarbons (HCFC's) and hydrobromofluorocarbons (HBFC's).
BRIEF DESCRIPTION OF TABLES 1 And 2
[0054] Table 1 lists compounds derived using the methods of the present invention. Compounds listed therein have boiling points greater than 40° C., ODP values less than about 0.02, a solubility parameter within a range of about ±10% of CFC-113, a CS value greater than or equal to 80% of the CFC-113 value, and TLT's less than that of CFC-113. In Table 1, CS/CS 113 refers to cardiac sensitization (CS), a measure of inhalation toxicity of the compound relative to CFC-113 with a predicted value of 1090 ppm; and SP is the solubility parameter. The values for this selected group of solvent properties are shown with CFC-113 as reference. Five more preferred compounds of this invention are denoted by the letters A though E in the table. The underlined numbers in Table 1 are experimental values. Others are predictions from quantitative structure property relations (QSPR's, see below), illustrating the necessity of using QSPR's as taught by this invention to compare and evaluate a large list of second-generation candidates.
[0055] Table 2 summarizes some of the preferred compounds, and their boiling points and solubility parameters relative to CFC-113.
DETAILED DESCRIPTION OF THE INVENTION
[0056] The solvent CFC-113 (1,1,2-trichloro-1,2,2-trifluoroethane) had been the solvent of choice for many applications until the mid-1980's. Due to its phase out, alternative solvents with similar overall properties have been sought. Those skilled in the art have attempted to find replacements with some success, believing that because CFC-113 possess so many desirable properties that must be matched, a replacement solvent must sacrifice or comprise on some performance properties.
[0057] Using a novel and heretofore never suggested approach, the inventors of the present invention first developed a comprehensive list of candidate replacements meeting key performance properties, and then tested these individual components as replacements. This approach is completely objective and unbiased by previously untested assumptions or generalities related to certain classes of compounds.
[0058] As a consequence, the inventors of the present invention discovered, as have others, that a single component replacement cannot meet all of the performance requirements of most first generation solvents, most notably, solvency. Our focus then turned to mixtures of compounds which possessed a difference in solubility parameter in order to increase the solubility range for the second generation solvent. It is by this process that we discovered certain synergies when combining these solvents. The general process by which we made this discovery is described below.
[0059] We considered a total of about 800 compounds. The compounds included halogenated alcohols, halogenated alkenes, halogenated amines, halogenated aromatics, halogenated carbonyls, halogenated ethers, halogenated alkanes, halogenated heterocyclics, halogenated cycloalkanes (cycloparaffins), and halogenated cycloalkenes (cycloolefins). The list of potential second-generation CFC solvent replacements was then mathematically analyzed to arrive at a list of compounds which simultaneously met the performance requirements for solvency, boiling point, and toxicity for a second-generation replacement to CFC-113. A mathematical database of properties critical to solvent function was tabulated with this large list of potential second generation solvents. If literature or experimental values for the performance properties were not available, we developed quantitative structure property relations (QSPR's) to model and predict the particular property which was then included in the database table. Those skilled in the art will understand the usefulness and accuracy of QSPR's in the development of products such as environmentally-friendly chemicals and pharmaceuticals. This overall method of objectively selecting compounds by considering a large number of constraining performance properties can be used for a variety of applications whereby target properties of the first generation solvent are known.
[0060] As stated previously, there are several critical performance properties which must be considered when prescribing solvent replacements. These properties include:
1) Cleaning effectiveness or solvency; 2) Volatility (Boiling point); 3) Compatibility (metals, elastomers, systems); 4) Toxicity (e.g., LC50, LD50, cardiac sensitization, skin irritation, mutagenicity); 5) Environmental persistence (e.g., Ozone depletion potential (ODP), Global warming potential (GWP), Tropospheric lifetime (TLT), Biodegradability); 6) Flammability (e.g., Autogenous ignition temperature (AIT), Flash point); and 7) Cost & availability.
[0068] Of the properties listed above, those having primary significance in selecting a second generation replacement are the solvency, volatility, toxicity, and environmental persistence. More specifically, an acceptable second generation solvent should generally have boiling points greater than about 40° C., ODP values less than about 0.02, high LD50 values greater than about 5 g/kg, and solubility parameters within about 10% of CFC-113. Other toxicity measures (e.g., cardiac sensitization or CS, mutagenicity, skin irritation, and inhalation LC50) should be minimized with respect to the compounds targeted for replacement. The remaining properties of compatibility and flammability are also important, and were measured for several compounds meeting the solvency, volatility, toxicity, and environmental persistence requirements. Table 1 shows a summary of numerous compounds resulting from the process described above which met these important performance properties. The values in underlined are experimental data, whereas the other values are QSPR model predictions. CFC-113 properties are shown on line 1 of Table 1 for comparison.
[0000]
TABLE 1
SP
BP
T.L.T.
(cal/
CHEMICAL NAME
(C)
GWP
ODP
(yrs.)
CS/CS 113
cm 3 ) 1/2
1,1,2-trichlorotrifluoroethane
47.6
5000
0.90
85
1.0
7.19
(CFC-113) (Comparative)
(A.) 4-bromo-3-chloro-3,4,4-
99.7
0
0.01
0.01
0.8
7.76
trifluoro-1-butene
(B.) 1-chloro-2,2,2-trifluoroethyl
48.8
200
0.02
4.0
50.2
7.58
difluoromethyl ether (isoflurane)
(C.) 2-chloro-1,1,2-trifluoroethyl
56.7
330
0.02
5.3
35.5
7.71
difluoromethyl ether (enflurane)
(D.) 1-bromo-2-(trifluoromethyl)-
49.3
2281
0.01
N/A
49.4
6.95
3,3,3-trifluoropropene
(E.) methyl 2,2,2-trifluroethyl-1-
50.8
28
0.00
0.18
107.3
7.26
(trifluoromethyl)ether
4-bromo-1,1,1,3,4,4-hexafluoro-2-
68.1
9849
0.01
0.44
103.2
6.51
(trifluoromethyl)-2-butene
heptafluoropropyl 1,2,2,2-
41.0
597
0.00
4.5
195.7
6.62
tetrafluoroethyl ether
perfluorodibutyl ether
110.1
33
0.00
1.2
896.2
6.65
4-bromo-1,1,1,4,4-pentafluoro-2-
61.0
7572
0.01
0.30
105.5
6.74
(trifluoromethyl)-2-butene
methyl perfluorobutyl ether
51.0
480
0.00
3.5
53.5
6.75
3-bromo-1,1,2,3,4,4,4-
47.5
422
0.01
0.62
21.9
6.75
heptafluorobutene
1,1,1,4,4-pentafluoro-4-bromo-2-
61.0
7572
0.01
0.30
105.5
6.77
trifluoromethyl-2-butene
1-bromo-1,3,3,3-tetrafluoro-2-
51.9
5061
0.01
0.62
71.9
6.78
(trifluoromethyl)-1-propene
(Z)-1-bromo-perfluoro-2-butene
48.0
2540
0.01
0.62
41.4
6.78
4-bromo-1,1,2,3,3,4,4-
51.5
422
0.01
0.62
23.4
6.78
heptafluorobutene
(Z)-2-bromo-1,1,1,3,4,4,4-
49.0
2540
0.01
0.62
48.6
6.79
heptafluoro-2-butene
3,3,3-trifluoro-bis-2,2-
86.1
1201
0.00
3.5
40.7
6.81
(trifluoromethyl)-1-propanol
1,2-(Z)-bis(perfluoro-n-
132.0
15
0.00
0.03
1188.5
6.81
butyl)ethylene
(E)-2-bromo-1,1,1,3,4,4,4-
49.0
2540
0.01
0.62
48.6
6.82
heptafluoro-2-butene
1,1,1,3,3,3-hexafluoro-2-
46.0
1292
0.00
13.1
61.2
6.84
(trifluoromethyl)-2-propanol
2H,3H-decafluoropentane (Vertrel
55.0
1300
0.00
26.8
91.5
6.84
XF)
ethyl-perfluorobutyl ether
73.0
70
0.00
1.14
69.0
6.85
(E)-1-bromo-perfluoro-2-butene
48.0
2540
0.01
0.62
41.4
6.85
1,1,1,5,5,5-hexafluoro-2,4-
69.9
97
0.00
0.00
140.5
6.90
pentanedione
perfluoro-2-butyltetrahydrofuran
103.0
13
0.00
2.4
65.4
6.94
1H,2H,4H-nonafluorocyclohexane
65.0
252
0.00
6.19
18.5
7.02
(E)-2-bromo-1,1,1,4,4,4-
45.1
1565
0.01
0.38
42.7
7.06
hexafluoro-2-butene
1-bromo-bis(perfluoromethyl)
45.1
1565
0.01
0.38
42.7
7.06
ethylene
1-(bromodifluoromethoxy)-2-
78.6
6104
0.01
0.11
187.0
7.06
(trifluoromethyl)-1,3,3,3-
tetrafluoro-1-propene
1-methoxy-2-trifluoromethyl-
44.5
933
0.00
0.07
154.6
7.09
1,3,3,3-tetrafluoro-1-propene
fluoromethyl 2,2,2-trifluoro-1-
59.0
1586
0.00
2.3
103.0
7.10
(trifluoromethyl)ethyl ether
(SEVOFLURANE)
(E)-2,3-dichlorohexafluoro-2-
68.5
1104
0.00
0.32
72.4
7.15
butene
2-bromo-3,3,4,4,4-
66.1
84
0.01
0.32
10.5
7.19
pentafluorobutene
3-bromo-2,3,4,4,4-
69.7
84
0.01
0.32
4.9
7.20
pentafluorobutene
4-bromo-2,3,3,4,4-
69.2
84
0.01
0.32
6.0
7.21
pentafluorobutene
(Z)-1-(bromodifluoromethoxy)-
65.2
1334
0.01
0.14
70.1
7.22
1,2,3,3,3-pentafluoro-1-propene
3-bromo-3,3-difluoro-2-
49.7
733
0.01
0.32
15.0
7.24
(trifluoromethyl)-propene
(Z)-1-bromo-1,1,4,4,4-pentafluoro-
40.0
620
0.02
0.23
36.6
7.25
2-butene
(E)-1-(bromodifluoromethoxy)-
65.2
1334
0.01
0.14
70.1
7.25
1,2,3,3,3-pentafluoro-1-propene
3,3-dichloro-1,1,1,2,2-
48.5
237
0.02
12.7
16.7
7.26
pentafluoropropane (HCFC-225)
1-(bromodifluoromethoxy)-2-
78.3
2729
0.01
0.08
151.6
7.26
(trifluoromethyl)-3,3,3-trifluoro-1-
propene
methyl-1,1,2,2,3,3-
40.1
99
0.00
2.34
36.5
7.27
hexafluoropropyl ether
trifluoroacetic anhydride
40.2
97
0.00
0.00
236.9
7.29
2-bromo-1,1,2,2-tetrafluoroethoxy-
81.9
137
0.01
0.14
33.0
7.30
trifluoroethene
2,2-difluoroethyl-1,1,2,2-
48.4
152
0.00
0.92
114.6
7.31
tetrafluoroethyl ether
1,3-dichloro-1,1,2,2,3-
52.7
350
0.02
6.6
9.2
7.31
pentafluoropropane (HCFC-225cb,
AK-225G)
bis(2,2,2-trifluoroethyl)ether
62.5
477
0.00
1.5
109.2
7.32
methyl heptafluoropropyl ketone
63.5
34
0.00
0.13
25.4
7.32
(E)-1-bromo-1,1,4,4,4-pentafluoro-
40.0
620
0.02
0.23
36.6
7.37
2-butene
difluoromethyl-2,2,3,3-
49.8
152
0.00
0.92
109.9
7.44
tetrafluoropropyl ether
4-bromo-3,3,4,4-tetrafluoro-1-
55.0
69
0.01
0.20
5.8
7.44
butene
bis(difluoromethoxy)-
58.0
172
0.00
0.86
362.3
7.50
tetrafluoroethane
2-chloro-1,1,2-trifluoroethyl ethyl
88.9
31
0.00
0.41
15.0
7.50
ether
1-(2,2,2-
113.7
112
0.00
0.05
70.2
7.51
trifluoroethoxy)nonafluoro-
cyclohexene
1,2-dichloro-3,3,4,4,5,5,6,6-
123.8
30
0.00
0.27
15.5
7.55
octafluoro-cyclohexene
(Z)-1-bromo-1,2-difluoro-2-(2,2,2-
87.9
138
0.00
0.04
52.7
7.61
trifluoroethoxy)-ethene
(bromodifluoromethyl)-
153.3
199
0.00
0.82
28.2
7.63
pentafluorobenzene
(Z)-1-(bromodifluoromethoxy)-2-
57.8
238
0.02
0.06
54.3
7.63
(trifluoromethyl)ethene
2-bromoheptafluorotoluene
151.3
199
0.00
0.82
21.5
7.64
(2,2,2-trifluoroethyl)(2-bromo-2,2-
73.0
238
0.02
0.96
52.1
7.64
difluoroethyl)ether
3-bromoheptafluorotoluene
153.0
199
0.00
0.82
21.1
7.66
4-bromoheptafluorotoluene
151.3
199
0.00
0.82
37.9
7.66
1-(bromodifluoromethoxy)-1-
66.3
340
0.01
0.10
27.7
7.67
(trifluoromethyl)ethene
ethyl-1,1,2,2-tetrafluoroethyl
45.9
61
0.00
0.66
38.5
7.67
ether
Perfluorotoluene
104.0
335
0.00
1.1
64.0
7.70
(E)-1-(bromodifluoromethoxy)-2-
57.8
238
0.02
0.06
54.3
7.73
(trifluoromethyl)ethene
1-bromo-2,4,6-
173.4
618
0.00
0.34
113.0
7.76
tris(trifluoromethyl)benzene
methyl pentafluoropropanoate
59.5
30
0.00
0.05
27.0
7.77
4-bromo-1,1,2,3,3-
80.4
314
0.00
0.15
25.3
7.79
pentafluorobutene
(E)-1-(bromodifluoromethoxy)-2-
76.5
682
0.02
0.04
144.9
7.79
(trifluoromethoxy)ethene
(Z)-1-(bromodifluoromethoxy)-2-
76.5
682
0.02
0.04
144.9
7.79
(trifluoromethoxy)ethene
1,1,4,4,4-pentafluoro-1-bromo-2-
89.0
340
0.01
0.09
17.1
7.89
butanone
1,1,5,5,5-pentafluoro-1-bromo-3-
118.4
197
0.00
0.03
34.2
7.89
pentanone
1,2-dichloro-hexafluoro-
90.0
45
0.00
0.34
9.9
7.90
cyclopentene
3-bromo-2,3,3-trifluoropropene
41.6
101
0.02
0.26
6.1
7.66
3-bromo-1,3,3-trifluoropropene
41.5
153
0.02
0.17
12.9
7.73
3-bromo-3,3-difluoro-1-propene
42.0
66
0.02
0.13
5.9
7.89
Table 1A Bromo-containing compounds of Table 1
1,1,2-
47.6
5000
0.90
85
1.0
7.19
trichlorotrifluoroethane
(CFC-113) (Comparative)
(A.) 4-bromo-3-chloro-3,4,4-
99.7
0
0.01
0.01
0.8
7.76
trifluoro-1-butene
(D.) 1-bromo-2-
49.3
2281
0.01
N/A
49.4
6.95
(trifluoromethyl)-3,3,3-
trifluoropropene
4-bromo-1,1,1,3,4,4-
68.1
9849
0.01
0.44
103.2
6.51
hexafluoro-2-
(trifluoromethyl)-2-butene
4-bromo-1,1,1,4,4-
61.0
7572
0.01
0.30
105.5
6.74
pentafluoro-2-
(trifluoromethyl)-2-butene
3-bromo-1,1,2,3,4,4,4-
47.5
422
0.01
0.62
21.9
6.75
heptafluorobutene
1,1,1,4,4-pentafluoro-4-
61.0
7572
0.01
0.30
105.5
6.77
bromo-2-trifluoromethyl-2-
butene
1-bromo-1,3,3,3-tetrafluoro-
51.9
5061
0.01
0.62
71.9
6.78
2-(trifluoromethyl)-1-
propene
(Z)-1-bromo-perfluoro-2-
48.0
2540
0.01
0.62
41.4
6.78
butene
4-bromo-1,1,2,3,3,4,4-
51.5
422
0.01
0.62
23.4
6.78
heptafluorobutene
(Z)-2-bromo-1,1,1,3,4,4,4-
49.0
2540
0.01
0.62
48.6
6.79
heptafluoro-2-butene
(E)-2-bromo-1,1,1,3,4,4,4-
49.0
2540
0.01
0.62
48.6
6.82
heptafluoro-2-butene
(E)-1-bromo-perfluoro-2-
48.0
2540
0.01
0.62
41.4
6.85
butene
(E)-2-bromo-1,1,1,4,4,4-
45.1
1565
0.01
0.38
42.7
7.06
hexafluoro-2-butene
1-bromo-
45.1
1565
0.01
0.38
42.7
7.06
bis(perfluoromethyl)
ethylene
1-(bromodifluoromethoxy)-2-
78.6
6104
0.01
0.11
187.0
7.06
(trifluoromethyl)-1,3,3,3-
tetrafluoro-1-propene
2-bromo-3,3,4,4,4-
66.1
84
0.01
0.32
10.5
7.19
pentafluorobutene
3-bromo-2,3,4,4,4-
69.7
84
0.01
0.32
4.9
7.20
pentafluorobutene
4-bromo-2,3,3,4,4-
69.2
84
0.01
0.32
6.0
7.21
pentafluorobutene
(Z)-1-
65.2
1334
0.01
0.14
70.1
7.22
(bromodifluoromethoxy)-
1,2,3,3,3-pentafluoro-1-
propene
3-bromo-3,3-difluoro-2-
49.7
733
0.01
0.32
15.0
7.24
(trifluoromethyl)-propene
(Z)-1-bromo-1,1,4,4,4-
40.0
620
0.02
0.23
36.6
7.25
pentafluoro-2-butene
(E)-1-
65.2
1334
0.01
0.14
70.1
7.25
(bromodifluoromethoxy)-
1,2,3,3,3-pentafluoro-1-
propene
1-(bromodifluoromethoxy)-2-
78.3
2729
0.01
0.08
151.6
7.26
(trifluoromethyl)-3,3,3-
trifluoro-1-propene
2-bromo-1,1,2,2-
81.9
137
0.01
0.14
33.0
7.30
tetrafluoroethoxy-
trifluoroethene
(E)-1-bromo-1,1,4,4,4-
40.0
620
0.02
0.23
36.6
7.37
pentafluoro-2-butene
4-bromo-3,3,4,4-tetrafluoro-
55.0
69
0.01
0.20
5.8
7.44
1-butene
(Z)-1-bromo-1,2-difluoro-2-
87.9
138
0.00
0.04
52.7
7.61
(2,2,2-trifluoroethoxy)-
ethene
(bromodifluoromethyl)-
153.3
199
0.00
0.82
28.2
7.63
pentafluorobenzene
(Z)-1-
57.8
238
0.02
0.06
54.3
7.63
(bromodifluoromethoxy)-2-
(trifluoromethyl)ethene
2-bromoheptafluorotoluene
151.3
199
0.00
0.82
21.5
7.64
(2,2,2-trifluoroethyl)(2-
73.0
238
0.02
0.96
52.1
7.64
bromo-2,2-
difluoroethyl)ether
3-bromoheptafluorotoluene
153.0
199
0.00
0.82
21.1
7.66
4-bromoheptafluorotoluene
151.3
199
0.00
0.82
37.9
7.66
1-(bromodifluoromethoxy)-1-
66.3
340
0.01
0.10
27.7
7.67
(trifluoromethyl)ethene
(E)-1-
57.8
238
0.02
0.06
54.3
7.73
(bromodifluoromethoxy)-2-
(trifluoromethyl)ethene
1-bromo-2,4,6-
173.4
618
0.00
0.34
113.0
7.76
tris(trifluoromethyl)benzene
4-bromo-1,1,2,3,3-
80.4
314
0.00
0.15
25.3
7.79
pentafluorobutene
(E)-1-
76.5
682
0.02
0.04
144.9
7.79
(bromodifluoromethoxy)-2-
(trifluoromethoxy)ethene
(Z)-1-
76.5
682
0.02
0.04
144.9
7.79
(bromodifluoromethoxy)-2-
(trifluoromethoxy)ethene
1,1,4,4,4-pentafluoro-1-
89.0
340
0.01
0.09
17.1
7.89
bromo-2-butanone
1,1,5,5,5-pentafluoro-1-
118.4
197
0.00
0.03
34.2
7.89
bromo-3-pentanone
3-bromo-2,3,3-
41.6
101
0.02
0.26
6.1
7.66
trifluoropropene
3-bromo-1,3,3-
41.5
153
0.02
0.17
12.9
7.73
trifluoropropene
3-bromo-3,3-difluoro-1-
42.0
66
0.02
0.13
5.9
7.89
propene
Total 44 compounds (excluding CFC-113)
Table 1B Non-bromine containing compounds in Table 1
1,1,2-trichlorotrifluoroethane (CFC-113)
47.6
5000
0.90
85
1.0
7.19
(Comparative)
(B.) 1-chloro-2,2,2-trifluoroethyl
48.8
200
0.02
4.0
50.2
7.58
difluoromethyl ether (isoflurane)
(C.) 2-chloro-1,1,2-trifluoroethyl
56.7
330
0.02
5.3
35.5
7.71
difluoromethyl ether (enflurane)
(E.) methyl 2,2,2-trifluroethyl-1-
50.8
28
0.00
0.18
107.3
7.26
(trifluoromethyl)ether
Heptafluoropropyl 1,2,2,2-
41.0
597
0.00
4.5
195.7
6.62
tetrafluoroethyl ether
perfluorodibutyl ether
110.1
33
0.00
1.2
896.2
6.65
methyl perfluorobutyl ether
51.0
480
0.00
3.5
53.5
6.75
3,3,3-trifluoro-bis-2,2-(trifluoromethyl)-
86.1
1201
0.00
3.5
40.7
6.81
1-propanol
1,2-(Z)-bis(perfluoro-n-butyl)ethylene
132.0
15
0.00
0.03
1188.5
6.81
1,1,1,3,3,3-hexafluoro-2-
46.0
1292
0.00
13.1
61.2
6.84
(trifluoromethyl)-2-propanol
2H,3H-decafluoropentane (Vertrel XF)
55.0
1300
0.00
26.8
91.5
6.84
ethyl-perfluorobutyl ether
73.0
70
0.00
1.14
69.0
6.85
1,1,1,5,5,5-hexafluoro-2,4-pentanedione
69.9
97
0.00
0.00
140.5
6.90
perfluoro-2-butyltetrahydrofuran
103.0
13
0.00
2.4
65.4
6.94
1H,2H,4H-nonafluorocyclohexane
65.0
252
0.00
6.19
18.5
7.02
1-methoxy-2-trifluoromethyl-1,3,3,3-
44.5
933
0.00
0.07
154.6
7.09
tetrafluoro-1-propene
fluoromethyl 2,2,2-trifluoro-1-
59.0
1586
0.00
2.3
103.0
7.10
(trifluoromethyl)ethyl ether
(SEVOFLURANE)
(E)-2,3-dichlorohexafluoro-2-butene
68.5
1104
0.00
0.32
72.4
7.15
3,3-dichloro-1,1,1,2,2-
48.5
237
0.02
12.7
16.7
7.26
pentafluoropropane (HCFC-225)
methyl-1,1,2,2,3,3-hexafluoropropyl
40.1
99
0.00
2.34
36.5
7.27
ether
trifluoroacetic anhydride
40.2
97
0.00
0.00
236.9
7.29
2,2-difluoroethyl-1,1,2,2-tetrafluoroethyl
48.4
152
0.00
0.92
114.6
7.31
ether
1,3-dichloro-1,1,2,2,3-
52.7
350
0.02
6.6
9.2
7.31
pentafluoropropane (HCFC-225cb, AK-
225G)
bis(2,2,2-trifluoroethyl)ether
62.5
477
0.00
1.5
109.2
7.32
methyl heptafluoropropyl ketone
63.5
34
0.00
0.13
25.4
7.32
difluoromethyl-2,2,3,3-tetrafluoropropyl
49.8
152
0.00
0.92
109.9
7.44
ether
bis(difluoromethoxy)-tetrafluoroethane
58.0
172
0.00
0.86
362.3
7.50
2-chloro-1,1,2-trifluoroethyl ethyl ether
88.9
31
0.00
0.41
15.0
7.50
1-(2,2,2-trifluoroethoxy)nonafluoro-
113.7
112
0.00
0.05
70.2
7.51
cyclohexene
1,2-dichloro-3,3,4,4,5,5,6,6-octafluoro-
123.8
30
0.00
0.27
15.5
7.55
cyclohexene
ethyl-1,1,2,2-tetrafluoroethyl ether
45.9
61
0.00
0.66
38.5
7.67
Perfluorotoluene
104.0
335
0.00
1.1
64.0
7.70
methyl trifluoroacetate
43.5
48
0.00
1.7
18.7
7.73
methyl pentafluoropropanoate
59.5
30
0.00
0.05
27.0
7.77
1,2-dichloro-hexafluoro-cyclopentene
90.0
45
0.00
0.34
9.9
7.90
(Total 34 compounds)
[0069] In general, the compounds of Table 1 are halogenated acetates, alcohols, alkanes, alkenes, anhydrides, aromatics, cycloalkanes, cycloalkenes, diones, esters, ethers, heterocyclics, or ketones, with or without the heteroatom bromine. Aside from these compounds meeting the other required properties for CFC-113 replacement, the presence of bromine also has the effect of reducing flammability, although this invention does not require a bromine atom be present to reduce flammability. We have found that the compounds most useful for second-generation solvent replacements of CFC-113 have the following chemical formula: C q H r Br x Cl y F z O p , where q=3-10, r=0-11, x=0-1, y=0-2, z>1, and p=0-3. Many of these compounds belong to the classes of hydrofluorochloro-ethers (HFCE's), hydrobromofluorochloro-alkenes (HBFCA's), and hydrofluoro-ethers (HFE's). This formula also incorporates compounds in the families of alkanes, alcohols, diones, acetates, ketones (e.g., butanones, pentanones), esters (e.g., propanoates), anhydrides, cycloalkanes (cycloparaffins), cycloalkenes (cycloolefins), heterocyclics (e.g., furans), and aromatics. As illustrated in Table 1, all of them meet the performance requirements detailed in this invention.
[0070] Some of the ethers we have identified to be suitable solvent replacements include 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether, 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether, methyl 2,2,2-trifluoroethyl-1-(trifluoromethyl)ether, fluoromethyl 2,2,2-trifluoro-1-(trifluoromethyl)ethyl ether, methyl-1,1,2,2,3,3-hexafluoropropyl ether, bis(2,2,2-trifluoroethyl)ether, 2-chloro-1,1,2-trifluoroethyl ethyl ether, difluoromethyl-2,2,3,3-tetrafluoropropyl ether, difluoromethyl 1-chloro-2,2,2-trifluoroethyl ether, (2,2,2-trifluoroethyl)(2-bromo-2,2-difluoroethyl)ether, and ethyl-1,1,2,2-tetrafluoroethyl ether.
[0071] Using the further restriction of cost and availability on the compounds, we identified in Table 1, some of the preferred compounds of this invention that are viable CFC-113 replacements, including:
[0072] A. 4-bromo-3-chloro-3,4,4-trifluoro-1-butene (CH 2 ═CH—CFC 1 —CF 2 Br), CAS registry number 374-25-4;
[0073] B. 1-chloro-2,2,2 trifluoroethyl difluoromethyl ether (CHF 2 —O—CHCl—CF 3 ), CAS registry number 26675-46-7,
[0074] C. 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether (CHClF—CF 2 —O—CHF 2 ), CAS registry number 13838-16-9,
[0075] D. 1-bromo-2-(trifluoromethyl)-3,3,3-trifluoropropene (CHBr═C(CF 3 ) 2 ), CAS registry number 328-15-0, and
[0076] E. methyl 2,2,2-trifluoroethyl-1-(trifluoromethyl)ether (CH 3 —O—CH(CF 3 ) 2 ), CAS registry number 13171-18-1.
[0077] Compound B above is also known as isoflurane, and compound C is known as enflurane, both common anesthetics. These preferred compounds of our invention for CFC-113 replacements have boiling points greater than about 40° C., solubility parameters within about 10% of CFC-113, ODP values less than about 0.02, lower TLT and GWP than CFC-113, and minimal toxicity lower than that of CFC-113. Of particular utility in this invention are HFCE's, previously overlooked by those skilled in the art, when combined with other halogenated ethers and/or halogenated alkenes. The use of anesthetics compounds also has advantages in that they have been thoroughly tested for toxicity by the medical community, and these compounds will be more easily and more quickly accepted as alternative solvents.
[0078] Note that the ODP for CFC-113 is much higher than 0.02, classifying it as a Class II Ozone Depleting Substance. The GWP and TLT of CFC-113 are also 5000 and 0.9, respectively. The toxicity of CFC-113 is also typically higher than those compounds shown in Table 1. Some of the compounds identified by this approach and listed in Table 1 have many properties improved over CFC-113 while having the same or similar solvency properties, (e.g., solubility parameter within 10% of CFC-113).
[0079] We then proceeded to verify the primary performance properties (e.g., solvency toward different contaminants such as oils and greases) of the compounds specified by this invention. The solvency properties of the compounds taught by this invention have been verified for compounds typically found in applications, such as oxygen handling systems and refrigeration system flushing. For example, certain oils, greases and cleaners such as Mil-spec 83232 hydraulic oil, Mil-spec 7808 engine oil, Mil-spec 81322 hydrocarbon grease, Krytox, and Simple Green are used in oxygen handling systems. The compounds listed above have been found to dissolve some of these contaminants, and when used in mixtures a broader range of contaminant types can be dissolved.
[0080] We then discovered that although some of these replacements identified and listed in Table 1 can meet or exceed some of the performance properties of CFC-113, the solvency toward a variety of greases and contaminants was inferior to CFC-113 and other single component second generation compounds. Further, we discovered that by combining 2 or more of these identified compounds, solvent blends can be tailored to provide optimized solvency toward a range of contaminant types. In fact, the combination of 2 or more solvents can provide improved solvency toward contaminants such as greases and oils since the solvency range can be extended or broadened when compared to a single compound. This also suggests that synergies exist when combining compounds identified in this invention would not have been expected if considering only the individual components of the mixture It must also be recognized that the solvency of the 2 or more compounds comprising the solvent must be similar, otherwise the 2 or more components will not be soluble in each other.
[0081] The advantage of using mixtures which increase the solubility range of the solvent replacement can be appreciated when considering the solubility parameters. The solubility parameter of CFC-113 is 7.2. The solubility parameter necessary to dissolve both fluorocarbon and hydrocarbon grease in oxygen systems has been found to be somewhere between 7.5 and 7.7. In general, values less than 7.5 favors dissolution of fluorocarbon but not hydrocarbon greases whereas values in excess of 7.7 tend to favor the opposite. Hence, the advantages to using the approach taught by this invention provides for improved and more versatile solvents that can not only dissolve a wide range of contaminant types, but they also meet the many other requirements placed on solvents such as environmental persistence, toxicity, and material compatibility. For example, by combining the two compounds, (A.) 4-bromo-3-chloro-3,4,4-trifluoro-1-butene and (B.) 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether (aka isoflurane), the solubility parameter will still be between the values 7.65 and 7.7 and is shown to effectively dissolve both types of grease contaminants in an oxygen handling system.
[0082] We then proceeded to characterize other properties such as compatibility, flash point, and autogenous ignition temperature. We discovered that, contrary to commonly held beliefs, it is not necessary for the compound or the mixture to contain bromine heteroatoms in order to possess desirable flammability properties. In fact, some of the tested compounds exhibited AIT temperatures categorized as “C”, or recommended for oxygen systems. We have also discovered that several of the compounds we have identified using the methods taught by this invention also have no flashpoints up to the boiling point of the compound.
[0083] This invention also teaches that a bromine-containing compound is not necessary for the mixtures of this invention to limit or eliminate flammability, but rather, these bromine containing compounds were identified by the mere virtue of their solubility parameter and other properties that have made them suitable in mixtures as replacements for CFC-113.
[0084] In using the methods taught by this invention, we have also discovered that a particularly preferred solvent replacements for CFC-113 based on solvency, ODP, boiling point, and toxicity, are those with 1 bromine atom. Compounds with multiple Br atoms were considered by the methods taught in this invention, but these compounds could not meet most of the required performance properties. Hence, we conclude that compounds containing more than one bromine atom will most likely be unsuitable as CFC-113 replacements.
[0085] We have also discovered that many of the compounds identified have similar or better LD 50 , mutagenicity and genotoxicity relative to CFC-113. Hence, combinations of these compounds will likewise have similar or better toxicity profiles. For example, the compounds 4-bromo-3-chloro-3,4,4-trifluoro-1-butene, 1-chloro-2,2,2 trifluoroethyl difluoromethyl ether, 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether, and methyl 2,2,2-trifluoroethyl-1-(trifluoromethyl)ether have LD 50 values of >40 g/kg, 8.1 g/kg, 13 g/kg, and >40 g/kg, respectively, compared to CFC-113 which has a value of 43 g/kg, all values being in a range considered to be a relatively low toxicity. These same compounds also have been found to be negative for the Ames mutagenicity assay, and not genotoxic using in vitro Chinese hamster oocytes. CFC-113 also is reported negative for the Ames test. Skin irritation is also an important consideration for a solvent. The compounds 4-bromo-3-chloro-3,4,4-trifluoro-1-butene, 1-chloro-2,2,2 trifluoroethyl difluoromethyl ether, 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether, and methyl 2,2,2-trifluoroethyl-1-(trifluoromethyl)ether have been tested and determined to be a moderate to non-irritants, whereas CFC-113 is listed as a mild irritant. Hence, this invention offers improvement in some categories of toxicity compared to CFC-113. Some of the ether compounds of this invention are also used as anesthetics or anesthetic intermediates, and consequently, have undergone a considerable amount of toxicity testing by the medical community.
[0086] Solvents used in oxygen handling systems, more particularly liquid oxygen system, must not pose any risks caused by mechanical impact. We have found that many of the compounds taught by this invention can be combined to produce a mixture that is liquid oxygen-compatible solvent even when the individual components may not be compatible. For example, the compound (A) 4-bromo-3-chloro-3,4,4-trifluoro-1-butene does not pass ASTM G86 for ignition sensitivity to mechanical impact in liquid oxygen, but when combined with the compound (B) 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether at 25% to 50% 4-bromo-3-chloro-3,4,4-trifluoro-1-butene, the mixture passes the impact test. This result and the observed synergy were unexpected.
[0087] Furthermore, many of the compounds taught by this invention and found to posses superior solvency properties have previously been used as anesthetics or are intermediates to producing anesthetics. These compounds have been extensively tested for toxicity and mutagenicity and pose minimal risk with regard to health. Examples of these halogenated ether compounds include, but are not limited to, isoflurane, enflurane, desflurane, sevoflurane, and methoxyflurane. We have also found that the anesthetics, isoflurane (1-chloro-2,2,2-difluoroethyl difluoromethyl ether), enflurane (2-chloro-1,1,2-trifluoroethyl difluoromethyl ether), sevoflurane (fluoromethyl 2,2,2-trifluoro-1-(trifluoromethyl)ethyl ether), and methyl 2,2,2-trifluoroethyl-1-trifluoromethyl ether, an intermediate in the production of sevoflurane, have additional advantages with respect to solvency and boiling point. These compounds have not been previously considered as solvents in combination with other compounds.
[0088] Furthermore, we have discovered that many of the compounds which exhibited the best cleaning performance were compounds having a linear structure with a non-polar portion of the molecule on one end and a high electron density on the other, or having a highly branched structure, or having a very asymmetric structure. This feature could result from either branching on one end or large halogen molecules on one end. Example compounds with these characteristics are 4-bromo-3,3,4,4-tetrafluoro-1-butene, 4-bromo-3-chloro-3,4,4-trifluoro-1-butene, and methyl 2,2,2-trifluoroethyl-1-(trifluoromethyl)ether. Many of the other compounds listed in Table 1, for example, exhibit these features.
[0089] One preferred embodiment of this invention are solvents blends comprised of 4-bromo-3-chloro-3,4,4-trifluoro-1-butene and 1-chloro-2,2,2-difluoroethyl difluoromethyl ether, where the weight percentage of 4-bromo-3-chloro-3,4,4-trifluoro-1-butene in the mixture varies between about 5 wt. % and about 75 wt. %. We have found that combinations of these 2 solvents provide exceptional cleaning performance in several applications including oxygen handling systems cleaning, and refrigeration system flushing.
EXAMPLES
Example 1
[0090] A sample comprising 25 volume percent (A.) 4-bromo-3-chloro-3,4,4-trifluoro-1-butene and 75 volume percent (B.) 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether was added to several beakers, each containing a metal coupon completely coated with one of the following materials: Mil Spec 83282 hydraulic oil, Mil Spec 7808 engine oil, Krytox fluorocarbon grease and Mil Spec 81322 aviation grease. Two batches were subjected to 15 minute immersion with 15 mL of solvent mixture but one was exposed to ultrasonic vibrations and the other kept static. Afterwards, the coupons were removed and weighed for gravimetric analysis. Results presented as percent (%) contaminant removed are shown in Table 2 below.
[0000]
TABLE 2
25% A + 75% B
100% CFC-113
Contaminant
Ultrasonic
Static
Ultrasonic
Static
83282 oil
100%
99.2%
100%
100%
7808 oil
100%
98.6%
99.2%
100%
Krytox
94.8%
63.7%
97.7%
36.2%
81322 grease
97.8%
84.0%
94.8%
24.1%
Example 2
[0091] A sample comprising 50 volume percent (A.) 4-bromo-3-chloro-3,4,4-trifluoro-1-butene and 50 volume percent (B.) 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether was added to several beakers, each containing a metal coupon completely coated with one of the following materials: Mil Spec 83282 hydraulic oil, Mil Spec 7808 engine oil, Krytox fluorocarbon grease and Mil Spec 81322 aviation grease. Two batches were subjected to 15 minute immersion with 15 mL of solvent mixture but one was exposed to ultrasonic vibrations and the other kept static. Afterwards, the coupons were removed and weighed for gravimetric analysis. Results presented as percent (%) contaminant removed are shown in Table 3 below.
[0000]
TABLE 3
50% A + 50% B
100% CFC-113
Contaminant
Ultrasonic
Static
Ultrasonic
Static
83282 oil
99.5%
99.2%
100%
100%
7808 oil
97.8%
99.6%
99.2%
100%
Krytox
99.3%
62.3%
97.7%
36.2%
81322 grease
98.6%
95.9%
94.8%
24.1%
Example 3
[0092] A sample comprising 75 volume percent (A.) 4-bromo-3-chloro-3,4,4-trifluorobutene and 25 volume percent (B.) 1-chloro-2,2,2 trifluoroethyl difluoromethyl ether was added to several beakers, each containing a metal coupon completely coated with one of the following materials: Mil Spec 83282 hydraulic oil, Mil Spec 7808 engine oil, Krytox fluorocarbon grease and Mil Spec 81322 aviation grease. Two batches were subjected to 15 minute immersion with 15 mL of solvent mixture but one was exposed to ultrasonic vibrations and the other kept static. Afterwards, the coupons were removed and weighed for gravimetric analysis. Results presented as percent (%) contaminant removed are shown in Table 4.
[0000]
TABLE 4
75% A + 25% B
100% CFC-113
Contaminant
Ultrasonic
Static
Ultrasonic
Static
83282 oil
99.0%
99.8%
100%
100%
7808 oil
99.8%
99.3%
99.2%
100%
Krytox
72.0%
13.8%
97.7%
36.2%
81322 grease
99.5%
99.4%
94.8%
24.1%
Example 4
[0093] Compounds having similar solubility parameter and boiling point relative to CFC-113 (solubility parameter of 7.2, boiling point of 47.6° C.) were selected using QSPR's. Table 1 summarizes these properties for some of the currently preferred compounds. The units for solubility parameter are (cal/cm 3 ) 1/2 .
[0094] The compounds were also required to have ODP's of less than 0.02 to be unclassified by EPA as a Class II Ozone Depleting Substance. The toxicity of the compounds as described by a 2 hr or 4 hr LC 50 value, and cardiac sensitization was also used as a criteria for selection. A list of compounds were compiled and ranked which met these requirements. If one of these critical performance properties was not known, it was calculated or predicted using QSPR's mathematical models. A total of 30 compounds were identified with a solubility parameter within 1% of CFC-113, and 106 compounds were identified with solubility parameter within 5% of CFC-113, and 201 compounds had solubility parameters within 10% of CFC-113. Table 2 shows a list of preferred compounds meeting the solubility parameter, boiling point and ODP restrictions.
[0095] The material compatibility of the second generation solvent must also be comparable or better than that of the first generation solvent, for example CFC-113. All of the identified second generation solvents listed above had corrosion rates with aluminum 6061 and stainless steel 304 which were negligible (less than 0.001 mil/year). Elastomer compatibility is also critical for a second generation solvent replacement. All of the second generation solvents of the present invention caused very little change in the mass, thickness, or diameter of PTFE. The solvents containing no chlorine or bromine had little effect on Buna-N, while the solvents containing chlorine and/or bromine had a more severe effect on Buna-N. Viton and Neoprene were significantly affected by CFC-113 and 4-bromo-3-chloro-3,4,4-tribromo-1-butene, however, the other second generation solvents only had a minor affect on Viton and Neoprene. EPDM-60 was significantly affected by all of the solvents tested, with significant increases in mass, diameter.
[0096] In addition to the solubility parameter, several second generation solvents were experimentally evaluated for solvency with contaminants specific to oxygen handling systems. These contaminants were Krytox and Jet Lube. The solvent CH 2 ═CH—CF 2 —CF 2 Br (4-bromo-3,3,4,4-tetrafluoro-1-butene), had solvency performance similar to CFC-113 with both contaminants. Five solvent candidates, CH 3 —CH 2 —O—(CF 2 ) 3 —CF 3 , CHF 2 —O—CHCl—CF 3 , CHClF—CF 2 —O—CHF 2 CF 3 —(CF 2 ) 2 —O—CHF—CF 3 , and CH 3 —O—(CF 2 ) 3 —CF 3 , had solvency performance as good or better than CFC-113 with Krytox, but had poor performance with Jet Lube. Conversely, one solvent candidate, CH 2 ═CH—CFC 1 —CF 2 Br, had solvency performance similar to CFC-113 with Jet Lube, but had poor performance with Krytox.
Example 5
[0097] Mineral oil is used in R-22 refrigeration systems. To clean these systems, a flushing solvent must be capable of quickly dissolving residual mineral oil and other contaminants or decomposition products that form during compressor failure. Solvent mixtures comprising (1) 50 wt. % A plus 50 wt. % B, (2) 75 wt. % A plus 25 wt. % B, and (3) 33.3 wt. % A plus 33.3 wt. % B plus 33.3 wt. % C were produced, where (A.) is 4-bromo-3-chloro-3,4,4-tribromo-1-butene, (B.) is 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether, (C.) is 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether, and (E.) is methyl 2,2,2-trifluoroethyl-1-(trifluoromethyl)ether. The mineral oil was heated in a vessel with R-22 using a torch to decompose it and form byproducts and residue which would be formed during a compressor burnout. This burnout oil was then applied to several metal coupons. The three solvent mixtures above were then added to separate beakers each containing one of the coupons. The coupons were subjected to 15 minute immersion with 15 mL of solvent mixture under static conditions at ambient temperature. Afterwards, the coupons were removed and weighed for gravimetric analysis. We found that 100%, 98.6%, and 99.3% of the compressor burnout oil was removed by solvent mixtures 1, 2, and 3, respectively.
Example 6
[0098] Alkylbenzene oil is also used in R-22 refrigeration systems. To clean these systems, a flushing solvent must be capable of quickly dissolving residual alkyl benzene oil and other contaminants or decomposition products that form during compressor failure. Solvent mixtures comprising (1) 50 wt. % B plus 50 wt. % D, and (2) 25 wt. % A plus 75 wt. % C were produced, where (A.) is 4-bromo-3-chloro-3,4,4-tribromo-1-butene, (B.) is 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether, (C.) is 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether, and (D.) is 1-bromo-2-(trifluoromethyl)-3,3,3-trifluoropropene. The alkylbenzene oil was heated in a vessel with R-22 using a torch to decompose it and form byproducts and residue which would be formed during a compressor burnout. This burnout oil was then applied to several metal coupons. The two solvent mixtures above were then added to separate beakers each containing one of the coupons. The coupons were subjected to 15 minute immersion with 15 mL of solvent mixture under static conditions at ambient temperature. Afterwards, the coupons were removed and weighed for gravimetric analysis. We found that 99.4% and 99.2% of the compressor burnout oil was removed by solvent mixtures 1, and 2, respectively. Table 5 below summarizes the cleaning performance for the mixtures of Examples 5 and 6.
[0000]
TABLE 5
Compound
Mixture
Compound
Compound
Compound
D,
% Removal of
Example
number
A, wt. %
B, wt. %
C, wt. %
wt. %
Residue, 15 min
5
1
50%
50%
100.0%
5
2
75%
25%
98.6%
5
3
33%
33%
33%
99.3%
6
1
50%
50%
99.4%
6
2
25%
75%
99.2%
Example 7
[0099] As described in Example 5, several mixtures of solvents were prepared and tested with residual mineral oil and other contaminants or decomposition products that form during compressor failure. Solvent mixtures comprising 1 wt. % A, 89 wt. % B, and 10 wt. % E, where (A.) is 4-bromo-3-chloro-3,4,4-trifluoro-1-butene, (B.) is 1-chloro-2,2,2 trifluoroethyl difluoromethyl ether, and (E.) is methyl 2,2,2-trifluoroethyl-1-(trifluoromethyl)ether. The solvent mixture was then added to beakers containing a metal coupons. The coupon was subjected to a 15 minute immersion with 15 mL of solvent mixture under static conditions at ambient temperature. Afterwards, the coupon was removed and weighed for gravimetric analysis. We found that 88% of the compressor burnout oil contaminant was removed.
Example 8
[0100] Combinations of 4 solvents ((A.) 4-bromo-3-chloro-3,4,4-trifluoro-1-butene, (B.) 1-chloro-2,2,2 trifluoroethyl difluoromethyl ether, (C.) 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether, and (E.) methyl 2,2,2-trifluoroethyl-1-(trifluoromethyl)ether) were tested for mineral oil burned in the presence of R-22. Solvents A, B, C, and E were varied in composition between 0-6 wt. %, 80-95 wt. %, 0-10 wt. %, and 0-5 wt. %, respectively. The solubility of these solvent mixtures was measured when contacting the oil and residue for 1, 5, and 10 minutes with the burned mineral oil contaminant. A composition of 13.6 wt. % A and 86.4% B was found to remove 98.8% of the residue in 1 minute, and performed better than the other combinations for this particular residue. Results for different combinations are shown in Table 6 below.
[0000]
TABLE 6
COM-
COM-
REMOVAL
POUND
POUND
COMPOUND
COMPOUND
OF RESIDUE
A, wt. %
B, wt. %
C, wt. %
E, wt. %
(10 min)
6%
79%
10%
5%
95.5%
90%
10%
97.5%
6%
94%
96.7%
95%
5%
94.4%
Example 9
[0101] The autogenous ignition (“autoignition”) temperature was measured using ASTM method G72 on several compounds selected using the method of this invention. For compounds (A.) 4-bromo-3-chloro-3,4,4-trifluoro-1-butene (CH 2 ═CH—CFCl—CF 2 Br), (B.) 1-chloro-2,2,2 trifluoroethyl difluoromethyl ether (CHF 2 —O—CHCl—CF 3 ), (C.) 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether (CHClF—CF 2 —O—CHF 2 ), (D.) 1-bromo-2-(trifluoromethyl)-3,3,3-trifluoropropene (CHBr═C(CF 3 ) 2 ), and (E.) methyl 2,2,2-trifluoroethyl-1-(trifluoromethyl)ether (CH 3 —O—CH(CF 3 ) 2 ), the AIT's were all categorized as B or C, with compounds categorized as B being marginally category C.
Example 10
[0102] The flash point temperature was measured using ASTM method D-93 on several compounds and mixtures selected using the method of this invention. For compounds (A.) 4-bromo-3-chloro-3,4,4-trifluoro-1-butene (CH 2 ═CH—CFCl—CF 2 Br), (B.) 1-chloro-2,2,2 trifluoroethyl difluoromethyl ether (CHF 2 —O—CHCl—CF 3 ), (C.) 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether (CHClF—CF 2 —O—CHF 2 ), (D.) 1-bromo-2-(trifluoromethyl)-3,3,3-trifluoropropene (CHBr═C(CF 3 ) 2 ), and (E.) methyl 2,2,2-trifluoroethyl-1-(trifluoromethyl)ether (CH 3 —O—CH(CF 3 ) 2 ), no flash point was observed up to their respective boiling points.
[0103] Flashpoints for mixtures of 4-bromo-3-chloro-3,4,4-trifluorobutene and 1-chloro 2,2,2 trifluoroethyl difluoromethyl ether were also measured where the concentrations of the components were 25-75% 4-bromo-3-chloro-3,4,4-trifluorobutene. No flashpoints were measured.
Example 11
[0104] Solvency tests with 50% by volume 4-bromo-3-chloro-3,4,4-trifluorobutene and 50% by volume ethyl nonafluorobutyl ether were performed. The solvency characteristics of these mixtures matched or exceeded that of CFC-113 with Krytox and Jet Lube. The solvency of the individual components was inferior to that of CFC-113 toward Krytox and Jet Lube, illustrating the effectiveness of using mixtures as taught by this invention. Similarly, mixtures of 4-bromo-3,3,4,4-trifluorobutene and methyl nonafluorobutyl ether produced solvency characteristic that met or exceeded those of CFC-113.
Example 12
[0105] The compound ethyl perfluorobutyl ether (solubility parameter of 6.69) has been measured to provide excellent solvency toward Krytox, and the compound 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether (solubility parameter of 7.61) provides solvency of Mil-spec 83232 hydraulic fluid, Mil-spec 7808 engine oil, and Mil-spec 81322 aviation grease. Mixtures of these ethers with about 25-75% by volume ethyl perfluorobutyl ether will provide solvency of a broad range of contaminants, improved over that of CFC-113, since CFC-113 is not a good solvent for Krytox, or Mil-spec 81322 aviation grease.
Example 13
[0106] The compound methyl perfluorobutyl ether (solubility parameter of 6.75) has been measured to provide excellent solvency toward Krytox, and the compound 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether (solubility parameter of 7.71) provides solvency of Mil-spec 83232 hydraulic fluid and Mil-spec 7808 engine oil. Mixtures of these ethers with about 25-75% by volume methyl perfluorobutyl ether will provide solvency of a broad range of contaminants, improved over that of CFC-113, since CFC-113 is not a good solvent for Krytox.
Example 14
[0107] The compound 4-bromo-3-chloro-3,4,4-trifluoro-1-butene (solubility parameter of 7.757) has been measured to provide excellent solvency toward Mil-spec 83232 hydraulic fluid, Mil-spec 7808 engine oil, Mil-spec 81322 aviation grease, and Simple Green aqueous cleaner, and the compound 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether (solubility parameter of 7.71) provides solvency of Krytox in an ultrasonic bath and moderate solvency of Simple Green aqueous cleaner. Mixtures of these compounds with about 25-75% by volume 4-bromo-3-chloro-3,4,4-trifluoro-1-butene will provide solvency of a broad range of contaminants, improved over that of CFC-113, since CFC-113 is not a good solvent for Krytox.
Example 15
[0108] The compounds methyl 2,2,2-trifluoroethyl-1-trifluoromethyl ether, 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether, 2-chloro-1,1,2-trifluoroethyl difluoromethyl ether, 25% 4-bromo-3-chloro-3,4,4-trifluoro-1-butene and 75% 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether, and 50% 4-bromo-3-chloro-3,4,4-trifluoro-1-butene and 50% 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether were subject to ignition sensitivity to mechanical impact in liquid oxygen per ASTM G86. These compounds passed this compatibility test. The compound 4-bromo-3-chloro-3,4,4-trifluoro-1-butene alone did not pass the test. This example illustrates the unexpected benefits of using an ether such as 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether in mixtures with compounds which may not alone be a suitable solvent for oxygen handling systems.
Example 16
[0109] The compounds (A) 4-bromo-3-chloro-3,4,4-trifluoro-1-butene and (B) 1-chloro-2,2,2-trifluoroethyl difluoromethyl ether, were mixed 50:50 by volume and tested to remove Krytox. The individual components, A and B, remove 17.0% and 98.7%, respectively, of this contaminant after 15 min. with ultrasonic treatment. The mixture removed 99.3% of the same contaminant under the same conditions. Hence, the mixture removes more of the contaminant than either of the individual compounds.
[0110] Although the invention has been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example, and is not to be taken by way of limitation. The spirit and scope of the present invention are to be limited only by the terms of the appended claims.
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CFC replacement solvent compositions, methods of using the same and methods of making the same. These compositions meet or exceed the solvency, flammability, and compatibility requirements for CFC's while providing similar or improved environmental and toxicological properties. These solvent compositions have applications including, but not limited to, oxygen handling, refrigeration or heat pumps, electronics, implantable prosthetic devices, and optical equipment.
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BACKGROUND OF THE INVENTION
This invention generally relates to fiber production and more particularly to apparatus for producing large diameter spun filaments.
In the manufacture of synthetic fiber filaments, it is generally recognized that filament size is a function of a "drawing" operation wherein a continuous spun strand is submitted to a battery of equipment especially designed to "finish" the filament according to a predetermined specification. The filaments may therefore be spun and spooled for future drawing or may be spun-drawn to effect particular characteristics to the filamentary material. The "drawing" operation is known and understood by persons knowledgeable in the art and is therefore considered beyond the scope of the instant invention.
Prior to drawing, the molten polymer is conventionally "pumped" through an orifice at a substantially constant pressure in a vertically oriented spinnerette and air-quenched in a vertical cooling unit or water-quenched in a horizontal water bath. For spun filaments of the larger sizes (5--30 mil) threadline stability is insufficient for vertical air-cooling inasmuch as "necking down" of the molten polymer occurs at the orifice exit. This natural drawing or necking down of the polymer is difficult to control and therefore it is not the practice to air-quench filaments of this larger size. In this circumstance, water-quenching becomes necessary but the throughput for this cooling process is low, thus increasing the expense of producing the larger sizes.
Filaments having drawn or "finished" diameters in excess of 3-mils have become attractive for various applications and it is desirable, therefore, to produce them economically. Inasmuch as liquid cooling decreases production throughput, it would seem ideal if larger size filaments could be air-cooled since high threadline speeds could be achieved. In conventional cross flow air-cooling processes, multi-filament spinning has a tendancy to fuse filaments while mono-filament spinning lacks threadline stability. Thus, problems exist in the state of the art where larger sizes are being considered.
The present invention applies a technique of electrostatic cooling that is described in the publication "Electronic Design", volume 19, No. 20, of Sept. 20, 1971, entitled "High Voltage Ionic Discharges Provide Silent Efficient Cooling". According to this technique, a high voltage ionic discharge cools a hot surface by producing a turbulence that disturbs the thin boundary layer of air molecules on the surface. These air molecules act as an insulating barrier against further cooling of the surface and thus decrease cooling efficiency.
In this respect, therefore, the present invention comprises apparatus for bombarding a molten polymer filament with accelerated electrons in the presence of forced air-cooling to substantially increase the rate of cooling and allow for the formation of larger filament diameters in the spinning process. More specifically, the invention comprises a collar configuration that is mounted proximate to a conventional extruder spinnerette orifice to effect electrostatic cooling of the molten filament as it exits from the spinnerette.
The features and advantages of the invention will become apparent from the following detailed description when considered in conjunction with the accompanyind drawings in which like parts bear like reference numerals.
In the Drawings:
FIG. 1 diagrammatically illustrates the application of the invention to polymer filament spinning;
FIG. 2 is an enlarged plan view, in section, of the electrostatic collar forming an essential part of the invention; and
FIG. 3 is a sectional perspective view of the collar taken on line 3--3 of FIG. 2.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the method of the invention is shown utilizing apparatus generally indicated by reference numeral 10 for cooling a molten polymer filament 12 as it exits an extruder spinnerette 14. The molten polymer passes through a cooling unit 16 which will be described in detail hereinafter with respect to FIGS. 2 and 3. A roller 18 picks up the filament whereupon it is fed to further processing equipment 20 which may/may not include finish drawing. An air supply 22 is connected into unit 16 to provide air quenching of the molten polymer as it passes down through the unit, and to increase the efficiency of the air-cooling, a high voltage, low amperage d.c. supply 24 is connected to electrode terminals in the unit.
With reference now to FIG. 2, the cooling unit 16 is shown in a sectional plan view looking down through the top with the polymer filament 12 assumed to be entering the page. As illustrated, unit 16 is essentially a cylinder or collar of a non-conductive plastic material. Mounted within the collar are at least three vertical rows of cathode electrodes 30, that are connected via line 32 to the negative terminal of the high voltage power supply 24. Opposite each vertical row of cathodes 30 is a vertical row of anode electrodes 34 connected via line 36 to the positive terminal of the power supply 24. FIG. 3 more clearly illustrates the row arrangement of the electrodes 30 and 34. To provide separation and prevent arcing between adjacent electrodes a plurality of T-section insulators 38 are mounted within the collar 16. The insulators support a screen 40 at the cross bar of the T-section, which screen is in coaxial alignment with the collar 16 and prevents any filament contact with the electrodes. Also mounted to opposite insulators are at least two non-conductive plastic tubes 42 that are closed at the top of the collar and connected at the bottom to the air supply 22. A plurality of vertically spaced orifices 44 are located in each air supply tube such that cooling air is directed to the axis of the collar for quenching filament 12.
In applying the electrostatic collar 16 to the production of polymer filaments, the following should be considered.
(1) The force, whether electrostatic or air, must be balanced or the resultant force kept to a minimum such that the filament or filament group will not be pushed to one side.
(2) Since the polymer is a poor conductor, static charges will build up surrounding the filament. This charge, if not evenly distributed, will eventually push the filament to the cathode or anode electrodes.
(3) When spinning multiple filament yarns, charge may accumulate on the individual filaments with the resultant tendency to repel each other and make spinning very difficult.
(4) The electron flux within the collar must be optimized to avoid ionization of the air and shortcircuiting of the electron flow.
In consideration of the above, an electrostatic collar configuration as illustrated in the drawing and having a 35 kv potential across it in the presence of air-cooling was successful in producing a filament having a 13.5 mil diameter. This filament was subsequently drawn to a "finished" filament exhibiting the following properties:
Diameter: 6 mil
Denier: 225
Tensile Strength: 3.54 lbs.
Tenacity: 7.17 g/d
Elongation to Break: 14.5%
While certain representative embodiments and details have been shown for the purpose of illustrating the invention, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit or scope of the invention.
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Large diameter filaments are produced by increasing the cooling efficiency of a molten polymer as it exits a spinnerette orifice. The cooling is accomplished in a collar configuration having means for directing cooling air and an ionic discharge in a direction transverse to the axis of the filament as it passes through the collar.
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RELATED APPLICATION
[0001] This application claims priority to European Patent Application No.12163128.7, filed on 4 Apr. 2012, the contents of which are herein incorporated by reference in their entirety for all purposes.
TECHNICAL FIELD
[0002] The invention relates to a switched power converter comprising a base plate on which at least one heat sink is arranged, the converter device further comprising at least one power transistor arranged on a side of the at least one heat sink.
BACKGROUND
[0003] When designing switched power converters, and in particular high voltage DC/AC converters or inverters, thermal management is of utmost importance. Since a considerable amount of energy is dissipated in the components of the converter, with a resulting heat emission, thermal dissipation must be arranged for.
[0004] In prior art high voltage switching converters, a base plate is provided on which a plurality of elongated heat sinks are arranged parallel to each other. On both sides of each heat sink, power transistors are arranged for switching a high DC voltage. The power transistors are mounted to a printed circuit board (PCB) which is placed on top of the heat sinks with the transistors facing the base plate. Between each power transistor and its corresponding heat sink, a ceramic substrate is arranged for insulting purposes. Typically, grease is applied on both sides of the ceramic substrate to facilitate better thermal contact. Further, the power transistors must be assembled onto the board such that they are carefully fitted with the heat sink and the ceramic substrate; it is important that the transistors are in close contact with the heat sink and the intermediate substrate in order to attain a low thermal resistance and thus god thermal management. It is generally of great significance for switched power converters that heat is carried off from the power transistors.
[0005] However, in the above described prior art converter, it is difficult to assemble the transistors such that they on the one hand all press against their respective heat sink with sufficient force and on the other hand that wedging of the transistors between the heat sinks is facilitated without an installer having to apply excessive force when the board is placed on top of the heat sink.
SUMMARY
[0006] An object of the present invention is thus to provide a switched power converter which solves or at least mitigates these problems in the art.
[0007] This object is achieved in an aspect of the present invention by a switched power converter comprising a base plate on which at least one heat sink is arranged. The converter further comprises at least one power transistor arranged on a side of the at least one heat sink. Further, at least one spring element is arranged to press against the power transistor arranged on a side of the at least one heat sink and an oppositely facing side of either an adjacent heat sink or a base plate end face parallel to the at least one heat sink.
[0008] This is highly advantageous in that a force is applied on the power transistor by the spring element. This will press the power transistor against the heat sink on whose side the transistor is arranged. Thermal contact is thus established between the power transistor and the heat sink, and heat dissipation from the transistor via the heat sink is greatly facilitated. Further, the spring elements are a cost-effective way of attaining a high compressive force on the power transistors. The spring elements are relatively small and do not require much base material, such as steel or plastic, for production.
[0009] In an embodiment of the present invention, the spring element is arranged to press against the power transistor arranged on a side of the at least one heat sink and a further power transistor arranged on an oppositely facing side of the adjacent heat sink. This is advantageous, since a single spring element wedged between two adjacent heat sinks applies a pressing force onto at least two oppositely arranged power transistors.
[0010] In an embodiment of the present invention, the base plate of the switched power converter comprises a plurality of elongated heat sinks arranged parallel to each other and which base plate further has two end faces at a respective end of the base plate extending parallel to the elongated heat sinks. Further, the converter device comprises power transistors arranged on both sides of each heat sink, and a plurality of spring elements, each being arranged to press against a first power transistor arranged on one side of the respective heat sink and a second power transistor arranged on the oppositely facing side of the adjacent heat sink when being arranged between two adjacent heat sinks, and being arranged to press against a base plate end face and a third power transistor arranged on the oppositely facing side of the adjacent heat sink when arranged between a base plate end face and a heat sink, said spring elements thereby applying a force to the power transistors for pressing the transistors against the heat sinks. Further advantageous is that a high pressing force is applied with the spring element arrangement of the present invention. Thus, the power converter comprises a number of elongated heat sinks with power transistors arranged on both sides along the length of the respective heat sink. In case a spring element is arranged between two heat sinks, it is arranged such that it applies a pressure to two opposing power transistors on a respective heat sink. Thus, a single spring element will advantageously apply a force onto two power transistors thereby pressing the two power transistors against its respective heat sink, which further facilitates cost-effectiveness. In case a spring element is arranged between a heat sink and a base plate end face, it presses against a power transistor arranged on a side of a heat sink and the oppositely located end face, thus pressing the power transistor against the heat sink.
[0011] In an embodiment of the present invention, the spring element is U-shaped when compressed, wherein the two ends of the spring element apply a force in a respective opposite direction. Thus, when a spring element is introduced between two heat sinks and set in its compressed state, its two ends will contact a respective power transistor arranged on two adjacent heat sinks. In an alternative embodiment of the present invention, the spring element is V-shaped when compressed. Other appropriate shapes of the spring element can further be envisaged within the scope of the present invention.
[0012] In a further embodiment of the present invention, the switched power converter comprises a printed circuit board on which the power transistors are mounted. The power transistors are mounted to the board in a standing fashion, such that they extend vertically from the board. The printed circuit board is arranged on top of the heat sinks with the transistors facing the base plate. Further, the printed circuit board is arranged with a plurality of housings, each arranged to house a respective spring element. Alternatively, the housings are appropriately positioned on the base plate before the board is placed on top of the heat sinks. The housings generally comes in two forms; in case the housing is to be inserted between two heat sinks, it is shaped to fit between two opposite transistors, whereas in case the housing is to be inserted between a heat sink and an end face, it is shaped to fit between a transistor and a base plate end face. This is advantageous for several reasons: firstly, the transistors can be mounted to the heat sinks and the base plate from above, which greatly facilitates production. Secondly, since the board is arranged on top of the heat sinks from above, possible end faces of the base plate can be in place during mounting of the transistors to the heat sinks, since there is no need to access the heat sinks, the transistors and the spring elements from the side of the base plate. Thus, all four end faces can be in place during mounting from the above, which is highly advantageous. Thirdly, since each spring element is arranged in a housing, it will stay in place during mounting of the board to the heat sinks. Fourth, the housings, which are mounted on the board adjacent to the power transistors, will act as support for the transistors when the transistors and housings are inserted between the heat sinks. Fifth, the housing will be part of the fixation of the power transistors while soldering the transistors to the printed circuit board (PCB) during production. Sixth, the housing itself will facilitate further insulation between the spring elements and the respective transistors.
[0013] In still a further embodiment of the present invention, each housing is arranged with one or more openings facing the board, and the board is arranged with a corresponding through-hole which at least partly overlaps the opening in the housing. Thus, when the board is mounted on top of the heat sinks and the power transistors, housings and spring elements are inserted between the heat sinks (and between the heat sinks and the base plate end face), the spring element can be accessed via the board through-hole to be set in a compressed state. This is highly advantageous from a mounting perspective; when the housings are in place between the heat sinks and face the base plate, a peg- or pin-like means (or even a finger, given the size of the openings) can be inserted in the board through-hole and into the housing to snap the spring element into its compressed state, where the ends of the spring element press against the power transistors via the housing.
[0014] In yet another embodiment of the present invention, each housing is arranged with a first recess in its interior for holding one end of the spring element, and a second recess arranged on an opposite side to the first recess. The second recess is arranged to receive the other end of the spring element when the spring element is snapped into the compressed state. Advantageously, the first recess holds the spring element in place in the housing in one of its ends when the printed circuit board assembly (PCBA), i.e. the board including the various components mounted to it, is mounted on top of the heat sinks. When the board is assembled on top of the heat sink, the pin-like means is inserted in the board trough-hole and into the opening of the housing, thereby pushing the spring element downwards towards the base plate. When the other end of the spring element has travelled downwards an appropriate distance along the interior side of the housing opposite , it will engage with the second recess arranged oppositely to the first recess and the spring element will thus snap into the compressed state.
[0015] In a further embodiment of the present invention, each housing is separated in two portions along a vertical section. Advantageously, this will facilitate pressing of the power transistors against the heat sink sides, as the force applied by the spring element to the respective section of the housing will press the respective section against two oppositely arranged power transistors. Thus, since the two housing sections are arranged to drift apart when the spring force is applied and press against the transistors, the force is consequently better utilized.
[0016] In yet another embodiment of the present invention, a flexible insulating sheet material is arranged between a heat sink and the transistors arranged along the sides of the heat sink. This is advantageous since the insulating material easily can be arranged on a heat sink before the PCBA is mounted on top of the heat sinks, even with possible end faces mounted to the base plate. Due to its flexible and sheet-like nature, the insulating material is placed over the heat sink and will naturally form to have a relatively tight fit around the heat sink. The thin, cloth-like insulating material will further facilitate low thermal resistance between the power transistors and the heat sink.
[0017] It is noted that the invention relates to all possible combinations of features recited in the claims. Further features of and advantages with, the present invention will become apparent when studying the appended claims and the following description. Those skilled in the art realize that different features of the present invention can be combined to create embodiments other than those described in the following.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The invention is now described, by way of example, with reference to the accompanying drawings, in which:
[0019] FIG. 1 shows a switched power converter according to an embodiment of the present invention;
[0020] FIG. 2 shows a switched power converter according to another embodiment of the present invention, illustrating a printed circuit board to be mounted on top of power converter heat sinks;
[0021] FIG. 3 shows a detailed view of a housing comprised in the power converter according to embodiments of the present invention;
[0022] FIG. 4 shows snapping of a spring element into a compressed state according to a further embodiment of the present invention; and
[0023] FIG. 5 illustrates a further embodiment of a switched power converter according to the present invention.
DETAILED DESCRIPTION
[0024] The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which certain 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 by way of example so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0025] FIG. 1 illustrates a power converter according to an embodiment of the present invention. The switched power converter comprises a base plate 1 on which a number of elongated heat sinks 2 a, 2 b, 2 c are arranged parallel to each other. In this particular exemplifying embodiment, three heat sinks are used, but any number is possible; from one single heat sink and up. The base plate has two end faces 5 a, 5 b extending parallel to the heat sinks. Further, the power converter comprises power transistors 3 b, 3 c arranged on both sides of each heat sink 2 b, even though it would be possible to place transistors only on one side of each heat sink. In practice, it is common to design a power converter that is capable of providing as much power as possible; thus, to attain a high power density, it is desirable to have as many power transistors as possible for a given physical volume and given power level. Most common configuration is a 3-phase DC/AC converter where each phase consists of two power switches connected in series between +DC and −DC and thereby forming a bridge leg. The mid point between the switches (bridge-leg output) is connected to each phase of the load. Each switch can consist of several paralleled power transistors with anti-parallel diode function. Hence a three-phase converter will consist of totally six switches resulting in three heat sinks with power transistors mounted on both sides of the heat sinks. Further, in an embodiment of the present invention, to adapt the power converter to different loads, the power transistors are arranged along the length of each heat sink and may be coupled in parallel such that current of a particular magnitude is delivered to a load having particular current requirements. Hence, in case a power converter must be capable of delivering a greater current, the length of each heat sink is extended and further power transistors are added in the design phase. The power converter further comprises a plurality of spring elements 4 a, 4 b, 4 c, 4 d, where an individual spring element, such as spring elements 4 b, 4 c, is arranged to press against a first power transistor 3 a arranged on one side of the respective heat sink 2 a and a second power transistor 3 b arranged on the oppositely facing side of the adjacent heat sink 2 b, when being arranged between two heat sinks. Correspondingly, in the case of e.g. spring element 4 d, when being arranged between a base plate end face 5 b and a heat sink 2 c, the spring element is arranged to press against the base plate end face and a third power transistor 3 d arranged on the oppositely facing side of the adjacent heat sink. Advantageously, each spring element applies a force to the power transistors such that the transistors are pressed against the heat sinks, thus improving thermal contact between the power transistors and the heat sinks. In FIG. 1 , for illustration purposes only, it should be noted that spring elements 4 a, 4 b and 4 d are shown in compressed state, while spring element 4 c is shown in uncompressed state. That is, in FIG. 1 , spring element 4 c is still to be set in its operating, compressed state.
[0026] As can be seen in FIG. 1 , in an embodiment of the present invention, the spring elements 4 a, 4 b, 4 c, 4 d are U-shaped when compressed, wherein the two ends 6 a, 6 b of each spring element apply a force in opposite directions. Thus, when a spring element 4 b is introduced between two heat sinks 2 a, 2 b and set in its compressed state, its two ends will apply a force onto a respective power transistor 3 a, 3 b arranged on the sides of the two heat sinks. As previously mentioned, the spring elements are in an alternative embodiment V-shaped when compressed.
[0027] With further reference to FIG. 1 , in yet another embodiment of the present invention, a flexible insulating sheet material 16 a, 16 b, 16 c is arranged between each heat sink 2 a, 2 b, 2 c and the transistors arranged along the sides of the heat sink. This is advantageous since the insulating material easily can be arranged on a heat sink before board 7 is mounted on top of the heat sinks, even with possible end faces 5 a, 5 b mounted to the base plate 1 . Even though it is not shown in FIG. 1 , the final power converter will have two further end faces perpendicularly arranged to the two end faces 5 a, 5 b show in FIG. 1 , thereby enabling encapsulation of the heat sinks. Due to its flexible and sheet-like nature, the insulating material is placed over the heat sink and will naturally form to have a relatively tight fit around the heat sink. The thin, cloth-like insulating material will further facilitate low thermal resistance between the power transistors and the heat sink. Alternatively, the flexible insulating sheet material 16 a, 16 b, 16 c can be integrated into a single insulating sheet.
[0028] As is further illustrated in FIG. 1 , in still another embodiment of the present invention, a current rail 15 a, 15 b, 15 c will be arranged on each heat sink 2 a, 2 b, 2 c. In this particular example, each current rail carries a respective phase current to be supplied to a converter three-phase load (not shown). Advantageously, the current rails are cooled by the same heat sinks employed for cooling the power transistors. As shown in FIG. 1 , each heat sink is arranged with a channel 17 a, 17 b, 17 c in its interior for housing a cooling medium, for example a mix of water and glycol. Alternatively, the heat sinks 2 a, 2 b, 2 c are not arranged with a respective channel and the base plate 1 may in such case be arranged with one or more cooling fins (not shown) on its underside for improving heat transfer, onto which forced air cooling is applied for further improving heat sink cooling.
[0029] FIG. 2 shows a different view of the switched power converter according to an embodiment of the present invention, where the printed circuit board 7 yet is to be mounted on top of the heat sinks 2 a, 2 b, 2 c. The power transistors 3 a, 3 b are mounted to the board in a standing fashion, vertically or almost vertically extending from the board. The printed circuit board assembly (PCBA), i.e. the board 7 including the various components mounted to it, is arranged on top of the heat sinks with the transistors facing the base plate 1 . Further, the printed circuit board is arranged with a plurality of housings 8 a, 8 b, 8 c, 8 d, each arranged to house a respective spring element 4 a, 4 b, 4 c, 4 d. Alternatively, the housings 8 a, 8 b, 8 c, 8 d are already appropriately positioned on the base plate 1 before the board 7 is placed on the heat sinks 2 a, 2 b, 2 c. The housings generally comes in two forms; in case a housing is to be inserted between two heat sinks 2 a, 2 b it is shaped to fit between two opposite transistors 3 a, 3 b, whereas in case a housing is to be inserted between a heat sink 2 a and an end face 5 a, it is shaped to fit between a transistor and a base plate end face.
[0030] FIG. 3 illustrates a housing and a corresponding spring element in further detail according to an embodiment of the present invention, where the housing 8 is arranged with an opening 9 facing the board.
[0031] As shown in FIG. 4 , the board 7 is arranged with a corresponding through-hole 10 which at least partly overlaps the opening in the housing 9 . Thus, when the PCBA is mounted on top of the heat sinks 2 a, 2 b, 2 c and the power transistors, housings and spring elements are inserted between the heat sinks (and between the heat sinks and the base plate end face), the spring element can be accessed via the board through-hole to be set in a compressed state. This is highly advantageous from a mounting perspective; when the housings are in place between the heat sinks and face the base plate, a peg- or pin-like means 18 (or even a finger, given the size of the openings) can be inserted in the board through-hole 10 and into the housing 8 to snap the spring element 4 into its compressed state, where the ends 6 a, 6 b (shown in FIG. 1 ) of the spring element press against the power transistors via the housing.
[0032] With further reference to FIGS. 3 and 4 , in yet another embodiment of the present invention, each housing 8 is arranged with a first recess 11 in its interior for holding one end 6 a (see FIG. 1 ) of the spring element 4 , and a second recess 12 arranged on an opposite side to the first recess. The second recess is arranged to receive the other end 6 b of the spring element when the spring element is snapped into the compressed state. Advantageously, the first recess holds the spring element in place in the housing in one of its ends when the printed circuit board assembly is mounted on top of the heat sinks. When the board is assembled on top of the heat sink, the pin-like means 18 is inserted in the board trough-hole and into the opening 9 of the housing, thereby pushing the spring element downwards towards the base plate 1 . During this movement downwards the spring element is gradually compressed and thereby a pressing force is applied to power transistors via the housings. When the other end of the spring element has travelled downwards an appropriate distance along the interior side of the housing opposite, it will engage with the second recess arranged oppositely to the first recess and the spring element will thus snap into the compressed state.
[0033] FIG. 4 illustrates a further embodiment of the present invention, where each housing 8 is separated in two portions 8 ′, 8 ″ along a vertical section VS. Advantageously, this will facilitate pressing of the power transistors against the heat sink sides, as the force applied by the spring element 4 to the respective portion 8 ′, 8 ″ of the housing will press the respective section against two oppositely arranged power transistors. Thus, since the two housing sections are arranged to drift apart when the spring force is applied and press against the transistors, the force is consequently better utilized.
[0034] FIG. 5 illustrates a further embodiment of a switched power converter according to the present invention showing a second printed circuit board 20 on which power converter DC bus capacitors 21 are arranged. Typically, a number of DC bus capacitors are arranged on the second PCB along the length of each heat sink 2 a, 2 b, 2 c (only heat sink 2 b is shown in FIG. 5 ). Further, a DC+ bus bar 22 and a DC− bus bar 23 are arranged at each heat sink between the second printed circuit board 20 and the printed circuit board 7 on which the power transistors 3 b, 3 c are arranged. The respective DC bus bar 22 , 23 extends along the length of the heat sink 2 b. Further, as previously has been described, a current rail 15 b, also known as an AC bus bar, is arranged between the printed circuit board 7 on which the power transistors are arranged and the heat sink 2 b, and extends along the heat sink. Further electrical insulation may be provided between current rail 15 b and heat sink 2 b, for example by means of the previously discussed insulation sheet material 16 b. Fastening means in the form of a screw or bolt 25 extends vertically from the second printed circuit board 20 to the heat sink 2 b via the DC bus bars 22 , 23 , the printed circuit board 7 on which the power transistors 3 b, 3 c are arranged and the current rail 15 b for applying a pressing force onto the second printed circuit board 20 against the heat sink 2 b. As can be seen in FIG. 5 , the screw 25 extends through the second PCB 20 , the PCB 7 and the current rail 15 b. However, the two DC bus bars 22 , 23 extend on a respective side of the screw 25 .
[0035] In order to achieve good electrical contact between the second PCB 20 and the DC bus bars 22 , 23 , the DC bus bars and the PCB 7 , the PCB 7 and the current rail 15 b, as well as to facilitate low thermal resistance from the DC bus capacitor 21 , the second PCB 20 , the DC bus bars 22 , 23 , the PCB 7 and the current rail 15 b to heat sink 2 b, a pressing force is applied by the screw 25 . The screw 25 is arranged to engage in a threaded aperture 26 in the heat sink 2 b at its one end and to engage in a spring 27 at its other end. This ensures a tight fit of the second PCB 20 , the respective bus bars 22 , 23 , the PCB 7 and the current rail 15 b to the heat sink 2 b. This embodiment will, by means of the tight fitting of the various components to the heat sink 2 b, further improve cooling of the various power converter components. Further, a single fastening means 25 is used to fixate the second PCB 20 , the respective bus bars 22 , 23 , the PCB 7 and the current rail 15 b to the heat sink 2 b. A thermal contact is further established between the various components and the cooling medium contained in the heat sink channel 17 b.
[0036] Even though the invention has been described with reference to specific exemplifying embodiments thereof, many different alterations, modifications and the like will become apparent for those skilled in the art. The described embodiments are therefore not intended to limit the scope of the invention, as defined by the appended claims.
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The present invention relates to a switched power converter comprising a base plate on which at least one heat sink is arranged. The converter further comprises at least one power transistor arranged on a side of the at least one heat sink. Further, at least one spring element is arranged to press against the power transistor arranged on a side of the at least one heat sink and an oppositely facing side of either an adjacent heat sink or a base plate end face parallel to the at least one heat sink.
This is highly advantageous in that a force is applied to the power transistor by the spring element. This will press the power transistor against the heat sink on whose side the transistor is arranged. Thermal contact is thus established between the power transistor and the heat sink, and heat dissipation from the transistor via the heat sink is greatly facilitated. Further, the spring elements are a cost-effective way of attaining a high compressive force on the power transistors.
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RELATED APPLICATIONS
[0001] The present application is related to U.S. Provisional Patent Application, Ser. No. 60/646,026, filed on Jan. 21, 2005, which is incorporated herein by reference and to which priority is claimed pursuant to 35 USC 119.
GOVERNMENT RIGHTS
[0002] This invention was made with Government support under Grant No. RR01192 awarded by the NIH. The Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates to the field of optical bone measurements and in particular to the use of measurement of optical parameters of bone and other tissue simultaneously to obtain tissue profiles on the bone and surrounding tissue.
[0005] 2. Description of the Prior Art
[0006] In recent years, as reported by Takeuchi “A new method of bone tissue measurement based upon light scattering” Department of Internal Medicine IV, Saitama Medical School, Japan. J Bone Miner Res February 1997; 12(2):261-6, time-resolved spectroscopy systems using near infrared pulsed laser have been applied to develop optical computed tomography.
[0007] Urakami, et al., “Optical measuring method and an optical measuring apparatus for determining the internal structure of an object,” U.S. Pat. No. 5,774,223 (Jun. 30, 1998) is directed to an optical measuring method and an optical measuring apparatus capable of obtaining the true mean time delay of a light waveform within a short time for the purpose of obtaining information on the internal structure of an object. Calculations include a first mean time delay when the light path includes the object, a second mean time delay when the light path does not include the object, and a subtraction of the second mean time delay from the first mean time delay to obtain a true mean time delay.
[0008] If a correlation is gained between the condition of disease or the condition of body and the mean time delay measured, useful information can be acquired directly from the mean time delay data. For example, if there is a correlation between a change of measured value and a structural change of tissue, a degree of the structural change can be obtained from the change of mean time delay, utilizing the correlation. If the arithmetic processing of the analyzing unit 50 is set to one for acquiring the information concerning the structural change of measured object, the optical measuring apparatus shown in FIG. 2 and FIG. 3 can be applied to diagnosis of osteoporosis.
[0009] For example, as described in Araki et al., “Optical measurement of osteoporotic bone (1) (2)” (Abstracts at the 65th Meeting of the Japanese Society for Hygiene), a temporal waveform of light passing through an osseous tissue changed in the structure from a normal condition shows a change in a peak, a spread, a mean time delay, or the like of waveform depending upon the structural change. Explaining more specifically, the light passing through the tissue propagates therein as scattered, and thus, the frequency of chances to be scattered decreases with a coarse tissue structure so as to change the response waveform. With less scattering, the width of the waveform of output light becomes narrower, and the peak and mean time delay are shifted to the shorter time side, as compared with those of normal tissues. Accordingly, the information concerning the osteoporosis can be obtained by measuring the mean time delay of output light. In this case, the analyzing unit 50 can be set to perform an arithmetic algorithm to obtain a parameter indicating a change degree of the structure based on the mean time delay data. The teaching here refers vaguely to a method for manipulating time domain data acquired from tissue. There is insufficient detail provided to be enabling.
[0010] Marchitto, et al., “Optical measurements of bone composition,” U.S. Patent Application 20020002336 (Jan. 3, 2002) provides an non-invasive and inexpensive method and/or device for detecting a disease in a bone or other tissues using an optical fiber based Raman spectrometer by detecting biochemical changes in the bone or the other tissues. The described method for detecting a bone disease in a test subject comprises the steps of transmitting radiant energy to surface of skin overlaying a bone in the test subject; detecting radiant energy reflected from the skin surface to obtain Raman spectra, wherein the Raman spectra from the skin surface reflect the spectral information on the bone, which reflects biochemical compositions of the bone; and comparing the biochemical compositions of the test bone with those of a normal bone, wherein if the biochemical compositions of the test bone differ from those of the normal bone, the test subject might have a diseased bone. The radiant energy is transmitted through a fiber-optic based reflectance probe, reflected from the skin surface is collected by a fiber optic, and is near-infrared light having a wavelength range of from about 600 nm to about 1500 nm. The reflected radiant energy is filtered through a long-pass filter, a band-pass filter or a polarization filter. The method is used for detecting a bone disease, such as osteomalacia, osteoporosis, a bone cancer, or a bone infection.
BRIEF SUMMARY OF THE INVENTION
[0011] The objects of the present invention include, but are not limited to: simultaneous determination of structural, biochemical, and functional changes in bone; a much more compact and inexpensive instrumentation than used to existing methods such as ultrasound and dual-energy x-ray absorptiometry (DEXA); and optical methods possess the same advantages in other tissues, thus allowing a single device for assessing tissue composition, structure, and physiology as well as bone.
[0012] The illustrated embodiment of the invention satisfies these objects and overcomes the following disadvantages. Several methods are available to measure bone density, but currently the most widely used technique is dual energy x-ray absorptiometry, which has been used to determine efficacy in recent large clinical trials, and to characterize fracture risk in large epidemiological studies. Newer techniques such as ultrasound appear to offer a more cost-effective method of screening bone mass. Ultrasound measurements are usually performed at the calcaneous and it is not possible to measure sites of osteoporotic fracture such as the hip or spine. Adding an ultrasound measurement to dual energy x-ray absorptiometry does not improve the prediction of fractures.
[0013] Although it is believed by some that ultrasound measures the “quality” of bone, more careful studies suggest that it mainly measures bone mass. Quantitative computed tomography (QCT) of the spine must be done following strict protocols in laboratories that do these tests frequently. In community settings the reproducibility is poor. The quantitative computed tomography measurements decrease more rapidly with aging, so the conventional T scores in older individuals will be much lower than dual energy x-ray absorptiometry measurements. A T score is the number of standard deviations the bone mineral density measurement is above or below the young-normal mean bone mineral density. Another conventional bone density measure is a Z score which is the number of standard deviations the measurement is above or below the age-matched mean bone mineral density.
[0014] Several techniques can measure bone density in the hand, radius or ankle. These techniques include single energy absorptiometry for metacarpal width or density from hand x-rays.
[0015] In the illustrated methods of the invention for assessing the condition of bone in-vivo using non-ionizing radiation, the use of non-ionizing radiation, including, but not limited to, the visible, near-infrared, and infrared spectral regions offer novel contrast mechanisms for monitoring the health or disease state of bone tissue.
[0016] The illustrated embodiment uses the techniques which include, but are not limited to:
a. A frequency domain photon migration (FDPM) as disclosed in U.S. Pat. No. 5,424,843, incorporated herein by reference, which discloses an apparatus and method for qualitative and quantitative measurements of optical properties of turbid media using frequency-domain photon migration; b. A method and apparatus for performing quantitative analysis and imaging of subsurface heterogeneities of turbid media using spatially structured illumination as disclosed in U.S. Patent Application 2003/0184757 (Ser. No. 10/391,166) filed Mar. 18, 2003, incorporated herein by reference; c. A combined frequency domain photon migration and broadband spectroscopy as disclosed in U.S. patent application Ser. No. 10/191,693, filed Jul. 9, 2002, incorporated herein by reference; and/or d. Continuous wave broadband spectroscopy at multiple distances.
[0021] The illustrated embodiments of the invention use measured optical properties to characterize bone tissue viability. The optical properties of bone are strongly influenced by composition, structure, and physiology. Disease alters these bone characteristics, and thus bone optical properties are parameters that gauge bone disease progression. Optical methods offer rapid, noninvasively quantifiable parameters for characterizing many types of biological tissues, including bone. The indicators of bone disease may be the optical properties of the bone itself or the optical property difference between bone and other tissues. For example, a comparison between tibia and calf muscle optical properties could reflect the health or disease state of the bone. Spatial, temporal or other variations of bone optical properties may also be used as indicators of disease. Absolute values of bone optical properties compared across a population may also form the basis of characterizing bone disease. The optical properties can also be correlated or formulated to provide traditional measures of bone such as the T score. The common feature is the use of nonionizing optical spectra as the noninvasive probe of bone tissue.
[0022] Bone optical properties, including, but not limited to, the absorption and reduced scattering coefficients provide unique information that is not currently provided by traditional methods. Other measured optical properties, such as the scattering angular dependence, also provide tissue information. These optical properties may be measured at either at a single wavelength or over a range of wavelengths. Since bone is composed of collagen fibers, which will weaken during osteoporosis or injury, measurements of the anisotropy of non-ionizing optical scattering in bone (NIR, visible or IR) can be indicative of disease.
[0023] In bone there is also a large fraction of bound water: namely, water that is tightly hydrogen bound to macromolecules. This water binding creates a spectral signature in the near-infrared region that is significantly different from free water, namely water that is hydrogen bound to water only. In particular, there is a free water absorption peak located at ˜980 nm, but when water is bound to macromolecules this absorption peak will red shift as much as 15 nm. Broadband Doppler optical spectroscopy (DOS) has the ability to measure absolute absorption spectra and therefore characterize this bound water shift in bone. This bound water shift parameter may prove to be a useful diagnostic for bone density through a correlation between shift strength and bone mineral content. It may also simply be a guide for broadband DOS to target the bone during a measurement.
[0024] Bone marrow is greater than 80% lipids and therefore, broadband DOS has the ability to characterize this tissue through its absorption. There is a lipid absorption peak located at 926 nm in the near-infrared. Preliminary broadband DOS measurements have shown that in the bone marrow this lipid absorption peak is blue shifted a few nanometers, which is consistent with lipids improperly hydrogen bound to water. This spectral signature gives broadband DOS the ability to separate subcutaneous superficial lipids from lipids in the marrow and can act as a guide to bone marrow measurements. The strength of the lipid peak blue shift can prove to be useful as diagnostic parameter.
[0025] Several analysis styles may be applied to determine tissue optical properties. First, frequency domain photon migration (FDPM) may be used to measure the absorption and reduced scattering properties of bone in-vivo. Spectral changes in absorption provide compositional and physiological information about the bone tissue. For example, the near-infrared absorption spectrum provides the concentrations of oxygenated and deoxygenated hemoglobin, lipids, and water. Changes in water concentration may be indicative of bone disease. Spectral changes in reduced scattering depend upon the density and size of tissue scatterers. For example, the near-infrared scattering spectral dependence of tissue varies according to a power law of the wavelength. Both the power and scale factor of this dependence may be used to assess bone structure and density. In addition, the raw optical signals measured in FDPM such as amplitude, average intensity, modulation, and phase, can all be used alone to assess bone optical properties. Simple models of light transport may be used to determine the bone optical properties. Other approaches, including, but not limited to, light transport models, other physical models, and chemometric analysis of FDPM and spectroscopic signals, can also be applied to these raw signals.
[0026] Second, spatially structured illumination may be used to determine the optical properties of bone. This method can determine changes in the optical properties in bone tissue and locate inhomogeneities in bone structure or composition that could be indicative of disease. Any of the above methods may also be used for this purpose.
[0027] Finally, it should be noted that our capability to analyze tissue as a function of wavelength, illumination structure and/or source modulation frequency enables a novel ability to characterize bone structure and functional status.
[0028] The optical method described is unique in its capability of delivering detailed composition related to structure and function. In addition, there is potential opportunity for spectroscopy to provide information that may be related to bone health that is not provided by pre-existing methods which report only “density.” For example, it is known that hydration state of bone is related to mechanical strength, yet hydration status is not provided by any existing method for determining bone mineral density in vivo in living bone tissue. Using out approach, this information can be accessed in vivo in near real time.
[0029] Potential application areas include, but are not limited to, medical diagnostics and bone density assessment, such as used in: monitoring of therapeutic efficacy of hormone therapies and other anti-osteoporosis measures; monitoring changes in bone (and muscle) status resulting from microgravity; monitoring efficacy of countermeasures for slowing or reversing the effects of microgravity; monitoring recovery, healing, or treatment of bone tissue from trauma and atrophy; osteoporosis screening, diagnosis or response to therapies; and assessment of bone and muscle health in microgravity and response to therapeutic countermeasures.
[0030] In summary, the illustrated embodiment of the invention includes a method for assessing bone tissue comprising the steps of: exposing a sample to nonionizing radiation; detecting nonionizing radiation after transit in the bone tissue; measuring optical properties from the detected nonionizing radiation to characterize bone tissue across an entire selected spectral range using a continuous wave model, a frequency domain model or a combination of both wave model and frequency domain models; and determining composition, structure, physiology or a combination thereof of bone tissue from the measured optical properties.
[0031] The step of measuring optical properties comprises measuring optical properties at each point in an entire fingerprint region including at least 600-1100 nm or at least does not depend on arithmetic differences in tissue transit of light.
[0032] The step of measuring optical properties comprises a method for qualitative and quantitative measurements of optical properties of turbid media using frequency-domain photon migration, a method for performing quantitative analysis and imaging of subsurface heterogeneities of turbid media using spatially structured illumination, a method for combined frequency domain photon migration and broadband spectroscopy, or a method for continuous wave broadband spectroscopy at multiple distances.
[0033] The method further comprises the step of determining disease states based on altered bone characteristics, or determining bone disease progression based thereon.
[0034] The step of determining disease states comprises: comparing bone characteristics between selected bone tissue and selected muscle tissue; determining spatial, temporal or compositional variations of bone optical properties; and/or comparing absolute values of bone optical properties across a population.
[0035] The method further comprises the step of correlating the optical properties of bone to provide conventional measures of bone such as the T score.
[0036] The step of measuring optical properties to characterize bone tissue comprises: measuring the absorption and reduced scattering coefficients or scattering angular dependence from the bone tissue; measuring the anisotropy of nonionizing optical scattering in bone (NIR, visible or IR) can be indicative of disease; using broadband DOS to measure absolute absorption spectra and characterize bound water shift in bone; measuring a blue shift of a lipid absorption peak using Doppler optical spectroscopy (DOS) in bone to separate subcutaneous superficial lipids from lipids in the marrow; using frequency domain photon migration (FDPM) to measure the absorption and reduced scattering properties of bone in-vivo to determine spectral changes in absorption in order to provide compositional and physiological information about the bone tissue, including a near-infrared absorption spectrum to provide concentrations of oxygenated and deoxygenated hemoglobin, lipids, and water; measuring spectral changes in reduced scattering including the power and scale factor of near-infrared scattering spectral dependence of tissue as a function of the wavelength to assess bone structure and density; measuring optical signals in FDPM (amplitude, average intensity, modulation, and phase) to assess bone optical properties; using models of light transport, physical models, and chemometric analysis of FDPM and spectroscopic signals to determine the bone optical properties; using spatially structured illumination to determine the optical properties of bone to determine changes in the optical properties in bone tissue and locate inhomogeneities in bone structure or composition indicative of disease; and/or analyzing tissue as a function of wavelength, illumination structure, source modulation frequency or a combination thereof to characterize bone structure and functional status.
[0037] The method further comprises the step of performing medical diagnostics and bone density assessment based on the measurement and determination of bone tissue optical properties. The step of performing medical diagnostics and bone density assessment comprises: monitoring of therapeutic efficacy of hormone therapies and anti-osteoporosis measures; monitoring changes in bone and muscle status resulting from microgravity; monitoring efficacy of countermeasures for slowing or reversing the effects of microgravity; monitoring recovery, healing, or treatment of bone tissue from trauma and atrophy; screening osteoporosis for purpose of diagnosis or response to therapies; and/or assessing bone and muscle health in microgravity and responses to therapeutic countermeasures.
[0038] It must be further understood that the invention includes embodiments defined as apparatus having means for performing each of the above embodiments of methodology. Such means include light or nonionizing sources, detectors, cameras, recording devices and digital signal processors, computers, logic circuits, memories, display devices and other conventional components used in optical data acquisition and processing.
[0039] While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112 are to be accorded full statutory equivalents under 35 USC 112. The invention can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] FIG. 1 is a graph of the oxy/deoxy ratio and S t O 2 in human bone as a function of age in human subjects.
[0041] FIG. 2 is a graph of the product of scatter power (SP) and oxy/deoxy ratio in human bone as a function of age in human subjects from the data of FIG. 1 .
[0042] FIG. 3 is a graph of the product of scatter power (SP) and oxy/deoxy ratio divided by body mass index in human bone as a function of age in human subjects of FIGS. 1 and 2 .
[0043] FIG. 4 is a diagram of a tibia showing two measurement geometries of a source and detector to measure in bone as a function of position along the longitudinal length of the tibia.
[0044] FIG. 5 is a graph of the reduced scattering coefficient measured ex vivo in three bovine tibia as a function of position and measurement geometry as depicted in FIG. 4 .
[0045] FIG. 6 is a graph of the reduced scattering coefficient measured in vivo in a human subject as a function of position and measurement geometry as depicted in FIG. 4 .
[0046] FIG. 7 shows in its upper portion a graph of the absorption coefficient spectra in bovine tibia as compared to the absorption coefficient spectra in human breast tissue. FIG. 7 shows in its lower portion a graph of the reduced scattering coefficient spectra in bovine tibia as compared to the absorption coefficient spectra in human breast tissue.
[0047] FIG. 8 is a graph of the absorption coefficient spectra in bovine tibia based on a steady state-frequency domain photon migration model assuming four chromophores showing the red shift of the water peak in the experimental data in dotted line as compared to the fitted data in solid line according to the assumed model.
[0048] FIG. 9 is in its left portion a graph of the absorption coefficient spectra in bovine tibia marrow based on a steady state-frequency domain photon migration model assuming four chromophores showing the blue shift of the water peak in the experimental data in dotted line as compared to the fitted data in solid line according to the assumed model. FIG. 9 in its right portion is a Doppler optical spectrogram of the cross section of bovine tibia corresponding to the left portion of the figure, where the measurements points in the marrow near the marrow-compact bone boundary are marked.
[0049] FIG. 10 is a bar chart of the ex vivo scattering coefficient in the tibia of four human subjects for the two measurement geometries of FIG. 4 .
[0050] The invention and its various embodiments can now be better understood by turning to the following detailed description of the preferred embodiments which are presented as illustrated examples of the invention defined in the claims. It is expressly understood that the invention as defined by the claims may be broader than the illustrated embodiments described below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] Consider first an illustrated embodiment of the invention which begins with data collection. Measurements were performed in the center of the right shins of 14 female subjects. All data points represent an average of three measurements of the same location. Each measurement was obtained using a laser breast scanner.
[0052] Each measurement used a combined frequency-domain photon migration (FDPM) and steady-state (SS) measurement procedure as described in U.S. Pat. No. 5,424,843. FDPM data was acquired from ten laser diodes within the spectral rage of 660 to 980 nm. Source modulation frequencies ranged from 50 to 600 MHz. Steady-state spectra were acquired over the 600 to 1000 nm spectral range immediately after the FDPM measurement. Both FDPM and steady state measurements were performed in a reflectance geometry using a source-detector separation of 29 mm. It is within the scope of the invention that many other source-detector separation distances may be employed as desired in order to optimize the assessment of bone status.
[0053] The FDPM data was fitted to a P 1 -Approximation to the Boltzmann transport equation in order to separate the effects of absorption from scattering within the tissue. Data presented below was fitted only from 50 to 400 MHz. The character of the fits is very different going out to 600 MHz for reasons that are unclear at present. The general trends of the fitted parameters are not noticeably affected by clipping the modulation frequency. We used only the first six diodes since they consistently represented the highest quality data. Again it is entirely within the scope of the invention that other kinds of light sources and other numbers of sources may be used without departing from the spirit and scope of the invention.
[0054] Once absorption and scattering coefficients were obtained, we integrated the steady state spectra using the technique described in U.S. patent application Ser. No. 10/191,693. Such a scheme provides absorption and scattering coefficients over the entire 650 to 1000 nm wavelength region. Absorption spectra were then fitted to the known extinction coefficients of oxy-hemoglobin (Hb-O 2 ), deoxy-hemoglobin (Hb-R), water, and lipids using a simple least-squares technique. Hemoglobin parameters are reported as concentrations (micromolar). Water and lipid values are reported as percentages of pure substance and do not represent true volume or mass fractions. Other parameters include the total hemoglobin concentration (THC=Hb-O 2 +Hb-R) and the tissue hemoglobin saturation (S t O 2 =Hb-O 2 /THC). Scattering spectra were quantified by a power law fit of the form A λ −S , where A and S are referred to as the ‘prefactor’ and the ‘scatter power,’ respectively.
[0055] It is believed that the fat layer contribution to the optical signal is minimal using a source-detector separation of 29 mm as in the case of muscle measurements, although a two-layer model could also be adopted. Products of power law scattering parameters may better describe the true scattering nature of the tissue. Other conventional models of the scattering dependence are contemplated as being within the scope of the invention and are regarded as equivalent substitutions to that disclosed.
[0056] There is no real correlation of the total hemoglobin content (THC) or the deoxyhemoglobin (Hb-O 2 or deoxy) with age, although there is a mild increase of oxyhemoglobin (Hb-R or oxy) with age. However, both the oxy/deoxy ratio and the oxidized hemoglobin (S t O 2 ) decrease with age, as shown in the graph of FIG. 1 where the oxy/deoxy ratio and the S t O 2 are plotted as a function of age. Assuming that there should be some sort of age dependence, we can design parameters that reflect what bone parameter should change with age. The scattering will change with age because the cellular density drops as the bone weakens. A change in cellular density results in altered optical transport characteristics.
[0057] If we include the scatter power SP as a multiplicative factor with the oxy/deoxy ratio and plot the result against age, the graph of FIG. 2 results. This shows reasonably good correlation and in fact is better than a great deal of the ultrasound and DEXA data that has been published in clinical journals. There has not yet found to be much improvement in water is included, but our investigations on how to incorporate the role of water have not been exhaustive and are contemplated as within the scope of the invention.
[0058] If we divide the scatter power-oxy/deoxy ratio product of FIG. 2 by the body mass index (BMI), the correlation improves even more. This is depicted in the graph of FIG. 3 . Such a tactic is reasonable because some bone strength indices take BMI into account. Yet there is some weak age dependence BMI (R 2 =0.15) so that this effect may be artificial. Error bars are not plotted because error in BMI is unknown.
[0059] Turn now to anisotropic optical properties used for the assessment of bone mineral density, for monitoring integrity of structure in the bone (i.e. collagen fibers) and for monitoring neoadjuvant chemotherapy for osteogenic sarcomas. Measurements were performed on three intact hind shaft (tibial) bovine bones 10 ex vivo as symbolically depicted in FIG. 4 . The tibias 10 were acquired one day post slaughter to mimic hydration properties most similar to in vivo tissue, cleaned of all tendons, cartilage and extraneous tissue and measured using steady state FDPM 2-days post-slaughter. Twelve (12) measurements were made along the tibia at 2 cm intervals from hoof to knee using a laser breast scanner employing 6 laser diodes at 650-850 nm and a steady-state light source at 650-1000 nm. Two measurement geometries were used: (1) “Parallel” where the source 12 and detector 14 were aligned along the long axis of the bone 10 as shown in the right end of FIG. 4 and (2) “perpendicular” where the source 12 and detector 14 were transverse the long axis of the bone 10 as shown in the right end of FIG. 4 . Two measurements were made in each location in both geometries. The tibia 10 then was dissected along the long axis and measurements were made directly on the marrow inside the bone.
[0060] FIG. 7 is a graph which shows the absorption and reduced scattering coefficients spectra for the ex vivo bovine tibia as compared to data for human breast tissue for the 650-1000 nm range of the illustrated embodiment. It must be understood in each case, that the spectra range can be chosen to be greater or less than that illustrated. There is a strong scattering dependence based on the alignment of the source and detection fibers with respect to the long axis of the bone in the case of the bovine bone as shown in the graph of FIG. 5 where the reduced scattering coefficient is graphed against position of measurement. The “perpendicular” geometry shows a 20-60% greater reduced scattering coefficient at 661 nm than the “parallel” geometry (p<0.0001). Over all wavelengths there is an average 30% greater scattering in the perpendicular geometry.
[0061] Fitting the bone data to a steady state-FDPM model which assumes four chromophores shows some consistent spectral differences as seen in the absorption spectra of FIG. 8 . Macromolecules bound to water causes a red shift in the water peak and broadening of the spectrum as compared to the fitted model as seen by the dotted line of experimental data.
[0062] Doppler optical spectroscopy was used directly at measurement points on the marrow by splitting the tibia as shown in the right side of FIG. 9 . Steady state-FDPM fits show that the marrow is 90% lipid and produces a blue shift in the lipid peak as seen by the dotted line of experimental data in the left side of FIG. 9 .
[0063] Identical measurements were made on the right shin of a 27 year old male at 12 measurement locations. Each measurement used a combined frequency-domain photon migration and steady-state instrument measurement procedure as disclosed in U.S. Pat. No. 5,424,843. FDPM data was acquired from 6 laser diodes within the spectral range of 680-850 nm. Source modulation frequencies ranged from 50-400 Mhz. Steady-state spectra were acquired over the 600-1000 nm spectral range. Steady state-FDPM measurements were performed in a reflectance geometry with a 10.5 mm source-to-detector separation for ex vivo measurements and 21.0 mm source-to-detector separation for in vivo measurements. The data fitting procedure was the same as described above.
[0064] In vivo measurements on a 27 year old male tibia show similar results as depicted in FIG. 6 where the reduced scattering coefficient is graphed against position of measurement. Twelve measurements were made along the right leg at 2 cm intervals and a source-to-detector separation of 21.5 mm was used. Results show the same scattering patterns as ex vivo. There is an average of 18% greater scattering in the perpendicular geometry at all wavelengths (p<0.0001). Scattering results for four different human subjects is shown in the bar graph of FIG. 10 for two fiber geometries of the source and detector.
[0065] This difference in scattering properties can be attributed to the directionality of the collagen fibers along the bone. The fibers may “track” the light along the long axis of the bone, thereby contributing to a lower scattering. Hydroxy-apatite aligns along the collagen fibers in the bone and studies with optical coherence tomography have shown that with demineralization of the bone, the difference of scattering with fiber orientation reduces. Thus, this geometry-dependent scattering is dependent upon mineralization. This demonstrates that designing a parameter that ratios perpendicular to parallel scattering from the bone mineral density, or changes in bone mineral density can be monitored using steady state-FDPM. This scattering ratio will decrease with increasing age because bone mineral density drops as the bone weakens.
[0066] Monitoring scattering changes can also be used in monitoring cancers of the bone such as osteosarcomas. Osteosarcomas (or osteogenic sarcomas) are the most common cancer of the bone. The lesion can present sclerosis, compression of the surrounding bone and muscle and destruction of bone. These will alter the bone structure which will present as scattering changes. In addition increased vasculature, edema and necrosis will present using steady state-FDPM as increased total hemoglobin concentration and water concentration.
[0067] A fully enabled steady state-FDPM system will not be required to provide the above measurements, but a continuous wave system or a simplified version of the steady state-FDPM system will suffice. A device for assessing bone integrity can be made very portable and inexpensive.
[0068] Thus this technique will be useful for assessing the integrity of bone in several ways. The ratio of scattering coefficient along the short axis to the scattering coefficient measured along the perpendicular axis can be used as an index to rapidly assess bone health. It is likely that the magnitude of the scattering coefficient in each orientation in addition to the ratio will be valuable as means to report response of bone to therapy, for example as a tool for developing pharmacologic therapies for bone disease such as osteoporosis, osteopinea, osteosarcoma, etc.
[0069] Bone strength/health will correlate directly with the magnitude of red-shift in the water absorption peak as described in the data below. The degree of red-shift in the water absorption band can be quantified and is related to the water binding with macromolecules including hydroxyapatite. As the bone matrix breaks down over the course of disease, water will have fewer sites with which to bind. Hence, healthy bone should demonstrate a greater red-shifted water band than diseased bone. This is likely to vary depending on anatomic location.
[0070] At the tumor margin in bone, the scattering coefficient is likely to show less heterogeneity as measured for example using the ratio previously discussed in the tumor infiltrated region than in adjacent healthy bone. Thus, measurement of the ratio of scattering coefficients is likely to be a reasonable method of helping to define the margin of bone cancer in the surgical field. Currently there are no other techniques that are used during the process of surgical remediation of bone cancer.
[0071] In may now be appreciated that the invention is particularly advantageous over the art in that it is in vivo process. Further, the invention interrogates the entire fingerprint region (600-1100 nm) of the tissue using inexpensive continuous wave and frequency domain apparatus. The ability to gather information over a wide wavelength range using continuous wave and/or frequency domain apparatus (or frequency domain alone) which enables us to assess relative tissue function in addition to structure (“bone density”). The invention is a method for quantizing tissue status, which does not hinge on simple arithmetical differences in tissue transit times of the light.
[0072] The invention does not depend on data acquisition techniques such as Raman spectroscopy as a method for quantifying the properties of bone. The chemical information provided by Raman spectroscopy is quite different than that provided by intrinsic optical properties such as absorption and scattering.
[0073] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following invention and its various embodiments.
[0074] Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations. A teaching that two elements are combined in a claimed combination is further to be understood as also allowing for a claimed combination in which the two elements are not combined with each other, but may be used alone or combined in other combinations. The excision of any disclosed element of the invention is explicitly contemplated as within the scope of the invention.
[0075] The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.
[0076] The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
[0077] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
[0078] The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptionally equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention.
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A method and apparatus for assessing bone tissue comprises the steps of and means for: exposing a sample to nonionizing radiation; detecting nonionizing radiation after transit in the bone tissue; measuring optical properties from the detected nonionizing radiation to characterize bone tissue across an entire selected spectral range using a continuous wave model, a frequency domain model or a combination of both wave model and frequency domain models; and determining composition, structure, physiology or a combination thereof of bone tissue from the measured optical properties.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to speech recognition systems. More particularly, the invention is directed to a system and method for normalizing a voice signal in a speech pre-processor for input to a speech recognition system.
2. Discussion of the Prior Art
A well recognized goal of speech recognition systems (hereinafter SR systems) is that of normalizing the voice signal to be processed, including its energy. Normalizing a voice signal enables successful comparison of the unknown spoken information with stored patterns or models. The process of energy normalization generally involves removing the long term variations and bias in the energy of the voice signal while retaining the short term variations that represent the phonetic information. The process of energy normalization enhances the accuracy of the SR system in proportion to the degree of normalization applied.
The undesirable long term variations in the energy of a voice signal can typically arise from multiple sources. A common source of energy variation comes from variations in microphone gain and placement. Current SR systems are very sensitive to variations in both the microphone gain and placement. Improper gain and/or placement result in higher error rates. At present, the only way to accommodate the SR system is to use an offline microphone setup to set the gain. This, however, presents several disadvantages. First, it is an added burden on the user. Second, it does not measure the audio quality on-line, and so does not detect changes that happened since the setup. Third, it does not measure the feature that is most relevant to the SR system: the instantaneous signal to noise ratio.
Additional contributing factors to energy variation, a which leads to higher error rates, include the intensity of a speaker's voice which will typically exhibit a large dynamic range. A further general problem is that different speakers will have different volume levels. Thus, the variations in amplitude or energy that occur between different utterances of the same word or sentence by different speakers, or even by the same speaker at different times, must be eliminated or at least reduced.
In the prior art, hardware solutions in the form of automatic gain controls have been used on sound cards to achieve energy normalization of raw signals. However, the degree of normalization provided by such cards has proven to be inadequate for the purposes of speech recognition.
The use of an unbiased mean value has also been used in the prior art, however, since the relative amounts of speech, silence, and noise contained within the signal is not known in advance an unbiased mean value is not a reliable norm. The peak value of the energy provides a more reliable norm, however, there is an associated drawback in tracking peak energy in that the system may suffer from being too sensitive to the instantaneous variations in energy. It is therefore desirable to have a reliable indicator of peak energy without being overly sensitive to peak energy variations.
A further general problem associated with energy normalization is that of silence detection. The signal energy is not a good indicator of silent periods because of background static. Static on one system could be at the level of speech on another system. Having no control over the sound cards and microphones that are used, it is therefore desirable to have some alternate measure of the silence level.
SUMMARY OF THE INVENTION
It is therefore a general object of the present invention to devise a system and method of speech signal normalization for eliminating or reducing variations in signal energy prior to a speech recognition process.
It is a particular object of the present invention to provide a method which can perform energy normalization of voice signals.
It is a further object of the present invention to discriminate between passages of silence and speech in a voice signal.
It is a still further object of the present invention to give the user of an SR system, feedback means for achieving optimal speech recognition accuracy.
It is yet a further object of the present invention to provide a method for normalizing a voice signal which can rapidly respond to the energy variations in a speaker's utterance.
It is a further object of the present invention to provide a method that will not distort the tracking of energy peaks during periods of silence.
These objects and other advantages are achieved by a voice normalization method and device which normalizes the energy in a voice signal by removing the long term variations and bias in the energy of the signal while retaining the short term variations that represent the phonetic information. A method of the present invention constructs a plurality of distinct energy tracks, preferably a high, mid, and low energy track. The values are mathematically smoothed and then used to track the upper and lower energy envelope of the voice signal. The smoothed high energy track is used to normalize the energy in the signal. The method further derives two figures of merit; a signal to noise ratio, and a measure of the noise floor, both of which are used to provide feedback means to a user of the SR system.
The present invention further provides a novel method for discriminating between periods of silence and speech in the voice signal.
In the preprocessor, there is provided an analyzer connected to receive a digital speech signal and generate therefrom a sequence of frames. Each frame has a plurality of samples from said digital speech signal. A device is further provided for tracking the energy in one or more consecutive frames of said digital speech signal by constructing a plurality of energy tracks to track the upper energy envelope, an average energy, and a lower energy envelope. Another device is yet further provided for calculating a value of normalized energy. Another device is yet further provided for providing the normalized energy to a speech recognition preprocessor. Another device is yet further provided for measuring the signal to noise ratio and absolute noise floor in one or more consecutive frames of said digital speech signal. Another device is yet further provided for displaying said signal to noise ratio and absolute noise floor to a user as a continuous display for providing feedback means to achieve optimal speech recognition accuracy. And, another device is yet further provided for discriminating between intervals of silence and speech in said digital speech signal.
According to the present invention, there is provided a method of normalizing energy in a voice signal. The method calculates a high energy track for tracking the upper energy envelope of said voice signal. The method further calculates a low energy track for tracking the lower energy envelope of said voice signal. The method yet further calculates a mid energy track for tracking the average energy of said voice signal. And, the method yet further calculates a value of normalized energy from said high energy track to be provided to a speech recognition system.
The invention and its operation will become more apparent from the following description of preferred embodiments and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a speech recognition pre-processor in accordance with the present invention, in conjunction with a speech recognition processor.
FIG. 2 shows a sample construction of a PCM waveform and associated observation window for practicing the present invention.
FIG. 3 is a flow diagram illustrating the removal of long term variations and bias in the energy of a voice signal according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The particular software implementation of the present invention should not be seen as limiting because the present invention may be implemented either wholly or in part in hardware.
Referring initially to FIG. 1, a block diagram is shown of a speech recognition pre-processor 100 to which the present invention is applied, in conjunction with speech recognition system 114 . The speech recognition pre-processor 100 includes an analyzer module 102 operatively coupled to an energy tracking module 104 . The energy tracking module 104 is operatively coupled to a normalized energy computation module 110 and to a measurement module 106 . The normalized energy module 110 is coupled to the speech recognition processor 114 . The measurement module 106 is coupled to a measurement display module 108 .
The analyzer module 102 receives a PCM voice signal as input. The analyzer module 102 partitions the PCM voice signal into a plurality of consecutive non-overlapping frames. Each frame represents a fixed time slice of the PCM waveform containing some number of digital samples. The divided PCM waveform is provided to the energy tracking module 104 .
The energy tracking module 104 receives the framed PCM waveform data as input and constructs an observation window that is incrementally shifted in discrete shift increments at times: (t, t+delta, t+(2*delta), etc . . . ), over the entire waveform. At each shift increment of the observation window, one or more frames of the PCM waveform will be contained within the observation window. At each shift increment of the observation window a feature vector is computed from the frame data located inside the window. One of the computed features of the feature vector is the RMS energy of the speech signal, preferably measured in decibels. In addition to the RMS energy, the zeroeth cepstral coefficient, C 0 , is also computed as part of the feature vector. The method may use either the RMS energy or C 0 to represent the instantaneous energy of the signal. The computed energy feature is used to calculate a plurality of energy tracks, preferably high, mid and low. The high energy track, Ahigh(t), is calculated to track the upper envelope of the signal energy, the mid energy track, Amid(t), is calculated to track the average signal energy, and the low energy track, Alow(t), is calculated to track the lower envelope of the signal energy. The high and low energy tracks are computed by summing two weighted terms wherein the weighting coefficients adapt to changes in the currently observable signal energy for the current shift increment. The middle energy track utilizes constant non-adaptable weighting coefficients. Each of the three energy tracks is of the general form of a running sum, defined by as:
current_running_sum( t )=(previous_running_sum( t− 1)* w 1 )+(currently_observed_value( t )*(1− w 1 )) [Eq. 1]
Variables (t), and (t−1) represent the shift increment times associated with the observation window, wherein time (t) represents the time associated with a current shift increment and time (t−1) represents the time associated with the most recent shift increment of the observation window. Further, Equation 1 is recursive whereby the previous running sum, at time (t−1), is added to a currently observed value at time (t) to generate a current running sum at time (t). Further, both the current and previous running sums represent mean values. As such, the high, mid, and low energy tracks, generally represented by equation 1, will hereinafter be respectively referred to as the high biased running mean, unbiased running mean, low and biased running mean. The details associated with the particular calculation for each of the three energy tracks will be provided below.
Subsequent, to computing the high bias, unbiased, and low bias running mean values, the energy track module 104 further calculates smoothed values for both the high and low bias running mean values, in the log domain, Epeak(t) and Efloor(t). The smoothed values measure the high and low energy envelopes of the PCM waveform, respectively. The smoothed values, however, are not indiscriminately computed at each shift increment, they are instead selectively computed at each shift increment depending upon whether the frame data contained within the observation window for the current shift increment is characterized as being an interval of speech or silence. To make such a determination, the energy tracking module 104 provides as input to the speech/silence discrimination module 112 , the unbiased running mean, Amid(t), and the low biased running mean, Alow(t). The speech/silence discrimination module 112 compares the unbiased running mean with the low biased running mean, and whenever the unbiased running mean is within some pre-defined threshold, Athresh, of the low biased running mean that interval is labeled a silence interval. Correspondingly, whenever the unbiased running mean, Amid(t) is greater than the low biased running mean value by the pre-defined threshold, Athresh, the interval is labelled a speech interval. The speech/silence determination result is provided as input to the energy tracking module 104 to insure that the high biased smoothed value, Epeak(t) is only updated for those intervals determined to be speech intervals. Correspondingly, the energy tracking module 104 only updates the low biased smoothed value, Efloor(t), only for those intervals determined to be silence intervals. Selectively updating the high and low bias smoothed values facilitates the optimal tracking of the high and low energy envelopes. For speech intervals, the smoothed low bias running mean, Efloor(t), is held constant (gated) to its value computed at the most recent silence interval. Correspondingly, for silence intervals, the smoothed high bias running mean, Epeak(t), is held constant(gated) to its value computed at the most recent speech interval. If the gating operation was not performed the smoothed high biased running mean value, Epeak(t), would eventually fall to the silence level during long segments of silence. Similarly, the low biased running mean value, Efloor(t), would eventually rise into the levels of speech during long segments of speech. The details of discriminating each interval as one of speech or silence will be described in connection with the preferred embodiment.
The energy tracking module 104 provides the smoothed high and low bias running mean values, Epeak(t) and Efloor(t), to the measurement module 106 , and further provides Epeak(t) and the instantaneous energy observed at the current shift increment to the normalized energy computation module 110 .
The measurement module 106 utilizes the provided inputs to calculate an estimate of the peak S/N ratio, and a figure for the absolute noise floor for the current shift increment. The S/N ratio and absolute noise floor values are in turn provided as input to a display module 108 to provide feedback to the user of the Speech recognition (SR) system as an indication of his audio quality.
The smoothed high bias running mean value, Epeak(t), is provided as input to the normalized signal energy module 110 Epeak(t) to calculate the normalized signal energy, Enorm(t) for the current shift increment. Enorm(t) is computed by subtracting the energy feature, either RMS energy or Co, from Epeak(t). The result is then provided as input to the speech recognition module 114 for processing.
Referring to FIG. 2, An exemplary embodiment of the present invention is illustrated. FIG. 2 illustrates a PCM voice signal 2 as a series of consecutive frames 4 . Each frame represents a 1/100 second time slice of the PCM waveform. Also shown is an observation window 6 of width 2/100 seconds which is incrementally shifted over the PCM waveform from start to end in shift increments of 1/100 seconds. The exemplary embodiment illustrates an observation window that is twice the width of a frame. Given the respective widths and shift increment magnitude, each frame will be sampled twice.
Referring now to FIG. 3, a flow diagram illustrates the method steps performed at each shift increment of the observation window. Beginning at step 40 , a number of parameters are initialized at time zero, they include: a tracking time constant, Tt, a smoothing time constant, Ts, a display time constant, Td, a contrast adjustment for bias weighting, K, an expected maximum observed value, Emax, an expected minimum observed value, Emin, a noise threshold for speech/silence discrimination, Ethresh measured in dB, and by conversion to the linear domain Athresh.
In addition to initializing parameters, a number of initial conditions are established, they include initial values for the high bias running mean, Ahigh( 0 ), which is initialized to the linear domain value of Emin, the expected minimum observed; a mid bias running mean initial value, Amid( 0 ), also initialized to Emin; and an initial value for the low bias running mean energy track, Alow( 0 ), initialized to the linear domain value of Emax, the expected maximum observed value. Further initial values include the gated and smoothed high energy track, Epeak( 0 ), initialized to Emax, and Efloor( 0 ), the gated and smoothed low track initialized to (Emax+Emin)/2. The display of the signal to noise ratio, Ds/n( 0 ) is set to zero as well as the display of the noise floor Dnoise( 0 ).
Further at time zero, the PCM waveform sampling rate of 22 k samples/sec is initiated, and the observation window is positioned to contain the first two frames of waveform data.
In the exemplary embodiment, sampling the PCM waveform at a rate of 22 k samples per second for a shift increment duration of 1/100 seconds yields 440 samples given an observation window width of 2/100 seconds (two frames).
At step 41 the observation window is shifted by 1/100 seconds,, (i.e. one shift increment along the PCM waveform). Referring now to FIG. 2, an observation window 6 is initially positioned to be located at a start of the PCM waveform at time, t=0. The observation window moves in time from a first frame to a last frame of the PCM waveform in discrete shift increments. FIG.2 illustrates a starting position of the observation window 6 and two successive shift increments 8 and 10 where each shift increment is equivalent to translation of the observation window in time by 1/100 seconds in the exemplary embodiment.
At step 42 , a feature vector is computed from the 440 samples where one of the computed features is the RMS energy of the speech signal, E obs , a log domain value measured in decibels. In addition to the RMS energy, C 0 , the zeroeth cepstral coefficient, is also computed as part of the feature vector. The method may use either the RMS energy or C 0 to represent the instantaneous energy of the signal. In the exemplary embodiment, tracking is done in the linear domain (A obs ), however, other embodiments may track the instantaneous energy in either the linear or log domain. Conversion from the log domain (measured in decibels) to the linear domain is given by Eq. 2 as:
A OBS ( t )=10 (K* obs (t)−E min )/(E max −E min ))) [Eq. 2]
The constant K determines the magnitude of the bias used for computing the running sums, and the remaining terms scale the energy to be in the range of 0 to 1, so that either the RMS energy or C 0 can be used.
In addition to computing a feature vector the high, mid and low biased running mean values are calculated at each shift increment. The calculation for the high biased running mean, Ahigh(t), is described as:
A high( t )=( W high( t )* A obs( t ))+((1− W high( t ))* A high( t− 1)) [Eq.3]
The calculation for the low biased running mean, Alow(t), is described as:
A low( t )=( W low( t )* A obs( t ))+((1− W low( t ))* A low( t− 1)) [Eq. 4]
Where Whigh(t) and Wlow(t) in equations 3 and 4 represent adjustable weighting coefficients
Whigh(t) and Wlow(t) are each computed as;
W high( t )=min (1.0, ( A obs( t )/ A high( t− 1)) 2 /Tt ) [Eq.5]
W low( t )=min (0.5, ( A low( t− 1)/ A obs( t )) 2 /Tt ) [Eq.6]
Equations 5 and 6 illustrate how the weighting coefficients adjust at each shift increment in response to the relative magnitude of the instantaneous observed amplitude, Aobs(t), and the previously computed high and low bias running mean values, Ahigh(t−1) and Alow(t−1), respectively. This adjustment capability at each shift increment is advantageous in that the high and low energy envelopes may be accurately tracked by adjusting the weighting coefficients in response to instantaneous variations in the signal level.
With specific reference to equations 3 and 5, when the currently observed value, Aobs(t) is much greater than Ahigh(t−1), the high biased running sum computed at the previous interval, the weight multiplier Whigh(t) would be adjusted upward (i.e. a value closer to 1) in equation 5 thereby giving proportionally higher weight to the Aobs(t) term in equation 3.
The weighting coefficient adjustment performed at each shift increment for the low biased running mean, Alow(t), is similar to the adjustment described for the high biased running mean, however, the weighting coefficient, Wlow(t), is adjusted to adapt to instantaneous changes in the low energy of the voice signal. Specifically, the relative magnitude of the instantaneous observed amplitude, Aobs(t), and the previously computed mean value, Alow(t−1) are compared and when the difference is large the weighting coefficient multiplier is adjusted in response. With specific reference to equations 4 and 6, when the current observation value, Aobs(t), is much lower than the previously computed low biased running mean, Alow(t−1), the weighting multiplier, Wlow(t) is adjusted upward in response, to rapidly adapt to the instantaneous large change in the low signal energy.
In addition to computing a high and low biased running mean value at each shift increment, the unbiased running mean (mid energy track), Amid(t), is computed and represents the running average of the voice signal's energy. The unbiased running mean, Amid(t), is calculated as:
A mid( t )=( W mid* A obs( t ))+((1− W mid)* A mid( t− 1)) [Eq.7]
The calculation of the unbiased running mean represents the average energy of the PCM waveform and is distinguishable from the previous calculations for the low and high biased running mean in that the weighting coefficient, Wmid, is constant and therefore does not change at each shift increment. As such, the calculation of the unbiased running mean is said to be energy independent. The weight multiplier Wmid in equation is calculated as:
W mid=1/ Tt [Eq.8]
Where Tt represents the tracking time constant, whose value is typically 0.1 seconds. The value for Tt is selected to be short enough to respond quickly to transitions from silence to speech, but long enough to ignore silences within words, such as stop consonants or low energy fricatives.
Step 50 is a determination step for discriminating between speech and silence. That is, at each shift increment of the observation window, a determination is made regarding whether the portion of the PCM waveform (i.e. digital samples) contained within the current position of the observation window constitutes an interval of silence or speech. To make that determination a comparison between the low biased running mean, Alow(t), and the unbiased running mean, Amid(t) is performed. Specifically, whenever the unbiased running mean, Amid(t) is within some pre-defined threshold, Athresh, of the low biased running mean that interval is labeled a silence interval. Correspondingly, whenever the unbiased running mean, Amid(t) is greater than the threshold, Athresh, the interval is labelled a speech interval. The threshold Athresh is computed as:
A thresh=10 (K*(Ethresh/(Emax−Emin))) [Eq.9]
where Ethresh represents the noise threshold for a speech/silence determination low enough to ignore low energy consonants, and high enough to quickly detect the onset of silence. For example 5 dB. Emax and Emin represent the expected maximum and minimum values of the observations, respectively. For example, 80 dB and 0 dB.
When the current interval is determined to be a speech segment, a branch to step 52 occurs. At step 52 , a smoothing operation is performed. Specifically, the high biased running mean, Ahigh(t), is mathematically smoothed yielding Epeak(t), (hereinafter referred to as the gated and smoothed high biased running mean).
In the exemplary embodiment the three energy tracks, (i.e., the high, mid, and low bias running mean values) are computed in the linear domain. However, the associated smoothed values for the high and low bias running mean values are computed in the log domain. To convert the linear high bias running mean from the linear to the log domain, equation 10 is provided:
E high( t )= E min+(log 10 ( A high( t ))*( E max− E min)/ K )) [Eq.10]
Using Ehigh(t), the smoothed value for the high biased running mean (i.e. the gated and smoothed high bias running mean) is then calculated as:
E peak( t ) ( W peak( t )* E high( t ))+((1− W peak( t ))* E peak(t−1)) [Eq.11]
Where Wpeak(t) represents the weighting coefficient for computing Epeak(t) and is calculated as:
W peak( t )=min[1.0, ( E high( t )− E min)/( E peak( t− 1)− E min))) 2 /T s ] [Eq.12]
At time zero the gated and smoothed high bias running mean, Epeak( 0 ) is initially set to Emax, the expected minimum value of the observations. For example 80 dB. Epeak(t) will then rapidly adjust to the correct value in subsequent shift increments.
The value of Epeak(t) is updated in only those intervals determined to be speech intervals. Otherwise for those intervals determined to be silence intervals the value of Epeak(t) is held constant to its value last updated at the most recent speech interval. This is required because if the smoothed high biased running mean were updated at silence segments its value would eventually fall to the silence level during long segments of silence thereby limiting its ability to optimally track the high energy envelope.
Correspondingly, a smoothed low bias running mean, Efloor(t), will be updated at silence intervals and held constant (gated) at speech intervals. That is, at speech intervals the value will be held constant to that value updated at the most recent silence interval. Gating the gated and smoothed low bias running mean, Efloor(t), is required because otherwise the smoothed value would eventually rise into the levels of speech during long segments of speech.
If it is determined at determination step 50 that the interval is a silence interval, a branch to step 53 occurs. At step 53 , the gated and smoothed low biased running mean is updated, Efloor(t). Efloor(t) is computed in the log domain. To compute Efloor(t) in the log domain it is necessary to first convert the low bias running mean, Alow(t), from the linear to the log domain.
E low( t )= E min+(log10( A low( t ))*( E max− E min)/ K ))[ Eq.13]
The value of Elow(t) is then used to compute the gated and smoothed high bias running mean as:
E floor( t )=( W floor(t)* E low( t ))+((1− W floor( t ))* E floor( t− 1)) [Eq.14]
Where Wfloor(t) represents the weighting coefficient for computing Efloor and is computed as:
W floor( t )=min((1.0, (( E max− E low( t )/( E max− E floor( t− 1))) 2 /Ts ) [Eq.15]
At was true for the gated and smoothed high biased running means, at time zero the gated and smoothed value, Efloor( 0 ) is initially set to some value that estimates what the envelope should look like and then the value rapidly adjusts to the correct value in subsequent shift increments.
At step 54 , the gated and smoothed high biased running mean, Epeak(t), is subtracted from the energy feature yielding the energy normalization vector, Enorm(t) which is used by the SR system. Enorm(t) is computed as:
E norm( t )= E obs( t )− E peak( t ) [Eq.16]
At step 55 , the value of the gated and smoothed low biased running mean is output to a user as a measure of the absolute noise level.
A measure of the signal to noise ratio is also displayed to the user by computing the difference between the gated and smoothed high biased and low biased running mean values.
In the exemplary embodiment, an audio status indicator would be displayed to a user, similar in form to a standard VU meter. The audio status indicator would continuously display the computed signal to noise (s/n) ratio to the user. At very low signal to noise levels the indicator would display a blue bar indicating that the user's speech is mostly incomprehensible to the SR system and that some adjustment is in order. At higher levels of s/n, both a blue and yellow bar are displayed indicating that some speech recognition is being achieved by the SR system, however, the situation is far from ideal. At still higher levels of signal to noise, where speech recognition is optimum, a blue, yellow and green bar will be displayed. If the audio level is so high that the signal may be clipped, then a red bar is displayed along with the blue, yellow and green bars. It is the absolute audio level, rather than the s/n ratio that determines whether the red bar will be displayed. During segments of silence, a black frame is displayed around the color bars. It is removed during intervals of speech (a gray frame replaces the black bar and blends in with the background during speech). These indicators provide a concise summary of the status of the audio quality which impact the SR system. Alternative embodiments would include numeric values in addition to the indicators described above.
Step 58 is a determination step to decide whether the observation window has reached the end of the PCM waveform. If not, a branch occurs back to step 41 where the observation window will be translated along the waveform by one shift increment. Otherwise, the process terminates at step 60 .
Thus, the present invention provides the objects described above, of energy normalization and of speech/silence discrimination.
Although illustrative embodiments of the present invention have been described herein with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various other changes and modifications may be affected therein by one skilled in the art without departing from the scope or spirit of the invention.
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Energy normalization in a speech recognition system is achieved by adaptively tracking the high, mid, and low energy envelopes, wherein the adaptive high energy tracking value adapts with weighting enhanced for high energies, and the adaptive low energy tracking value adapts with weighting enhanced for low energies. A tracking method is also provided for discriminating waveform segments as being one of “speech” or “silence”, and a measure of the signal to noise ratio and absolute noise floor are used as feedback means to achieve optimal speech recognition accuracy.
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BACKGROUND OF THE INVENTION
There exists a great need for copper base alloys which possess a combination of high mechanical strength properties with high electrical conductivity properties. Generally, such alloys are utilized for electrical conductor applications which require greater tensile strength than that possessed by pure copper in the same applications.
A variety of copper base alloys have been proposed to fill this need for an alloy capable of displaying the combination of high mechanical strength properties and high electrical conductivity. Among these alloys, copper base alloys containing titanium and antimony have been proposed as being capable of maintaining both strength and conductivity properties at high levels. Copper base alloys consisting of copper alloyed with 0.08 to 0.7% by weight of titanium and 0.05 and 1.0% by weight of antimony have been described in U.S. Pat. Nos. 3,773,505 and 3,832,241 to Donald J. Nesslage and Lin S. Yu, as being capable of maintaining moderately high mechanical strength while overcoming undesirably low electrical conductivities.
SUMMARY OF THE INVENTION
The present invention provides for improvements in strength of the copper-titanium-antimony ternary system along with improvements in conductivity over those values obtainable from such systems as disclosed in the Nesslage et al. patents. This improvement is accomplished by the addition of chromium to the cooper-titanium-antimony ternary system. The chromium is added in the amount of 0.1 to 1.0% by weight to the ternary system composed of 0.08 to 1.0% by weight of titanium, 0.05 to 1.5% by weight of antimony with the balance copper.
The addition of chromium to the ternary system permits significantly higher strength properties, albeit at electrical conductivity levels lower than those presented in the Nesslage et al. patents when the resulting quaternary system is processed in accordance with the optimum processing taught in U.S. Pat. Nos. 3,773,505 and 3,832,24l. The influence of the chromium addition, when the system is processed according to the present invention, is shown in an increase in strength properties when compared to the alloys of, for example, Nesslage et al., while maintaining an electrical conductivity level fairly equivalent to the alloys presented in the Nesslage et al. references.
Therefore, the main objective of the present invention is to provide a copper base alloy which contains 0.1 to 1.0% by weight of chromium in addition to 0.08 to 1.0% by weight of titanium and 0.05 to 1.5% by weight of antimony, said alloy possessing a unique combination of high strength and high electrical conductivity.
Another object of the present invention is to provide such an alloy as described above which can be processed according to methods already well known in this field.
A further object of the present invention is to provide a process for producing an alloy as described above which results in an increase in strength without a significant reduction in electrical conductivity properties of the alloy.
Other objects and advantageous features of the invention will become more apparent to those skilled in this art from the following detailed description of the preferred compositions and procedures in accordance with the present invention.
DETAILED DESCRIPTION
The present invention requires that copper of adequate purity be alloyed with 0.08 to 1.0% by weight of titanium, 0.05 to 1.5% by weight of antimony and 0.1 to 1.0% by weight of chromium. Between 0.1 and 0.6% by weight of chromium is preferred in the alloy system. It is essential to the properties of the alloy obtained from these elements that the atomic ratio of the titanium to antimony be equal to or close to, but not substantially in excess of, the ratio 5:3. This ratio is critical in that when the alloy composition is such that the ratio of titanium to antimony substantially exceeds 5:3, for example by 10%, the resulting properties of the alloy are marked by a substantial decrease in the electrical conductivity of the alloy. In contrast, up to 20% excess amounts of antimony cause a relatively slight decrease in the electrical conductivity properties of the alloy. For example, the titanium and antimony may be present in the alloy at an atomic ratio of 3 to 3.6 atoms of antimony per 5 atoms of titanium.
The alloys of this invention may be prepared as molten metal by the conventional operation of known melting equipment, the alloying additions being made by any convenient method, including the use of copper master alloys. The alloy ingots are cast using conventional equipment and techniques.
The combination of optimum strength characteristics and high electrical conductivity is developed in the alloy through a properly coordinated schedule of mechanical operations to reduce the cross-sectional area of the cast ingot or billet. Thermal operations may also be utilized to develop the strength characteristics and high electrical conductivity of the alloy. The mechanical operations include extrusion, forging, wire drawing and preferably a combination of hot and cold rolling. The hot rolling may, by itself, perform a solution annealing function on the worked alloy if the operation is performed at a temperature which is high enough to put the alloying elements into solution. The hot rolling may also be utilized with a separate solution annealing step to place the alloying elements into solution. After either solution annealing step, the alloy is rapidly cooled to maintain the maximum solid solution of all alloying elements. The alloy is then subjected to cold working. The cold working may be accomplished in cycles, utilizing intervening solution anneals, provided that the final step of the cycle is a cold working step. After cold working, the alloy is aged to effect the desired precipitation of alloying elements throughout the alloy. Aging of the worked alloy may be performed utilizing temperatures of 250° to 500° C. for 1/2 to 24 hours, preferred conditions for thermal treatments being set forth in the specific examples which follow. The extent of cold working will vary according to requirements for articles produced from the alloy. The alloy processing may also include short time recrystallization treatments utilized to result in reduced grain size in the alloy without affecting the homogeneity of the alloy.
The extent of the improvement in strength properties over the prior art presented by the alloys of the instant invention is demonstrated in the following examples.
EXAMPLE I
Two alloys having a nominal composition of 0.3 weight percent titanium, 0.4 weight percent antimony and, respectively, 0.2 and 0.5 weight percent chromium, balance copper, were processed according to the optimum processing defined in U.S. Pat. Nos. 3,773,505 and 3,832,241. This processing included casting the alloys, hot working the alloys at an elevated temperature below the melting point of the alloys (with a range of from about 1500° to 1750° F. or 815.5° to 954.4° C. being preferred). After hot working, the alloys were rapidly cooled and then were cold rolled to a reduction of 75%, aged at 800° F. (426.7° C.) for 2 hours, cold rolled again to a reduction of 60% and finally aged at 700° F. (371.1° C.) for 1 hour. The properties of the alloys along with the properties of the alloy utilized in said patents (from Table V of each patent) are indicated in Table I.
TABLE I______________________________________Comparison of Cu-Ti-Sb-Cr Alloy Properties toCu-Ti-Sb Alloy Properties Using Same Processing______________________________________ 0.2% Electrical UTS YS ConductivityAlloy Composition (ksi) (ksi) (% IACS)______________________________________Cu-0.3 Ti-0.4 Sb-0.2 Cr 91 88 71Cu-0.3 Ti-0.4 Sb-0.5 Cr 96 94.5 66Cu-0.33 Ti-0.42 Sb 87 79.2* 75______________________________________ *Measured at 0.1% YS.
The values presented in Table 1 indicate that the alloys of the present invention, particularly at the higher end of the chromium range, exhibit clearly superior strength when compared to the alloys of U.S. Pat. Nos. 3,773,505 and 3,832,241 albeit at conductivity ranges below those exhibited by the patented alloys.
EXAMPLE II
The two alloys incorporating chromium, identified in Example I, and a ternary alloy within the patent composition range described in Example I were processed according to the following procedure. All alloys were hot rolled, subjected to a 950° C. solution anneal for 1 hour, rapidly cooled to maintain the maximum solid solution of all alloying elements, cold rolled to a 50% reduction, aged at 450° C. for 4 hours, cold rolled to a 60% reduction and finally aged at 350° C. for 1 hour. The properties obtained for each alloy are indicated in Table II. For additional comparative purposes, the strength values achieved by the patent ternary system, via processing defined in Table III of each patent at similar conductivity values are also included in Table II.
TABLE II______________________________________Comparison of Cu-Ti-Sb-Cr Alloy Properties toCu-Ti-Sb Alloy Properties Using Same ProcessingAnd Different Patent Process______________________________________ 0.2% Electrical UTS YS ConductivityAlloy Composition (ksi) (ksi) (% IACS)______________________________________Cu-0.3 Ti-0.4 Sb-0.2 Cr 86 83 76Cu-0.3 Ti-0.4 Sb-0.5 Cr 92 89 72Cu-0.3 Ti-0.4 Sb 79.5 75 76Cu-(0.30-0.43) Ti-(0.56-0.61) Sb* 80.2 78.5 75.2______________________________________ *processed according to Table III of U.S. Patents 3,773,505 and 3,832,241 YS measured at 0.5% offset.
The values presented in Table II indicate that the alloys of the present invention exhibit clearly superior strength compared to the alloys of U.S. Pat. Nos. 3,773,505 and 3,832,241 at the electrical conductivity range of 72-76% IACS, when all alloys are processed according to the present invention. The combination of the chromium addition and the processing of the present invention, when compared to the optimum processing of the prior art alloys, provides the final alloys with a significant increase in strength properties without reducing the electrical conductivity thereof in the process.
This invention may be embodied in other forms or carried out in other ways without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered as in all respects illustrative and not restrictive, the scope of the invention being indicated by the appended claims, and all changes which come within the meaning and range of equivalency are intended to be embraced therein.
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Copper base alloys which exhibit a combination of high electrical conductivity and superior strength properties are presented. These alloys consist essentially of 0.08 to 1.0% by weight of titanium, 0.05 to 1.5% by weight of antimony, 0.1 to 1.0% by weight of chromium, balance copper. The desired properties are attained by the proper application of mechanical processing steps and thermal treatments.
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FIELD OF THE INVENTION
[0001] The present invention pertains to a method for detecting quinolone-resistant Escherichia coli strains in a biological sample material. The present invention also relates to a kit adapted to perform the present method.
BACKGROUND OF INVENTION
[0002] Bacterial infections are generally treated with antibiotics, among which quinolones have proven to be one of the most highly potent agents for use in human. In the past, fluoroquinolones have been widely used as broad spectrum antimicrobial agents in clinical medicine with the result that bacteria have developed resistance against this agent.
[0003] One of the most concerned species of bacteria to be treated with quinolones is E. coli , which causes a number of infections, primarily in and around artificial or natural openings of the body, such as lesions in the skin or the urinary tract. Particularly, experience in and information about the treatment of urinary tract infections shows that 90% of the antibiotics administered are quinolones, while in the meantime about 8% of the E. coli strains have become resistant. Therefore, the ordinary regimen does not apply in a number of cases, which the attending physician will normally recognize only at a later stage of the infection/bacterial growth, with a concurrent destruction of the infested tissue. In addition, quinolone-resistant E. coli may also prove to be a potential threat to neutropenic patients with leukemia, who receive a quinolone as prophylaxis.
[0004] In general, the therapeutic or prophylactic use of quinolones without considering possible resistance of the infecting pathogen may lead to treatment failures as well as to an induction of new resistances.
[0005] Therefore, there is a need in the art to get information about potential resistances occurring in the bacterial population to be treated.
[0006] Up to now the standard methods to determine an antibiotic resistance are based on phenotypic identification, which is time consuming and is in certain cases not sensitive and precise enough.
[0007] An approach in the art to cope with these problems focuses on the investigation of polypeptides accounting for the quinolone resistance in pathogenic bacteria. Several analyses have been developed in order to gain such information, for example a single-stranded conformational polymorphism (SSCP) analysis (Ouabdesselam S, Hooper D C, Tankovic J, Soussy C J, Antimicrobial Agents and Chemotherapy 39 (1995), 1667-70), a mismatch amplification mutation assay (MAMA; Qiang Y Z, Qin T, Fu W, Cheng W P, Li Y S, Yi G., J Antimicrob Chemother 49 (2002), 549-52) and a restriction fragment length polymorphism (RFLP) analysis (Hooper D C, Wolfson J S, Ng E Y, Swartz M N., Am J Med 82 (1987), 12-20).
[0008] However, all the above methods and assays exhibit a variety of different shortcomings. In particular, with a SSCP only the region of mutation may be detected, but not the exact position of mutation. With the MAMA procedure, only one variant may be determined at a time, or else a cost and work intensive multiplex PCR has to be performed. RFLP detects only the position of the mutation, but not the substitution. In addition, none of the methods accurately predicts whether the bacterial sample exhibits resistance to the agents utilized.
[0009] Therefore, a need exists to rapidly and reliably detect the presence of resistant strains of bacteria. Furthermore, such a detection assay should process multiple samples simultaneously and inexpensively.
SUMMARY OF THE INVENTION
[0010] It is, therefore, one object of the present invention to provide a method for detecting the presence of quinolone resistant E. coli strains in a biological sample.
[0011] It is also an object of the present invention to provide micro-arrays and kits for use in detecting the presence of quinolone resistant E. coli strains in a biological sample.
[0012] In accomplishing these and other objects of the invention, there is provided, in accordance with one aspect of the invention a method for detecting the presence of quinolone resistant E. coli strains in a biological sample, which method comprises the steps (i) obtaining DNA from a biological sample, (ii) optionally amplifying the DNA contained in the sample with primers specific for the target sequence, (iii) contacting the DNA contained in the biological sample or obtained in step (ii) with a micro-array comprising at specific pre-determined locations of the array two sets of capture probes, which are derived from the sequence of a gyrA gene of E.coli , and comprise the sequence R 1 -(X)-R 2 , wherein (a) X designates all permutations of the triplet at amino acid position 83 and 87 of the gyrA polypeptide of E. coli , and wherein (b) R 1 and R 2 are sequences derived from the gyrA gene of E. coli adjacent to the triplet of either position 83 or 87 of the gyrA polypeptide and comprising of from about 5 to 20 nucleotides, under conditions allowing hybridization of complementary strands, and (iv) determining, at which location on the array binding occurs, wherein a change in the nucleic acid at the said positions resulting in a change of an amino acid is indicative of the development of a resistance against quinolones. In one embodiment, the change in the nucleic acid sequence results in an amino acid change of the gyrA polypeptide to leucine at position 83 and/or asparagine or tyrosine at position 87.
[0013] The invention also provides a micro-array containing at specific predetermined locations of the array two sets of capture probes, derived from the sequence of a gyrA gene of E.coli , comprising the sequence R 1 -(X)-R 2 , wherein (a) X designates all permutations of the triplet at amino acid position 83 and 87 of the gyrA polypeptide of E.coli and (b) R 1 and R 2 are sequences derived from the gyrA gene of E.coli adjacent to the triplet of either position 83 or 87 of the gyrA polypeptide and comprising of from about 5 to 20 nucleotides.
[0014] In another embodiment, there is provided a kit for detecting the presence or absence of a quinolone resistant E. coli strain in a biological sample, containing a micro-array containing at specific predetermined locations of the array two sets of capture probes, derived from the sequence of a gyrA gene of E.coli , comprising the sequence R 1 -(X)-R 2 , wherein (a) X designates all permutations of the triplet at amino acid position 83 and 87 of the gyrA polypeptide of E.coli and (b) R 1 and R 2 are sequences derived from the gyrA gene of E.coli adjacent to the triplet of either position 83 or 87 of the gyrA polypeptide and comprising of from about 5 to 20 nucleotides, and optionally buffers and reagents.
[0015] Other objects, features and advantages of the present invention will become apparent from the following detailed description. The detailed description and specific examples, while indicating preferred embodiments, are given for 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. Further, the examples demonstrate the principle of the invention and cannot be expected to specifically illustrate the application of this invention to all the examples where it will be obviously useful to those skilled in the prior art.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIGS. 1 A-D show the results of a hybridization of clinical isolates with labeled target DNA on a micro-array.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In the studies leading to the present invention a number of clinical isolates of E. coli known to be quinolone resistant have been investigated, while it has been surprisingly noted that in contrast to the quinolone sensitive strain, all of the resistant strains exhibited mutations in the gyrA polypeptide in at least one of amino acid positions 83 and 87. This focus on these two amino acid positions in resistant strains has been confirmed by additional studies so that the present invention is essentially based on the finding that in order to detect a quinolone resistance in E.coli , it is sufficient to provide data about these two positions in the gyrA polypeptide of E.coli , only.
[0018] Without wishing to be bound to any theory, it is presently believed that even though these two positions are not the sole mutations occurring in the gyrA polypeptide of quinolone resistant strains, they seem to be mainly involved in the development of resistance due to a folding of the resulting polypeptide preventing interaction with quinolones.
[0019] Another gene of interest that conveys quinolone resistance is topoisomerase IV. Of particular interest is subunit A, which is encoded by the parC gene. In this gene, three amino acid positions, 80, 84 and 87, are proposed as locations for the detection of quinolone resistance. Definitions
[0020] In the present description the following definitions apply:
[0021] The terms “micro-array” and “array of oligonucleotides”, which are used interchangeably in the present invention, refer to a multiplicity of different nucleotide sequences attached or positioned on one or more solid supports where, when there is a multiplicity of supports, each support bears a multiplicity of nucleotide sequences. Both terms may refer to the entire collection of nucleotides on the support(s) or to a subset thereof. In one embodiment, the nucleotide sequence is attached through a single terminal covalent bond. The support is generally composed of a solid surface which may be selected from the group consisting of glasses, electronic devices, silicon supports, silica, metal or mixtures thereof prepared in format selected from the group of slides, discs, gel layers and/or beads.
[0022] As used in present invention, the term “probe” or “capture probe” in the sense of the present invention is defined as a nucleotide sequence representing specific parts of the gyrA gene or parC gene, respectively, of E.coli covering amino acid positions 83 and 87 (gyrA) or 80, 84 or 87 of parC, respectively. The sequences have different lengths, e.g. between about 10 and 43 nucleotides, and are either chemically synthesized in situ on the surface of the support or laid down thereon. They are capable of binding to a target nucleic acid of complementary sequence through one or more types of chemical bonds, usually through complementary base pairing, usually through hydrogen bond formation. As used herein, a nucleotide probe may include natural (i.e. A, G, C, or T) or modified bases (7-deazaguanosine, inosine, etc.). In addition, the bases in an oligonucleotide probe may be joined by a linkage other than a phosphodiester bond, such as e.g. peptide bonds, so long as it does not interfere with hybridization.
[0023] The term “target nucleic acid” refers to a nucleic acid, to which the nucleotide probe specifically hybridizes.
[0024] The term “gyrA gene” as used in the present application comprises the gyrA gene of E.coli and its variants due to mutations and changes in different strains.
[0025] The term “parC gene” as used in the present application comprises the parC gene sequence of E.coli and its variants due to mutations and changes in different strains.
[0026] Th term “nucleotide sequence” as used herein refers to oligonucleotide(s), polynucleotide(s) and the like including analogous species wherein the sugar-phosphate backbone is modified and/or replaced, provided that its hybridization properties are not destroyed.
[0027] The phrase “hybridizing specifically to” refers to the binding, duplexing or hybridizing of a molecule substantially to or only to a particular nucleotide sequence or sequences under stringent conditions when that sequence is present in a complex mixture of DNA or fragments thereof.
[0028] The terms “background” or “background signal intensity” refers to hybridization signals resulting from non-specific binding, or other interactions, between the labeled target nucleic acids and components of the nucleotide array (e.g., the nucleotide probes, control probes, the array substrate, etc.).
[0029] Description
[0030] In order to perform the present method, a DNA from a biological sample is obtained in a first step from an individual to be treated or deemed to harbor a resistant strain. The biological sample/material may be any material supposed to contain a pathogenic E.coli , such as tissue from an area of a lesion, blood, or body secretions, such as sputum or urine. For some applications, it may be appropriate to transfer the biological sample into a medium suitable for the growth of E.coli , e.g. on LB agar plates.
[0031] The DNA contained in the biological sample may liberated from the E.coli cells or isolated according to techniques well known in the art, e.g. via QIAprep™ Spin Miniprep Kit protocol (Qiagen, Hilden, Germany). Alternative appropriate methods for obtaining DNA may be chosen, depending on the specific starting material. Such an isolation step assists in preventing the development of extensive background signals during the hybridization step, in case no other selection step is applied.
[0032] In one embodiment, the DNA contained in the biological sample or isolated therefrom may be amplified via a polymerase chain reaction (PCR) using one or more primers, which provides the advantage of augmenting the specific material to be investigated only and also to incorporate a selection step. In case of using one primer only, the complementary strand of the DNA of interest will be synthesized. Alternatively, at least two primers are utilized, allowing an exponential amplification of the material to be investigated. According to an alternative embodiment a nested PCR is carried out, wherein 2 pairs of primers are put to use. A first set of primers is selected to amplify a sequence largely around the target sequence. Then, the second pair of primers are used to amplify a sequence lying within the sequence amplified first. Proceeding accordingly gives the inherent advantage that a second selection step is incorporated in the present method, which assists in reducing the background. After the completion of the PCR reaction, the PCR product may be purified if desired.
[0033] When using an amplification step, the DNA may at the same time be labeled, e.g. by including in the amplification process nucleotides harboring an appropriate label. Alternatively, a label may be attached to the nucleic acid, including, for example, nick translation or end-labeling by attachment of a nucleic acid linker joining the sample nucleic acid to a label.
[0034] Detectable labels suitable for use in the present invention include any composition detectable by spectroscopic, photochemical, biochemical, immunochemical, electrical, optical or chemical means. Useful labels in the present invention include biotin for staining with labeled streptavidin conjugate, magnetic beads (e.g., Dynabeads™), fluorescent dyes (e.g., cyanine dyes, such as Cy5, fluorescein, texas red, rhodamine, green fluorescent protein, and the like), radiolabels (e.g., 3 H, 125 I, 35 S, 14 C, or 32 P), enzymes (e.g., horse radish peroxidase, alkaline phosphatase and others commonly used in an ELISA), and colorimetric labels such as colloidal gold or colored glass or plastic (e.g., polystyrene, polypropylene, latex, etc.) beads. Patents teaching the use of such labels include U.S. Pat. Nos. 3,817,837; 3,850,752; 3,939,350; 3,996,345; 4,277,437; 4,275,149; and 4,366,241.
[0035] In order to allow detection of the presence of a single mutation, the target- or probe-DNA should not be too long, since otherwise renaturation in solution, or base-pairing with a capture probe allowing mismatches may occur. The desired length of such a probe DNA should be of from about 10 to 50 nucleotides, preferably 15 to 40, more preferably 15-30, even more preferred 15-25 nucleotides and may be obtained by either selecting the primers during the amplification step accordingly, or by fragmenting the DNA put to use after an amplification step.
[0036] The target-/probe-DNA thus obtained is then contacted with the capture probes on the micro-array under conditions allowing hybridization of complementary strands only. In general, since a difference in at least one nucleotide is studied under certain conditions, stringent hybridization conditions are selected, e.g. adjusting the hybridization temperature to be about 1°-5° C. below the calculated thermal melting point (T m ) of a the specific sequence at a defined ionic strength and pH. The T m is the temperature (at the defined ionic strength, pH) at which 50% of the probes complementary to the target sequence hybridize to the target sequence at equilibrium. Another possibility to adjust stringent conditions resides in adding destabilizing agents, such as e.g. formamide.
[0037] In principle, the capture probes on the micro-array comprise the sequence R 1 -(X)-R 2 and are provided in two sets on the array. In one set, the sequences R 1 and R 2 , which may be of a length of from about 5 to about 20 nucleotides each, are derived from the sequences of the gyrA gene of E.coli adjacent to the triplet encoding the amino acid at position 83 in the gyrA polypeptide, while in the second set of capture probes the sequences R 1 and R 2 , which may exhibit the same length as indicated above, are derived from the sequence of the gyrA gene of E.coli adjacent to the triplet encoding the amino acid at position 87 in the gyrA polypeptide.
[0038] In a preferred embodiment the sequences R 1 and R 2 are designed such that known mutations of the gene encoding the gyrA polypeptide around positions 83 and 87, e.g. at positions 85 and 89, are taken into account. Hence, the positions 85 and 89 may also be permutated to cover all potential exchanges at these positions and permit an extremely accurate means to determine a SNP at positions 83 and 87, respectively.
[0039] An exemplary set of capture probes is shown in table I below.
TABLE I Amin Name Position Variation Sequence (3′ → 5′) Acid E.coli_GyA83A1 83 85(GTC) AT GGT GAC T A G GCG GT C TA Stop code E.coli_GyA83T1 83 85(GTC) AT GGT GAC T T G GCG GT C TA Leu E.coIi_GyA83G1 83 85(GTC) AT GGT GAC T G G GCG GT C TA Trp E.coli_GyA83C1 83 85(GTC) AT GGT GAC T C G GCG GT C TA Ser E.coli_GyA83A2 83 85(GTT) AT GGT GAC T A G GCG GT T TA Stop code E.coli_GyA83T2 83 85(GTT) AT GGT GAC T T G GCG GT T TA Leu E.coli_GyA83G2 83 85(GTT) AT GGT GAC T G G GCG GT T TA Trp E.coli_GyA83C2 83 85(GTT) AT GGT GAC T C G GCG GT T TA Ser E.coli_GyA83AU 83 85(GTI) AT GGT GAC T A G GCG GT I TA Stop code E.coli_GyA83TU 83 85(GTI) AT GGT GAC T T G GCG GT I TA Leu E.coli_GyA83GU 83 85(GTI) AT GGT GAC T G G GCG GT I TA Trp E.coli_GyA83CU 83 85(GTI) AT GGT GAC T C G GCG GT I TA Ser E.coli_GyA87A1 87 85(GTC)/89(ATT) GCG GT C TAT A AC ACG AT T G Asn E.coli_GyA87T1 87 85(GTC)/89(ATT) GCG GT C TAT T AC ACG AT T G Tyr E.coli_GyA87G1 87 85(GTC)/89(ATT) GCG GT C TAT G AC ACG AT T G Asp E.coli_GyA87C1 87 85(GTC)/89(ATT) GCG GT C TAT C AC ACG AT T G His E.coli_GyA87A2 87 85(GTT)/89(ATT) GCG GT T TAT A AC ACG AT T G Asn E.coli_GyA87T2 87 85(GTT)/89(ATT) GCG GT T TAT T AC ACG AT T G Tyr E.coli_GyA87G2 87 85(GTT)/89(ATT) GCG GT T TAT G AC ACG AT T G Asp E.coli_GyA87C2 87 85(GTT)/89(ATT) GCG GT T TAT C AC ACG AT T G His E.coli_GyA87A3 87 85(GTC)/89(ATC) GCG GT C TAT A AC ACG AT C G Asn E.coli_GyA87T3 87 85(GTC)/89(ATC) GCG GT C TAT T AC ACG AT C G Tyr E.coli_GyA87G3 87 85(GTC)/89(ATC) GCG GT C TAT G AC ACG AT C G Asp E.coli_GyA87C3 87 85(GTC)/89(ATC) GCG GT C TAT C AC ACG AT C G His E.coli_GyA87A4 87 85(GTC)/89(ATT) GCG GT T TAT A AC ACG AT C G Asn E.coli_GyA87T4 87 85(GTC)/89(ATT) GCG GT T TAT T AC ACG AT C G Tyr E.coli_GyA87G4 87 85(GTC)/89(ATT) GCG GT T TAT G AC ACG AT C G Asp E.coli_GyA87C4 87 85(GTC)/89(ATT) GCG GT T TAT C AC ACG AT C G His E.coli_GyA87AU1 87 85(GTI)/89(ATI) GCG GT I TAT A AC ACG AT I G Asn E.coli_GyA87TU1 87 85(GTI)/89(ATI) GCG GT I TAT T AC ACG AT I G Tyr E.coli_GyA87GU1 87 85(GTI)/89(ATI) GCG GT I TAT G AC ACG AT I G Asp E.coli_GyA87CU1 87 85(GTI)/89(ATI) GCG GT I TAT C AC ACG AT I G His E.coli_GyA87A5 87 85(GTC)/89(ATT) GCG GT C TAT G A C ACG AT T G Asn E.coli_GyA87T5 87 85(GTC)/89(ATT) GCG GT C TAT G T C ACG AT T G Tyr E.coli_GyA87G5 87 85(GTC)/89(ATT) GCG GT C TAT G G C ACG AT T G Asp E.coli_GyA87C5 87 85(GTC)/89(ATT) GCG GT C TAT G C C ACG AT T G His E.coli_GyA87A6 87 85(GTT)/89(ATT) GCG GT T TAT G A G ACG AT T G Asn E.coli_GyA87T6 87 85(GTT)/89(ATT) GCG GT T TAT G T C ACG AT T G Tyr E.coli_GyA87G6 87 85(GTT)/89(ATT) GCG GT T TAT G G C ACG AT T G Asp E.coli_GyA87C6 87 85(GTT)/89(ATT) GCG GT T TAT G C C ACG AT T G His E.coli_GyA87A7 87 85(GTC)/89(ATC) GCG GT C TAT G A G ACG AT C G Asn E.coli_GyA87T7 87 85(GTC)/89(ATC) GCG GT C TAT G T G ACG AT C G Tyr E.coli_GyA87G7 87 85(GTC)/89(ATC) GCG GT C TAT G G G ACG AT C G Asp E.coli_GyA87C7 87 85(GTC)/89(ATC) GCG GT C TAT G C C ACG AT C G His E.coli_GyA87A8 87 85(GTC)/89(ATT) GGG GT T TAT G A G ACG AT G G Asn E.coli_GyA87T8 87 85(GTC)/89(ATT) GGG GT T TAT G T G ACG AT G G Tyr E.coli_GyA87G8 87 85(GTC)/89(ATT) GGG GT T TAT G G G ACG AT G G Asp E.coli_GyA87C8 87 85(GTC)/89(ATT) GGG GT T TAT G C G ACG AT G G His E.coli_GyA87AU2 87 85(GTI)/89(ATI) GGG GT I TAT G A G ACG AT I G Asn E.coli_GyA87TU2 87 85(GTI)/89(ATI) GGG GT I TAT G T G ACG AT I G Tyr E.coli_GyA87GU2 87 85(GTI)/89(ATI) GGG GT I TAT G G G ACG AT I G Asp E.coli_GyA87CU2 87 85(GTI)/89(ATI) GGG GT I TAT G C G ACG AT I G His Capture probes directed against amino acid position 83 and 87 of GyrA with consideration of nucleotide variations at position 85 and 89. All the probes are 19mer and with the SNPs position almost in the middle. Bold letter indicate the SNPs positions and underline letter indicate the positions with variation. For position 83 two sets of probes (eight probes) and for position 87 eight sets of probes (32 probes) were designed, which four sets were directed against the first position of the triplet code, while the other four sets are directed against the second position of the triplet code. Both for position 83 and 87 were universal probes (for position 83 one set and for position 87 two sets) designed, which had inosine at the positions with variations.
[0040] According to a preferred embodiment the array may contain at least one additional set of capture probes, derived from the parC gene of E.coli . In fact, the topoisomerase IV is the secondary target for quinolone in the case of E.coli . The point mutation of the A subunit of this enzyme, which is encoded by parC gene, is the main cause for the resistance. Three amino acid positions, i.e. residues, 80, 84 and 87, have been chosen as locations for the detection. Frequent mutations at position 80 include Ser to Ile or Arg. Common mutations at position 84 include Glu to Lys or Gly.
[0041] As for the set of probes directed to the gyrA mutations also in this set of probes (directed to the parC gene), the capture probes on the micro-array comprise the sequence R 1 -(Y)-R 2 and may be provided in either of one or two or three sets on the array. In one embodiment, the inventive micro-array contains, apart from the capture probes directed to the gyrA gene, capture probes directed to the parC gene. The sequences R 1 and R 2 , which may be of a length of from about 5 to about 20 nucleotides each, are derived from the sequences of the parC gene of E.coli adjacent to the triplet encoding the amino acid at position 80 in the parC polypeptide. In a second and third set of capture probes, respectively, the sequences R 1 and R 2 , which may exhibit the same length as indicated above, are derived from the sequence of the gyrA gene of E.coli adjacent to the triplet encoding the amino acid no. 84 or 87 in the parC polypeptide.
[0042] In a next step it will be determined at which location on the array binding occurred, which is generally achieved by detecting the label that has been attached to/incorporated in the target-DNA prior to the hybridization step, or by performing a labelling reaction on the array. So called “direct labels” are detectable labels that are directly attached to or incorporated into the target (sample) nucleic acid prior to hybridization. In contrast, so called “indirect labels” are joined to the hybrid duplex after hybridization. The indirect label may also be attached to a binding moiety that has been attached to the target nucleic acid prior to the hybridization. For a detailed review of methods of labelling nucleic acids and detecting labelled hybridized nucleic acids see Laboratory Techniques in Biochemistry and Molecular Biology, Vol. 24: Hybridization With Nucleic Acid Probes, P. Tijssen, ed. Elsevier, N.Y., (1993)).
[0043] Also, the capture probes present on the array may contain a label at their 3′-end. After binding of the target DNA, the DNA/DNA hybrids are then cleaved with a particular enzyme thus releasing the label from those capture probes, where the target DNA had bound. Therefore, in this embodiment the decrease in signal is representative of the presence of a given nucleotide sequence in the gyrA gene.
[0044] Means of detecting labeled target nucleic acids hybridized to probes are well-known to those skilled in the art.
[0045] Two types of divergent results may be obtained.
[0046] On the one hand it may be noted that at the location representing the triplet of the native, i.e. quinolone sensitive strain, binding occurred, which will be indicative of a quinolone sensitive strain.
[0047] On the other hand it may also be observed that binding occurs on a location representing a triplet different from the native one. In this case, it should be first determined whether the change in the triplet has led to a change in the respective amino acid, either in one or two of the positions, preferably from serine to leucine (at position 83) and/or aspartate to asparagine or tyrosine at position 87.
[0048] This step of evaluating whether the mutation has led to a change of an amino acids may also be obviated by spotting only such kind of mutations on the array which also lead to a change of an amino acid (cf. wobble hypothesis). However, proceeding accordingly harbors the disadvantage that in such a case no signal will be obtained for this position, wherein the skilled person has to rely solely on the positive control to be ascertained that the experiment really worked. For this reason, a micro-array harboring all of the possible mutations of the respective triplets in the corresponding sets is preferred for use in the present method.
[0049] The present method, therefore, provides a reliable and rapid means for determining, whether or not a given biological sample contains an E.coli strain, having developed resistance against quinolones. Since the assay is easy to carry out an attending physician may quickly obtain the required information and may apply an appropriate regimen
EXAMPLE
Micro-array for detecting quinolone-resistant Escherichia coli
[0050] 1. Biological Material
[0051] A total of 29 quinolone-resistant E. coli clinical isolates from four different hospitals in Germany and one quinolone-sensitive clinical isolate were used in this study. These strains have been isolated from urine (n=20), swab (from the lower leg n=1, foot n=1, throat n=2, groin n=1, abscess n=1, unknown n=1) (n=7), secretion (tracheal secretion n=1, bronchial secretion n=1) (n=2) and blood (n=1) of patients. The susceptibility of the strains against quinolone was determined either by using Ciprofloxacin (n=23) alone or by using both Ciprofloxacin and Levofloxacin (n=7). Genomic DNA was isolated using QIAamp DNA Mini Kit (Qiagen) according to protocol provided by the manufacturer.
[0052] 2. DNA Sequencing and Amplification
[0053] The gyrA gene of some isolates was sequenced by amplifying the gene from the isolates using primers that yielded overlapping fragments. The sequencing of 5 isolates gave the preliminary result that apart from a variety of different mutations all of them had a common mutation at position 83 and 87 in the gyrA gene.
[0054] In order to verify the initial finding the region in the gyrA gene, a 417 bp long fragment from nucleotide position 119 to 535 around these positions was amplified by using the following primers:
[0055] forward primer Gyr_coli_F1 (5′-ccatacctacggcgataccg-3′), and
[0056] reverse primer Gyr_coli_R1 (5′-gcctgaagccggtacaccgt-3′).
[0057] The PCR mixtures (50 μl) included about 80 ng template of genomic DNA of E. coli ), 0.4 pM (pmol/L) of each primer, 0.25 mM dNTPs (desoxyribonucleoside-5′-triphosphate), 1.5 mM Mg 2+ (mmol/L) and 2.5 U Taq Polymerase (Eppendorf). The PCRs were performed in a thermocycler (Eppendorf) using following parameters: 94° C. 5 min; 94° C. 1 min, 52° C. 1 min, 72° C. 1 min for 30 cycles; final elongation 72° C. 10 min. The amplified fragment, which was purified using QIAquick PCR purification kit (Qiagen) according to the manual provided by the manufacture, was used for direct sequencing. The sequencing was done using the same primer pairs with big-dye terminator cycle sequencing kit (Applied Biosystem) and Prism™ 377A-DNA-sequencer (Applied Biosystems).
[0058] For all the investigated resistant strains it was noted that they exhibited a mutation at positions 83 and 87, which were at position 83 from serine (codon TCG) to leucine (codon TTG) (n=28) and at position 87 from aspartate (codon GAC) to asparagine (codon AAC)(n=27) or to tyrosine (codon TAC) (n=1) or to glycine (codon GGC) (n=1). It was also noted that these 30 isolates belong to two variants. The one variant (n=27) had at position 85 codon GTT (Val), at position 91 codon CGT (Arg) and at position 100 codon TAC (Tyr). The other variant (n=3) had at position 85 codon GTC (Val), at position 91 codon CGC (Arg) and at position 100 codon TAT (Tyr).
TABLE 2 Position Number of Position 83 Position 85 Position 87 Position 89 100* Isolate Phenotype TCG (Ser) GT T GAC (Asp) CG T TA C 1 sensitive TTG (Leu) GT C AAC (Asn) CG C TA T 3 resistant TTG (Leu) GT T AAC (Asn) CG T TA C 24 resistant TTG (Leu) GT T TAC (Tyr) CG T TA C 1 resistant TCG (Ser) GT T GGC (Gly) CG T TA C 1 resistant
[0059] 3. Array Fabrication
[0060] The possibility of using a micro-array to enable high through-put analysis was evaluated. Using Microgrid II (Biorobotics), 20 μM or 40 μM oligonucleotide capture probes (cf. table I), which have been dissolved in 50% (Vol./Vol.) in DMSO, were spotted on poly-L-lysine slides (Sigma) in two subarrays. Each slide was also spotted with spotting control (5′-Cy5-tctagacagccactcata-3′) (Cy5 labeled oligonucleotide), hybridization control (5′-gattggacgagtcaggagc-3′) oligonucleotide with unrelated sequence referring to gyrA, whose Cy5 labeled complement oligonucleotide would be included in hybridization solution) and process control (5′-taatgggtaaataccatcc-3′) oligonucleotide with consensus sequence of gyrA). After spotting, the slides were irradiated with UV light at 120 mJ/m 2 using UV crosslinker (Biometra) and blocked using an aqueous blocking solution (0.18 M succinic anhydride in methyl-pyrrolidinone /44 mM Na-borate pH 8.0) for 10 min, followed by rinse in distilled water and subsequently in 100% ethanol, and finally dried for about 10 min.
[0061] 4. Amplification and Labeling
[0062] An amplification of target DNA an concurrent labeling was performed using the following primers:
[0063] Forward primer GyrA_coli_F3 (5′-acgtactaggcaatgactgg-3′); and
[0064] reverse primer GyrA_coli_R3 (5′-agagtcgccgtcgatggaac-3′).
[0065] The 50 μl PCR mixture included about 80 ng template (genomic DNA of E. coli ), 0.4 pM (pmol/L) of each primer, 0.1 mM dATP, 0.1 mM dGTP, 0.1 mM dTTP, 0.06 mM dCTP, 0.04 mM Cy5-dCTP, 1.5 mM Mg 2+ and 2.5 U Taq polymerase (Eppendorf). The PCRs were performed in a thermocycle (Eppendorf) using the same parameters as described before. The amplified 189 bp fragment, which was purified using QIAquick PCR purification kit (Qiagen) according to the manual provided by the manufacture, was used for hybridization.
[0066] 5. Hybridization, Washing and Scanning
[0067] The purified amplicon in 40 μl hybridization solution (6×SSPE) plus 0.1 pmol Cy5 labeled DNA for the hybridization control were incubated on the slides prepared as above at 45° C. over night in a hybridization chamber (Corning) or alternatively three hours in a hybridization station. For manual hybridization 4 pmol target DNA was used, while for hybridization in a hybridization station 0.78 pmol target DNA was used. After hybridization, the slides were washed with 2×SSC, 0.1% (w/v) SDS for 15 min, with 0.2×SSC for 3 min at room temperature and dried with N 2 . For detection slides were scanned using Array Scanner GMS 418 (Affymetrix) at Cy5 channel. The images were analyzed using ImaGene (BioDiscovery) and saved as plain-text file as raw data.
[0068] The results obtained by means of the array correspond to the results achieved by means of sequencing. The present method, therefore, provides an efficient means to rapidly, i.e. within about there to 5 hours, determine the presence or absence of a quinolone sensitive or resistant strain.
[0069] 6. Hybridisation of labelled target DNA of clinical isolate on microarray
[0070] To further demonstrate the applicablity of the claimed invention, a micro-array was designed to evaluate position 83. An array was prepared with the capture probes depicted in Table 1 for position 83. The layout of the probes is depicted in FIG. 1 (A). Two variants were used: GTC at position 85 for variant 1, and GTT at position 85 for variant 2. The results are depicted in FIG. 1 . Panel (B) depicts a quinolone-senstive E.coli , while panels (C) and (D) show two different E. coli variants with quinolone resistance.
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The present invention pertains to a method for detecting quinolone-resistant Escherichia coli strains in a biological sample. The present invention also relates to a kit adapted to perform the inventive method.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the transmission of information between a downhole location and a surface location, and more specifically to an apparatus and method for the transmission of information between downhole and surface locations during the conduct of a subterranean drilling operation using air or gas as the energy source for a downhole drilling motor.
2. State of the Art
Drilling for oil and gas with downhole motors employing dry air, mist, or foams (all referred to hereinafter generically as "air") as a drilling fluid has been contemplated and practiced with some limited success for a number of years. Use of air as the drilling fluid, because of its low density, can result in faster penetration rates. Moreover, air drilling is less damaging to the producing formation than oil- or water-based drilling fluids. However, the reduced hydrostatic head of the air drilling fluid cannot effectively control formation pressures nor support borehole wall against collapse, and therefore air drilling is substantially limited to competent formations and requires religious use of blow-out preventors ("BOP's").
The foregoing limitations notwithstanding, air drilling has many applications, and improved motor technology has popularized its use in recent years, particularly in navigational drilling operations where a bottomhole assembly including a drilling motor may be steered to drill either a curved path or straight ahead. When drilling a nonlinear path, the bottomhole assembly is oriented in a particular direction, and drilling proceeds under power of the motor alone. For straight ahead drilling, the drillstring is rotated to negate the drill bit tilt angle or offset from the longitudinal axis of the bottomhole assembly. One suitable and recently developed bottom hole assembly for air drilling is the Navi-Drill Mach 1/AD, employed by Eastman Christensen Company of Houston, Tex., which assembly includes a positive displacement Moineau-type air motor and an adjustable bent sub between the motor and the drill bit, the bent sub providing the desired bit tilt angle for nonlinear drilling. An additional bent sub may be placed above the motor to enhance the assembly's kick off abilities, but such an arrangement precludes drillstring rotation and straight ahead drilling.
When drilling directionally or navigationally it is, of course, imperative to track the azimuth and inclination of the actual borehole against the intended well plan. Many survey, steering and measurement-while-drilling ("MWD") devices and techniques have been developed and employed over the years, but experience has confirmed many deficiencies and limitations of the prior art apparatus and methods when employed in an air drilling environment.
Conventional survey instrumentation, and particularly high accuracy gyroscopic instrumentation, is somewhat delicate for use in air drilling, as the drilling fluid does not provide dampening of deleterious vibration and resonance effects. Moreover, when conducting a navigational drilling operation, drilling torque may drastically change the toolface orientation and thus the borehole path over a short drilling interval, and survey techniques only confirm such changes after the fact.
Conventional MWD systems employ pressure pulses in the drilling fluid to transmit information from the downhole probe to the surface. As air is highly compressible, it cannot be pulsed effectively, and so conventional mud-pulse MWD technology is inoperative in air-drilled boreholes. Electromagnetic MWD ("EM MWD") systems, which employ the drillstring as the transmission media for electromagnetic waves, have been employed in air-drilled holes with mixed results. Rougher drilling conditions in air-drilled holes commonly cause tool failure, and EM MWD use can be severely hampered by formation resistivity. Finally, use of EM MWD requires a conductive drilling fluid, and therefore cannot be used for dry air drilling.
A steering tool offers significant advantages while navigationally drilling, as it provides continual surface readout of survey data while drilling, including the highly important toolface readout, solving the problem of reactive torque effects causing toolface orientation change. Steering tools also offer almost instantaneous information, unlike MWD tools, which do not continuously transmit data between the downhole location and the surface. Wireline-controlled steering systems have been employed in directional drilling, such systems including a side-entry sub and split kelly for the wireline to maintain contact with the probe. With a side-entry sub, the wireline is on the outside of the drillstring, and therefore subject to kinking, wear and breakage. If the probe signal is lost, the drillstring must be pulled out of the hole to the location of the side-entry sub, and the probe retrieved. Moreover, these systems preclude rotation of the drillstring due to the exterior location of the wireline. If a swivel assembly is used instead of a side-entry sub, the steering tool must be round-tripped out of the hole whenever a drill pipe joint connection is made, although in this case the drillstring may be rotated for straight ahead drilling. Finally, use of a wireline exterior to the drillstring precludes full closure of the BOP's unless the wireline is seuered.
Wet-connect systems have been developed wherein a steering tool probe having a wireline leading to a connection on the upper end thereof is run into the drillstring at the kickoff point, the upper end clamped off at the connection, and an upper wireline section with a mating connection on the lower end thereof is run into the drillstring to electrically connect the probe for directional drilling. While effective, such systems cause lost rig time due to the necessity for wireline retrieval prior to drillstring rotation.
Horizontal air-drilled wells provide additional problems as, at well inclinations exceeding 70 degrees from the vertical, a steering or survey tool will no longer fall down the drillstring, nor will air passing by the tool generate enough drag to carry it downhole. Currently, two methods are used to address this problem. In the first, the drillstring is pulled from the hole until the bit is at 70 degrees of inclination, a side-entry sub installed and a survey or steering tool run on electric line to a latching assembly above the drill bit, and the drillstring tripped back to bottom with the wireline above the side entry sub on the outside of the drillstring. A survey is then taken, the drillstring tripped back out to the side-entry sub, the survey tool and side-entry sub removed, and the drillstring run back to bottom to continue drilling. Obviously, a great deal of rig time is wasted with this method, and the driller learns of deviations from the well plan after the fact. The second method reduces time somewhat, by running a survey tool on a slickline with a releasing overshot when the drillstring has been pulled to the 70 degree inclination point. Upon reaching the monel drill collars, a monel sensor activates the releasing overshot, disconnecting the survey tool from the slick line, which is then removed from the hole. The drillstring is tripped back to the bottom to take the survey, subsequent to which the drillstring is pulled to 70 degrees, and the survey tool retrieved with a standard overshot run in on slickline. It will be appreciated that significant rig time is still involved with this method.
SUMMARY OF THE INVENTION
In contrast to the prior art apparatus and methods, the apparatus and method of the present invention allows a bottom hole assembly employing an air-powered drilling motor to be employed as a steerable drilling system combining directional and straight hole drilling capabilities to provide precise directional control.
The present invention provides a realtime survey system having the capability of withstanding the air harmonics and vibration attendant to air drilling operations. The major system components include a steering tool incorporated in a probe or latch down assembly which is releasably securable to a latching module located within the non-magnetic drill collars of a drillstring above the downhole motor, a first wireline extending upwardly to carry a signal from the steering tool to a clamp-off sub secured in the drillstring whereat the wireline is electrically connected to the free, lower end of a cable spooled on a cable cartridge secured in the drillstring, from which point a second wireline extends upwardly from the upper end of the cartridge cable to a pressure-tight rotating slip ring assembly at the surface. A surface cable transmits the signal from the slip ring assembly to a surface processing unit which provides data to a driller's remote display and a computer.
For highly deviated and horizontal boreholes, the steering tool may be a tri-axial steering tool of the type such as is commercially available from Eastman Christensen Company or Sharewell, Inc., both of Houston, Tex., to provide inclination, azimuth and toolface orientation. Such tools are shielded against pressure and temperature effects of downhole use to the degree required for the well being drilled.
The clamp-off sub provides mechanical support for the connection of the first wireline from the steering tool to the cable from the cartridge, and is secured between the pin and box of a drill pipe connection after the probe or latch down assembly is run and latched into the drillstring at the kick off point of the borehole, where the inclined portion thereof is commenced. The cartridge is initially secured at the pipe joint next above the clamp-off sub, and the second, upper wireline connected to the cartridge cable extends to the slip ring assembly above the kelly for transmission of data during drilling. After the kelly is made up and first pipe joint is drilled down, the wireline cartridge is pulled upwardly through the next joint after connection to the top of the drillstring, reconnected electrically to the slip ring assembly, the kelly made up and drilling recommenced. If a single cartridge does not provide sufficient cable, additional cartridges may be added sequentially as drilling progresses.
Since no wireline or other cable is exterior to the drillstring, rotation thereof for straight ahead drilling is possible, the use of the cartridge eliminates tripping of the drillstring when pipe joints are added, and operations of the BOP's is unaffected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 of the drawings is a schematic representation of the major components of the data transmission apparatus of the present invention;
FIG. 2 is an elevation of a suitable steering tool probe assembly for use with the present invention;
FIGS. 3A and 3B are schematic elevations showing the latching of the steering tool probe assembly into the non-magnetic drill collars above the downhole motor;
FIG. 4 is a schematic of a clamp-off sub for use with the present invention;
FIG. 5 is an elevation of the wireline cartridge assembly employed in the present invention;
FIG. 5A is an enlarged partial sectional elevation of the cartridge body of the wireline cartridge of FIG. 5;
FIGS. 6A, 6B and 6C are, respectively, schematic elevations showing a wireline cartridge locked in a connection between two pipe joints, a wireline cartridge with a landing assembly removably positioned within a pipe joint connection, and a wireline cartridge during upward withdrawal though a joint of drill pipe;
FIG. 7 is an exploded schematic view of the components of a float valve bypass assembly of the present invention; and
FIG. 8 is a schematic of a slip ring sub assembly for use in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 depicts the major elements of the data transmission apparatus 10 of the present invention. From the bottom of the drawing, steering tool probe 12 is assembled into a probe or latch down assembly 40 (see FIG. 2) by which it is mechanically and electrically connected to a lower single conductor electric wireline 14, which extends to a clamp-off sub 16 for mechanically and electrically connecting wireline 14 to cable 18 extending from the lower end of cable cartridge 20. The cable 18 of cable cartridge 20 is mechanically and electrically connected at the upper end of cartridge 20 to an upper single conductor electric wireline 22, the latter extending upwardly to a rotating slip ring assembly 24 located above the kelly 23, slip ring assembly 24 providing a pressure-proof rotatable electrical connection to surface output cable 26 extending to processing unit 28. With such an arrangement, information such as inclination, azimuth and toolface from steering tool probe 12 may be transmitted uphole to processing unit 28, the output of which is graphically depicted on driller's remote display 30 and/or on the monitor of computer 32, whereat the processed information from steering tool probe 12 may also be stored. Elements 12 through 22 of apparatus 10 of the present invention are disposed within a string of drill pipe (shown schematically at 34) during the drilling operation, the drillstring 34 also including below steering tool probe 12 a steerable bottomhole assembly (not shown) of the type previously described. It is also contemplated that the information transmission apparatus of the present invention may be employed to transmit commands from the surface to the steering tool, which in some future applications may be employed to actively change the path of the borehole.
FIG. 2 depicts the components of a probe or latch down assembly 40 which includes steering tool probe 12. At the top of probe or latch down assembly 40 is cable head 42, by which probe assembly 40 is lowered into the drillstring on wireline 14, which is secured to a rope socket in cable head 42. Cable head also 42 includes a fishing head 44 at the top thereof, for retrieval of probe or latch down assembly 40 via an overshot should wireline 14 part. Below cable head 42, probe 12 (in a ruggedized, pressure-proof housing) is secured to and bracketed by upper and lower centralizers 46 and 48, respectively, below which are secured one or more spacers bars 50 having centralizing fins 52 thereon, the number of spacer bars 50 being determined by calculation of the required magnetic isolation from the bottom hole assembly below probe 12. Shock absorber 54 is located below the lowermost spacer bar 50 to provide longitudinal and preferably radial shock isolation for probe 12 during landing of probe or latch down assembly 40 in the non-magnetic drill collars. Stinger 56 at the bottom of probe or latch down assembly 40 positively latches into a latch down module at the bottom of the string of non-magnetic drill collars at the lower end of drillstring 34 to secure probe or latch down assembly 40 thereinto, and also to properly rotationally orient probe 12 via exterior profile 58 with respect to the drill bit for proper toolface readings. The housing of steering tool probe 12, as noted previously, comprises a pressure barrel, and may include flexible rubber fins on the exterior thereof for centralization of the probe within the non-magnetic drill collars. The use of rubber fins permits the probe to pass through a 21/8" diameter drill collar bore followed by re-expansion of the fins to centralize the probe in a 2 13/16" non-magnetic drill collar bore below the constriction. However, it has been difficult to achieve a good compromise between fin flexibility for passage through the constriction and rigidity required for centralization. Therefore, it has also been proposed to utilize radially inwardly extending fins on the non-magnetic drill collar bore for support and centralization of the probe. Such an arrangement has been disclosed in U.S. patent application Ser. No. 750,615, filed Aug. 27, 1991, assigned to the assignee of the present invention, and incorporated for all purposes herein by this reference. Use of internal drill collar fins obviously eliminates the problem of probe passage through the constricted drill collar bores.
FIGS. 3A and 3B depict, respectively, the lowering of probe or latch down assembly 40 into latch down module 60 at the bottom of a string of non-magnetic drill collars 62 above steerable bottom hole assembly 70. The latch down module 60 includes a latch down sleeve 64 which engages stinger 56 to retain probe or latch down assembly 40 against upward motion, and which, via key 66, interacts with exterior profile 58 to rotate probe or latch down assembly 40 as previously mentioned. The stinger 56 and latch down module 60 may be of any design previously known in the art, but it has been discovered that the retention capability of the latter should be increased for use in air drilling, in order to prevent inadvertent upward release of probe or latch down assembly 40 due to pressure differentials when air pressure is bled off from the drillstring, such as when new pipe joints are being added.
Probe or latch down assembly 40 is lowered into drillstring 34 when a predetermined depth has been reached and the wellbore is to depart from the vertical. Wireline 14 is pulled taut after engagement of stinger 56 with latch down sleeve 64. Clamp-off sub 16 is then placed around wireline 14 in the bore back of the uppermost joint of drill pipe at the surface, clamped about wireline 14, and wireline 14 is then severed above clamp-off sub 16. Clamp-off sub 16 preferably comprises two mating sections, each having a vertical recess therein to define a passage for wireline 14, the passage being of smaller diameter than the wireline 14 so that the wireline 14 is clamped and held therebetween when the two sections of the clamp-off sub 16 are transversely bolted together.
FIG. 4 depicts clamp-off sub 16, whereat wireline 14 terminates and is electrically joined to cable 18 extending from a cable cartridge 20. As noted above, clamp-off sub 16 employs technology well known in the art for wireline cable heads to mechanically grip and support the upper end of wireline 14. The lower end of cable 18 is also mechanically locked in transition section 80 of sub 16, so that the electrical connection of the two, made within transition section 80, remains mechanically unstressed. As drilling progresses, collar 82 of clamp-off sub 16 rests between a pin 84 of one tool joint 86 and the box back 88 of the adjacent joint 86, so as to prevent movement of the clamp-off sub 16 within the drillstring. Collar 82 includes apertures therethrough so as to permit passage past clamp-off sub 16 of air to drive the drillstring motor of the bottom hole assembly. Those components of data transmission apparatus 10 from clamp-off sub 16 and below remain in position until the wellbore reaches its end point, unless a bit, motor or other lower drillstring component is changed.
FIG. 5 illustrates cable cartridge 20 including landing assembly 90 secured to the top of cartridge head 94, and fishing head 92 secured to the top of landing assembly 90. Cartridge head 94 has cable spool 96 secured to the bottom thereof, a portion of which is shown enlarged in partial section in FIG. 5A. Cable 18 is wrapped transversely about inner mandrel 98 of cable spool 96 in a single layer, and protected by heat shrink tubing 100 which is applied to mandrel 98 after cable 18 is wrapped thereabout. The upper end of cable 18 is secured to cartridge head 94, terminating at a connector such as a keystone seat, by which the cable 18 may be positively mechanically secured and electrically connected to an upper wireline 22 leading to slip-ring assembly 24 or to the lower end of another cable from another cable cartridge 20 in the drillstring. The design of cable cartridge 20 is based upon a cartridge design developed by Sharewell, Inc., of Houston, Tex. for use in pipelines, utility conduits, and river crossings, and the principle of operation remains the same. If cable is pulled from the bottom of mandrel 98, friction will stop the payout of cable after three to four feet, at most. However, if cable cartridge 20 is moved upwardly, cable will pay out for the upward distance the cartridge is moved. A patent application was filed on the Sharewell, Inc. cartridge design on Feb. 9, 1990 and assigned Ser. No. 477,720 and has now issued as U.S. Pat. No. 5,105,878. The original Sharewell cartridge had concentric inner and outer mandrels, with a plastic or elastomeric sleeve surrounding the cable inside the outer mandrel. Furthermore, the original Sharewell design employed spring-loaded dogs to lock the cartridge against downward or backward movement in the pipe or conduit, requiring the size of the dogs to be changed for each pipe or conduit I.D.
The cable cartridge design of the present invention employs a landing assembly 90 removably secured to the top of cartridge head 94, landing assembly 90 including three pivotally mounted, coil spring-loaded, downwardly and radially outwardly extending legs 102 to accommodate different drill pipe bore diameters. The spring loading of the portion of the legs 102 inside the landing assembly 90 can be adjusted upwardly for use of the landing assembly in a large bore drill pipe, or downwardly for use in a small bore drill pipe. Additionally, a landing seat plate or hold down ring 104, is employed with cartridge head 94 when landing assembly 90 is not in use. Finally, the cartridge design employed in the present invention is of much smaller diameter and greater length than the Sharewell design, to accommodate small diameter drill pipe while providing an acceptable length of cable, approximately 380 feet, or ten pipe joints.
With reference to FIGS. 6A, 6B and 6C, the use of cartridges 20 will be hereinafter discussed. After the lower end of a cable 18 is secured to clamp-off sub 16, the next pipe joint 86 to be connected to the top of drillstring 34 is picked up with the elevators, an overshot is dropped through the pipe joint, locked onto fishing head 92 and cable cartridge 20 including cartridge head 94 and landing assembly 90 is pulled upwardly into the next pipe joint 86 (See FIG. 6C). The pipe joint 86, with cable cartridge 20 in its bore, is connected to the pipe string and the string is lowered until the box of the uppermost pipe joint 86 is on the surface. The overshot is then retrieved, pulling the cable cartridge 20 through the pipe bore to the box connection 88 on surface. In that position, landing seat plate or hold down ring 104, preferably having a beveled or chamfered periphery, as shown, and having a U-shaped mouth or aperture therein extending between the center and one side thereof is inserted about neck 106 of cartridge head 94 and cable cartridge 20 is lowered into the bore back 88 of box 87 (see FIG. 6A). Landing assembly 90 with attached fishing head 92 is then removed from the top thereof. The kelly 23 is picked up, positioned above the drill pipe box 87 on surface and upper wireline 22 extending from slip ring sub 24 through the kelly 23 is connected to the upper end of cable 18 at the cartridge head 94. The kelly 23 is made up and drilling commences. Cartridge 20 is supported in the box back 88 of the pipe joint 86, and the pin of the kelly 23 prevents upward movement of cartridge 20. The foregoing procedure is employed every time a cable cartridge is added to the drillstring. Drilling may progress either with or without drillstring rotation, with the steering tool latched into the non-magnetic drill collars being employed for guidance in the latter instance.
The drillstring 86 is drilled down to the top of the kelly 23, the slips are set and the drillstring is pulled up so that the uppermost pipe joint box is on surface, the kelly 23 broken from the drillstring, upper wireline 22 disconnected from cartridge head 94, the landing assembly 90 resecured to cartridge head 94, and hold down ring 104 removed. Cable cartridge 20 is again lowered into the top pipe joint 86 until the landing assembly legs 102 seat into the bore back 88, landing assembly 90 maintaining cable cartridge 20 in position (see FIG. 6B). The next joint of drill pipe is picked up by the kelly 23 from the mouse hole, lowered onto the box connection containing the cable cartridge 20, and made up. The slips are removed, and the drillstring lowered until the highest drill pipe box (at the new top pipe joint) is on surface. The slips are again set, the kelly 23 broken from the drill pipe, and moved to one side. An overshot 108 is run into the top joint 86 to engage fishing head 92 on top of landing assembly 90, and cartridge 20 pulled (see FIG. 6C) above the top of the top pipe joint 86, where the hold down ring 104 is reinstalled and cable cartridge 20 lowered into the box bore back 88. The landing assembly 90 is removed, the kelly 23 brought across and positioned above the drill pipe box on surface, wireline 22 retrieved and reconnected to cable head 94. The kelly is made up and drilling again proceeds. This process continues joint by joint until the cable 18 is fully payed out from a cartridge, whereupon the lower end of a cable from another cable cartridge 20 is connected to the cable at the cartridge head 94 according to the procedure described above with respect to the first cable cartridge 20.
FIG. 7 depicts a float valve bypass assembly 200 including a float valve 202 of standard design, a float valve sub 204, and a float valve bypass sleeve 206 which accommodates the passage of cartridge cable 18 in channel 208 past float valve 202 installed therein while preventing pressure bypass thereof. Several float valves will be employed in the drillstring, commencing with a hammer float at the drill bit, a standard float valve above the motor, and several others in the string above the clamp-off sub. The float valve bypass assembly 200 of the present invention accommodates the use of the cable cartridges 20, and permits bleedoff of only the top portion of the drillstring between the uppermost float valve 202 and the surface, reducing the time required for connecting each new tool joint. Seals 210 are located at the top and bottom of the channel 208, and O-rings disposed in grooves 212 about the periphery of bypass sleeve 206 for sealing against the bore wall of float sub 204.
Slip ring sub assembly 24, depicted schematically in FIG. 8, fits above the kelly and includes a pack-off 300 in slip ring sub 302 which enables upper wireline 22 extending from the inside of the kelly below slip ring subassembly 24 to electrically contact the slip ring in a pressure-tight manner, the slip ring rotating with the slip ring sub 302, kelly and the drillstring (See FIG. 1). The outer stationary sub 304 of the assembly 24 contacts the rotating slip ring via collector brushes (not shown), information thus being transferred to processing unit 28 via surface cable 26. Slip ring subs and wireline pack-offs being known in the art, no further description thereof will given herein.
In certain drilling conditions, such as when continual jarring of the drillstring is required, cartridges cannot be used due to cable stretch and/or resonance, and so an alternative approach must be contemplated. Similarly, the operator may not tolerate the continual presence of cable in the drillstring above the clamp-off assembly. Therefore, it is also contemplated that the present invention may be used with a wet connect device, wherein the lower half of the wet connect is secured to the clamp-off assembly. When a survey is desired, the drillstring pulled to a point of suitable inclination, and the upper half of the wet connect run into the drillstring down to the mating wet connect at the clamp-off assembly, at which point the string is lowered to bottom, and a survey taken. After the survey, the upper portion of the wet connect is pulled. Of course, drilling may proceed with the engaged wet connect if desired or required by the operator.
A novel and unobvious apparatus and method has thus been disclosed in terms of a preferred embodiment. However, additions, deletions and modifications to the invention as disclosed will be readily appreciated by one skilled in the art, and such may be made without departing from the scope of the claimed invention.
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An apparatus and method for the transmission of information between downhole and surface locations through a drillstring. The apparatus includes a wireline extending from instrumentation at the downhole location to a clamp-off sub in the drillstring where it is connected to the lower end of a cable spooled on a cable cartridge above the clamp-off sub in the drillstring. The cable cartridge is moved upwardly through successive pipe joints added to the drillstring as drilling progresses, to permit rotation of the drillstring and use of blowout preventors without retrieving the wireline or cable. Cartridge cable is releasably connected at its upper end to a wireline extending through a pack-off to a slip ring assembly at the surface, for transmitting data from downhole instrumentation to surface equipment. Multiple cable cartridges may be sequentially added in series if drilling proceeds beyond the length of cable in a single cartridge.
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This application is a continuation of application Ser. No. 076,841, filed Sept. 19, 1979, now U.S. Pat. No. 4,380,667, issued Apr. 19, 1983.
FIELD OF INVENTION
Specifically substituted 2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilides; anxiolytic agents; pharmaceutical compositions thereof; method of treating therewith.
OBJECTS OF INVENTION
It is an object of the invention to provide novel 2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilides, including acid addition salts thereof, which are useful as medicaments and particularly useful as anxiolytic agents; pharmaceutical compositions thereof in association with a pharmaceutically acceptable carrier, diluent, or excipient, and a method of treating a patient suffering from anxiety or an anxious state by administering to the patient a compound of the invention in an amount effective for alleviation of such condition. Other objects will become apparent hereinafter and still others will be obvious to one skilled in the art.
SUMMARY OF THE INVENTION
The present invention relates to novel derivatives of 2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilides, their method of preparation, pharmaceutical compositions thereof, and their use as medicaments, e.g., as anxiolytic agents.
The new compounds of the present invention have the general formula I: ##STR2## in which
R represents hydrogen or alkyl, preferably methyl;
R 1 and R 2 may be identical or different and are selected from hydrogen, alkyl, hydroxyalkyl, alkenyl and alkynyl, optionally substituted one or more times by alkyl; and cycloalkyl having three to six ring carbon atoms and optionally substituted by alkyl, provided that, when one of R 1 and R 2 represents hydrogen, the other is not lower-alkyl or hydroxyalkyl; and provided further that R 1 and R 2 cannot simultaneously represent either lower-alkyl or hydrogen.
R 1 and R 2 may furthermore form, with the nitrogen atom to which they are connected, a nitro heterocycle possibly containing a second heteroatom selected from oxygen and nitrogen.
An illustrative explanation of certain meanings given with respect to the radicals R, R 1 and R 2 will now be indicated. First, they contain up to and including eight (8) carbon atoms in any event and, where lower-alkyl, lower-alkenyl, or lower-alkynyl, preferably five (5) carbon atoms or less. The alkyl groups may be straight or branched-chain alkyl such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec.butyl, tert.butyl, pentyl, isopentyl, neopentyl, tert.pentyl, hexyl, isohexyl, heptyl, and octyl. "Cycloalkyl" preferably has three to six ring carbon atoms, such as cyclopropyl, cyclobutyl, cyclopentyl, methyl or propyl cyclopentyl, and cyclohexyl. Alkenyl groups may representatively be allyl, butenyl, pentadienyl, or the like. Alkynyl groups may representatively be ethynyl, propargyl, or the like. Finally, the saturated or unsaturated heterocycles are selected, for instance, from among the pyrrolyl, imidazolyl, pyrazolyl, isoxazolyl, pyridyl, pyrazinyl, pyrimidinyl, pyridazinyl, pyrrolidinyl, imidazolidinyl, pyrazolidinyl, piperidyl, piperazinyl, and morpholinyl groups, and the like. Hydroxyalkyl are alkyl with one or more hydroxy groups therein, at least one of which is preferably an omega-hydroxy group, such as omega-hydroxyethyl, propyl, butyl, and amyl, 3-hydroxybutyl, 3,4-hydroxyamyl, and the like. The present invention especially concerns compounds of formula I in which the radical R represents lower-alkyl, and particularly methyl.
The present invention applies also to pharmaceutically-acceptable acid addition salts of a compound of formula I with the usual therapeutically-acceptable acids. By way of nonlimitative examples of therapeutically or physiologically-acceptable addition salts, mention may be made of the salts of inorganic acids such as hydrochloric, phosphoric and sulfuric acids, and the salts of organic acids such as maleic, succinic, fumaric, citric, and the like.
The present invention also concerns a process of preparing compounds of formula I characterized by condensing a compound of general formula II: ##STR3## in which:
R has the meaning given in connection with formula I and X represents a replaceable halogen atom, with an amine of formula III: ##STR4## in which R 1 and R 2 have the meanings given in connection with general formula I. The starting materials of general formula II can be prepared from aminobenzophenones obtained by the method of L. H. STERNBACH and R. Ian FRYER--J. Org. Chem. 27, 3781, 1962, or in accordance with the process of French Pat. No. 78 26918, in accordance with the following reaction sequence: ##STR5## wherein X represents a replaceable halogen atom, e.g., bromine or chlorine, and R has the meaning given previously. From the foregoing, it is apparent that to vary the alkyl group of R and R 1 in final product of formula I, it is only necessary to vary the alkyl group R of the starting material of formula II, or to vary the alkyl group R 1 of the starting material of formula III, or both, all according to the foregoing reaction sequence. Similarly, variation of the cyclic group or groups R 1 R 2 is effectively accomplished merely by variation of these groups in the starting material of formula III.
The present invention also concerns the use of the compounds of general formula I as medicaments which act on the central nervous system and, in particular, as anxiolytic agents, as well as sedative, anticonvulsive, and hypnotic agents, and as muscle relaxants, and pharmaceutical compositions thereof containing the active ingredient plus the usual pharmaceutically-acceptable carrier, diluent, or excipient.
DETAILED DESCRIPTION OF INVENTION
The present invention will be described in further detail hereinafter on a basis of the following examples, which are given by way of illustration only and are not to be construed as limiting.
EXAMPLE 1
N-methyl-N-(2-hydroxyethyl) 2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide
(a) Preparation of 2-bromoacetamido-2',5-dichlorobenzophenone
To an iced solution of 266 g (1 mol) of 2-amino-2',5-dichlorobenzophenone in 3 liters of ethyl ether there are added, drop by drop, 90 cc (1.1 mol) of bromoacetyl chloride dissolved in 500 cc of ethyl ether. The batch is allowed to come to room temperature, whereupon it is evaporated to dryness and the crystalline residue extracted with petroleum ether and filtered. In this manner, 371 g of crystals are recovered.
Yield: 96%
Melting point: 136°-137° C.
Plate chromatography:
support: Silica gel 60 F 254 Merck
solvent: ethyl acetate/petroleum ether 30/70
development: UV and iodine
Rf: 0.82
(b) Preparation of N-methyl-N-(2-hydroxyethyl)-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide
To a suspension of 139.3 g (0.36 mol) of 2-bromoacetamido-2',5-dichlorobenzophenone and 2 liters of acetone there are added 60 cc (0.76 mol) of 2-methylaminoethanol followed by heating for 15 hours under reflux. The reaction solvent is then evaporated to dryness and the crystalline residue absorbed with isopropyl ether and extracted with a 1N hydrochloric acid solution. The aqueous phase is treated with sodium bicarbonate and then extracted with ethyl acetate, decanted, washed with water until neutral, and dried over sodium sulfate. After filtration and evaporation of the solvent, 130 g (yield 95%) of a product of the following formula are recovered: ##STR6##
Empirical formula: C 18 H 18 Cl 2 N 2 O 3
Molecular weight: 381.26
White crystals
Melting point: 119°-120° C.
Plate chromatography:
support: Silica gel 60 F 254 Merck
solvent: ethyl acetate
development: UV and iodine
Rf: 0.73
EXAMPLE 2
N,N'-dimethyl-N-(2-hydroxyethyl)-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide
(a) Preparation of N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-bromoacetanilide
To a solution of 56 g of 2-methylamino-2',5-dichlorobenzophenone in 400 cc of ethyl acetate there are added an equal volume of ice and then 23 cc of bromoacetylbromide. After stirring overnight at room temperature, 300 cc of ethyl ether are added. The solvent layer is decanted, washed with 2N caustic soda, and then washed with water until neutral. It is then dried over sodium sulfate, filtered, and evaporated to dryness. The residue is treated with petroleum ether and then recrystallized from ethyl acetate. In this way there are obtained 65 g of crytals; yield: 81%.
Melting point: 86° C.
Plate chromatography:
support: Silica gel 60 F 254 Merck
solvent: ethyl acetate/petroleum ether 30/70
development: UV and iodine
Rf: 0.33
(b) Preparation of N,N'-dimethyl-N-(2-hydroxyethyl)-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide
To a solution of 60.15 g (0.15 mol) of N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-bromoacetanilide in 500 cc of acetone there are added 25 cc (0.31 mol) of 2-methylaminoethanol, followed by heating for 2 hours under reflux. The solution is evaporated to dryness. The residue is dissolved in 1N hydrochloric acid and washed with ether. The acid aqueous phase is treated with sodium bicarbonate, whereupon it is extracted with ether and washed with water until neutral. It is dried over sodium sulfate and filtered, and the organic phase evaporated. The residue obtained is recrystallized from hexane/ethyl acetate. There is thus recovered, in a yield of 80%, the product of the formula: ##STR7##
Empirical formula: C 19 H 20 Cl 2 N 2 O 3
Molecular weight: 395.27
Crystals: off white
Melting point: 79° C.
Plate chromatography:
support: silica gel 60 F 254 Merck
solvent: butanol/acetic acid/water 6/2/2
development: UV and iodine
Rf: 0.41
EXAMPLE 3
(Compound F 1933)
N,N-bis-(2-hydroxyethyl)-N'-methyl-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide hydrochloride
To a solution of 40.1 g (0.1 mol) of N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-bromoacetanilide in 300 cc of acetone there are added 20 cc (0.2 mol) of diethanolamine, followed by agitation for 24 hours at room temperature. The reaction solvent is evaporated to dryness, the residue treated with a bicarbonate solution and extracted with ethyl acetate. The organic phase is washed three times with water and dried over sodium sulfate. After filtration and evaporation there are recovered 43 g of an oil which is treated with a saturated ethanolic solution of hydrochloric acid; it is precipitated with ethyl ether and iced. After filtration and drying, 32 g of crystals are recovered. Yield: 70% of product of the formula: ##STR8##
Empirical formula: C 20 H 23 Cl 3 N 2 O 4
Molecular weight: 461.77
White crystals
Melting point: 187°-188° C.
Plate chromatography:
support: silica gel 60 F 254 Merck
solvent: butanol/acetic acid/water 6/2/2
development: UV and iodine
Rf: 0.35
EXAMPLE 4
N-(1,1-dimethylpropargyl)-N'-methyl-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide hydrochloride
To a solution of 7.37 g (0.09 mol) of 1,1-dimethylpropargyl amine in 30 cc of acetone there are added 4.01 g of N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-bromoacetanilide. After 5 hours at room temperature, the acetone is evaporated, the residue treated with a bicarbonate solution and extraction effected with ethyl acetate. After the customary treatments, as in the preceding Examples, the residual oil is treated with a saturated ethanolic solution of hydrochloric acid. There are recovered, in a yield of 75%, 3.29 g of crystals of the formula: ##STR9##
Empirical formula: C 21 H 21 Cl 3 N 2 O 2
Molecular weight: 439.77
White crystals
Melting point: 176° C.
Plate chromatography:
support: silica gel 60 F 254 Merck
solvent: butanol/acetic acid/water 6/2/2
development: UV and iodine
Rf: 0.62
EXAMPLE 5
(Compound F 1935)
N-cyclopropyl-N'-methyl-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide hydrochloride
To a solution of 3.15 g (0.0078 mol) of N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-bromoacetanilide in 25 cc of methylene chloride there are added 1.6 cc (0.0231 mol) of cyclopropylamine. Agitation is effected for four hours at room temperature; the solvent is evaporated and the residue is treated with a bicarbonate solution. Extraction is effected with ethyl acetate followed by decantation, washing with water and drying over sulfate. After filtration and evaporation, the residual oil obtained is treated with a saturated ethanolic solution of hydrochloric acid. In this way there is recovered, with a yield of 85%, a product of the formula: ##STR10##
Empirical formula: C 19 H 19 Cl 3 N 2 O 2
Molecular weight: 413.73
White crystals
Melting point: 201° C.
Plate chromatography:
support: silica gel 60 F 254 Merck
solvent: butanol/acetic acid/water 6/2/2
development: UV and iodine
Rf: 0.53
Solubility: 0.3% soluble in water.
EXAMPLE 6
N-cyclopentyl-N'-methyl-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide hydrochloride
In the manner described in Example 5, but using cyclopentylamine, there is obtained the product of the formula: ##STR11##
Empirical formula: C 21 H 23 Cl 3 N 2 O 2
Molecular weight: 441.79
White crystals
Melting point: 210° C.
Plate chromatography:
support: silica gel 60 F 254 Merck
solvent: methanol/chloroform 50/50
development: UV and iodine
Rf: 0.78
Solubility: 0.5% soluble in water.
EXAMPLE 7
N-cyclohexyl-2'-(ortho-chlorobenzoyl)-4'-glycylanilide hydrochloride
In the manner described in Example 1, but using cyclohexylamine, there is obtained the product of the formula: ##STR12##
Empirical formula: C 21 H 22 Cl 2 N 2 O 2
Molecular weight: 405.33
White crystals
Melting point: 115° C.
Plate chromatography:
support: silica gel 60 F 254 Merck
solvent: ethyl acetate/petroleum ether 30/70
development: UV and iodine
Rf: 0.44
Solubility: 10% soluble in DMSO, methyl pyrrolidone, ethyl acetate, DMA and chloroform.
EXAMPLE 8
N-cyclohexyl-N'-methyl-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide acid maleate
In the manner described in Example 5, but using cyclohexylamine as amine and maleic acid as salifying agent, there is obtained a product of the formula: ##STR13##
Empirical formula: C 26 H 28 Cl 2 N 2 O 6
Molecular weight: 535.43
White crystals
Melting point: 150° C.
Plate chromatography:
support: silica gel 60 F 254 Merck
solvent: butanol/acetic acid/water 6/2/2
development: UV and iodine
Rf: 0.63
Solubility: 1% soluble in propylene glycol. Insoluble in water. 10% soluble in DMA.
EXAMPLE 9
(Compound F 1939)
N-cyclohexyl-N,N'-dimethyl-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide acid maleate
In the manner described in Example 5, but using N-methylcyclohexylamine as amine and maleic acid as salifying agent, there is obtained the product of the formula: ##STR14##
Empirical formula: C 27 H 30 Cl 2 N 2 O 6
Molecular weight: 549.45
White crystals
Melting point: 192° C.
Plate chromatography:
support: silica gel 60 F 254 Merck
solvent: butanol/acetic acid/water 6/2/2
development: UV and iodine
Rf: 0.41
Solubility: Insoluble in water. 5% soluble in DMSO.
EXAMPLE 10
(Compound F 1940)
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-morpholinoacetanilide acid maleate
In the manner described in Example 5, but using morpholine as amine and maleic acid as salifying agent, there is obtained the product of the formula: ##STR15##
Empirical formula: C 24 H 24 Cl 2 N 2 O 7
Molecular weight: 523.37
White crystals
Melting point: 125° C.
Plate chromatography:
support: silica gel 60 F 254 Merck
solvent: butanol/acetic acid/water 6/2/2
development: UV and iodine
Rf: 0.50
Solubility: 1% soluble in water.
EXAMPLE 11
N-methyl-N'-(2-methylallyl)-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide
In the manner described in Example 5, but using methyl allylamine, there is obtained a product of the formula: ##STR16##
Empirical formula: C 20 H 20 Cl 2 N 2 O 2
Molecular weight: 391.3
White crystals
Plate chromatography:
support: silica gel 60 F 254 Merck
solvent: butanol/acetic acid/water 6/2/2
development: UV and iodine
Rf: 0.67
EXAMPLE 12
N-cyclohexyl-N,N'-diethyl-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide acid maleate and other N,N'-dialkyl variations
In the manner described in Example 5, but using N-ethylcyclohexylamine as amine, maleic acid as salifying agent, and N-ethyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-bromoacetanilide as starting material of Formula II, there is obtained the above-identified product.
Similarly, in the manner described in Example 5, but using N-propylcyclohexylamine as amine, and maleic acid as salifying agent, there is obtained the product N-cyclohexyl-N-propyl-N'-methyl-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide acid maleate.
In substantially the same manner as described in Example 5, but using N-methylcyclohexylamine as amine, maleic acid as salifying agent, and N-amyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-bromoacetanilide for the starting material of Formula II, there is obtained the product N-cyclohexyl-N-methyl-N'-amyl-2'-(ortho-chlorobenzoyl)-4'-chloro-glycylanilide acid maleate.
Similarly, in the manner described in Example 5, but using N-ethylcyclopropylamine, there is obtained the compound N-cyclopropyl-N-ethyl-N'-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-glycylanilidehydrochloride.
In the same manner as described in Example 5, but using morpholine as amine, maleic acid as salifying agent, and N-butyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-bromoacetanilide as starting material of Formula II, there is obtained the product N-butyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-morpholinoacetanilide acid maleate.
In the same manner, by varying the substituents R and R 1 in the starting material of Formula II and in the amine reactant of Formula III, numerous additional variations in the R and R 1 alkyl groups are conveniently obtained.
EXAMPLE 13
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-(4"-methylpiperazino)acetanilide acid maleate
In the manner described in Example 5, but using N-methylpiperazine as amine and maleic acid as salifying agent, the above-identified product is produced.
EXAMPLE 14
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-pyrrolidinoacetanilide acid maleate and additional cyclic variations of R 1 and R 2
In the manner described in Example 5, but using pyrrolidine as amine and maleic acid as salifying agent, the above-identified product is produced.
In the same manner as given in Example 5, but using piperidine as amine and maleic acid as salifying agent, there is obtained the product N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-piperidino-acetanilide acid maleate.
In the same manner as given in Example 5, but using pyrrolidine as amine, maleic acid as salifying agent, and N-propyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-bromoacetanilide as starting material of Formula II, there is obtained the product N-propyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-pyrrolidinoacetanilide acid maleate.
In the same manner as given in Example 5, but using imidazolidine instead of cyclopropylamine, there is obtained the product N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-imidazolidino-acetanilidehydrochloride.
In exactly the same manner, but substituting pyrazolidine for imidazolidine, there is obtained the product N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-pyrazolidinoacetanilidehydrochloride.
In exactly the same manner, but substituting pyrrole, imidazole, pyrazole, isoxazole, pyridine, pyrazine, pyrimidine, or pyridazine for the cyclopropylamine of Example 5, the following products are obtained:
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-pyrrolinoacetanilide hydrochloride,
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-imidazolinoacetanilide hydrochloride,
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-pyrazolinoacetanilide hydrochloride,
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-isoxazolinoacetanilide hydrochloride,
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-pyridinoacetanilide hydrochloride,
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-pyrazinoacetanilide hydrochloride,
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-pyrimidinoacetanilide hydrochloride, and
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-pyridazinoacetanilide hydrochloride.
Similarly, by substituting additional heterocyclic amines for the morpholine of Example 10 or the cyclopropylamine of Example 5, additional compounds within the scope of the invention are obtained, having additional cyclic variations of the R 1 and R 2 substituents.
EXAMPLE 15
N-methylcyclopentyl-N'-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-glycylanilide hydrochloride
In the manner of Example 6, but substituting methylcyclopentylamine for cyclopentylamine, there is obtained the above-identified product.
EXAMPLE 16
N-ethylcyclopentyl-N'-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-glycylanilide hydrochloride
In the manner of Example 6, but substituting ethylcyclopentylamine for the cyclopentylamine of Example 6, there is obtained the above-identified product.
EXAMPLE 17
N-ethylcyclohexyl-N'-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-glycylanilide hydrochloride
In the same manner as given in Example 6, but using ethylcyclohexylamine instead of the cyclopentylamine there employed, there is obtained the above-identified product.
EXAMPLE 18
N-cyclohexyl-N,N'-diamyl-2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilide acid maleate
In the same manner as given in Example 5, but using N-amylcyclohexylamine as amine, maleic acid as salifying agent, and N-amyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-bromoacetanilide as starting material of Formula II, there is obtained the above-identified product.
EXAMPLE 19
N-methyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-ethylmorpholinoacetanilide acid maleate
In the manner of Example 5, but using ethylmorpholine as amine and maleic acid as salifying agent, there is obtained the above-identified product.
EXAMPLE 20
N-propyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-methylmorpholinoacetanilide acid maleate
In the manner of Example 5, but using methylmorpholine as amine, maleic acid as salifying agent, and N-propyl-2'-(ortho-chlorobenzoyl)-4'-chloro-2-bromoacetanilide as starting material of Formula II, there is obtained the above-identified product.
PHARMACOLOGY AND TOXICOLOGY
The compounds of the present invention, which exert remarkable activity on the central nervous system, can therefore be administered to man or to animal orally or by injection in the form of a free base or else in the form of a therapeutically acceptable salt. The new derivatives obtained in the foregoing manner, which are bases, can be converted into addition salts with acids, which form part of the invention. The addition salts can be obtained by the reaction of the new derivatives with acids in suitable solvents such, for example, as shown by the examples. As acids used for the formation of these addition salts there may be mentioned, in the mineral series: hydrochloric, hydrobromic, methanesulphonic, sulphuric and phosphoric acid; in the organic series: acetic, propionic, maleic, fumaric, tartaric, citric, oxalic, benzoic acid, to name a few. The invention accordingly also relates to the salts with organic or inorganic acids, especially lipophilic acids, e.g., fatty acids having 14 to 22 carbon atoms, inclusive, which are linear or branched, saturated or unsaturated, including palmitic, linoleic, linolenic, and oleic acids, and the like, as well as of the naphthoic type, especially pamoic acid, in addition to the usual organic and inorganic acids of the type already mentioned. The selection of the free base or acid addition salt thereof and preparation of the desired acid addition salt of a compound in any particular case will be apparent and fully within the ability of one skilled in the art. The novel compounds are frequently used in the form of their pharmaceutically acceptable acid addition salts, e.g., their hydrochlorides, hydrobromides, or the like. The salt is usually the best form for pharmaceutical formulations. Innumerable other pharmaceutically-acceptable acid addition salts can be prepared from the hydrochlorides via the free bases in conventional manner.
By way of simple illustration, there will be set forth below a few results of the various toxicological and pharmacological tests carried out on the compounds of the invention.
(a) Toxicity study
The compounds of the present invention were subjected to toxicity verifications. The toxicity of certain compounds, determined by the fifty percent lethal dose, is set forth in the following table. It was determined on lots of ten mice by oral administration and calculated by the method of MILLER and TAINTER (Proc. Soc. Exper. Biol. Med., 1944, 57, 261).
(b) Activity in the Rota Rod test
This test is carried out on male mice of Swiss strain.
The mice are placed on a wooden rod of a diameter of three cm, rotating at the rate of five rpm. The mice which can remain on the rod for at least three minutes during successive tests are selected and collected in groups of ten for the test of each dose.
If the mouse falls from the rod in less than two minutes, the compound tested is considered effective.
The results are expressed in ED 50 in accordance with N. W. DUNHAM and T. S. MIVA (J. Amer. Pharm. Asso., 1957, 46, 208).
(c) Antagonistic activity to pentetrazol
This test is carried out on a group of ten male mice of Swiss strain. Within fifteen minutes after subcutaneous injection of 125 mg/kg of pentetrazol, the mice have tonic convulsions resulting in death. For the test, the compounds are administered orally sixty minutes before the injection of pentetrazol. The animals are observed for two hours after administration of the pentetrazol.
The results are expressed by the ED 50 dose in accordance with GOODMANN et al. (J. Pharmacol. 108, 1953).
TABLE OF RESULTS__________________________________________________________________________ ##STR17## TOXICITY per os ROTA ROD per os PENTETRAZOL per osY DE.sub.50 mg/kg DE.sub.50 mg/kg DE.sub.50 mg/kg__________________________________________________________________________ ##STR18## 750 17 0.9 ##STR19## ≃1000 15 0.5 ##STR20## 420 19 1 ##STR21## >1000 7 0.3 ##STR22## 750 16 1.9 ##STR23## >1000 20 0.7 ##STR24## >1000 21 0.8 ##STR25## >1000 20 0.8 ##STR26## >1000 10 0.4__________________________________________________________________________
On a basis of their pharmacological properties and their low toxicity, these chemical compounds can be used in therapy for the treatment of anxiety and neuroses.
These compounds and their therapeutically acceptable acid addition salts can be used as medicaments, for instance, in the form of pharmaceutical preparations adapted for oral or parenteral administration in admixture with, for instance, water, lactose, gelatin, starches, magnesium stearate, talc, vegetable oils, gums, polyalkylene glycols, vaseline, etc. These preparations may be in solid form, for instance, in the form of tablets, pills, capsules, etc., or in liquid form, for example, solutions, suspensions or emulsions.
Pharmaceutical preparations in a form suitable for injection are preferred. These preparations may be subjected to conventional pharmaceutical operations such as sterilization and/or may contain adjuvants, for example, preservatives, stabilizers, wetting or emulsifying agents, buffering compounds, etc.
The doses in which the active compounds and their therapeutically compatible acid addition salts can be administered can vary within wide ranges depending on the size, weight, and condition of the patient. A daily dose of about 0.01 mg to 1 mg/kg of body weight is, however, preferred.
The pharmaceutical compositions of the invention can be used in internal medicine, as anxiolytic agents, i.e., for the treatment of anxiety states of whatever origin, for instance in the treatment of organic pathological conditions such as arterial hypertension and coronaritis, accompanied and aggravated by a state of anxiety or in psychosomatic medicine, for instance for the treatment of asthma, gastro-duodenal ulcers, colonopathy and other functional digestive ailments, accompanied by or resulting from anxiety, as well as in psychiatry, for instance for treatment of anxiety conditions of agitation in psychotic subjects.
For these various purposes, the compounds of the invention are, of course, administered in doses which vary with their nature, with the method of administration, and with the treatment desired.
Pharmaceutical preparations containing these active principles may be administered orally, parenterally, rectally and locally, in each case for their intended purpose.
For oral administration tablets, capsules and elixirs may be used, the unit dose being 5 to 500 mg, in accordance with a usual maximum daily dose in man of 500 mg. For rectal administration these quantities are usually 100 to 500 mg respectively.
The pharmaceutical compositions may also contain other pharmaceutically and therapeutically compatible active principles.
A few examples of pharmaceutical preparations which contain a representative active principle forming an object of the invention are given below, by way of illustration only and not by way of limitation:
(a) tablets F 1933, 1935, 1939 or 1940 150 mg+excipient
(b) suppository, adult, strong: F 1933, 1935, 1939 or 1940 200 mg+suppository excipient
(c) capsules: F 1933, 1935, 1939 or 1940 75 mg plus excipient 100 mg; or F 1933, 1935, 1939 or 1940 alone.
For oral use, the compounds are usually administered as tablets, solutions, suspensions, or the like, in which they are present together with usual pharmaceutical carriers, excipients, binders, and the like. For example, tablets may be prepared conventionally by compounding one of the new compounds with customary carriers and adjuvants, e.g., talc, magnesium stearate, starch, lactose, gelatin, gums and the like. In their most advantageous form, then, the compositions of the present invention will contain a non-toxic pharmaceutical carrier in addition to the active ingredient. Exemplary carriers are: Solids: lactose, magnesium stearate, calcium stearate, starch, terra alba, dicalcium phosphate, sucrose, talc, stearic acid, gelatin, agar, pectin, acacia, or other usual excipient; Liquids: peanut oil, sesame oil, olive oil, water, elixir, or other usual excipient. The active agents of the invention can usually be most conveniently administered in such compositions containing about 0.01 to 67 percent, preferably 0.04 to 12.15 percent, by weight of the active ingredient. Such formulations are representatively illustrated in U.S. Pat. No. 3,402,244.
A wide variety of pharmaceutical forms suitable for many modes of administration and dosages may be employed. For oral administration, the active ingredient and pharmaceutical carrier may, for example, take the form of a granule, pill, tablet, lozenge, elixir, syrup, or other liquid suspension or emulsion; and for rectal administration, a suppository. For topical or dermatological use and administration, an ointment, salve, solution, or suspension of usual type may be employed.
The method of using the compounds of the present invention comprises administering a compound of the invention, preferably admixed with a pharmaceutical carrier, for example, in the form of any of the above-mentioned compositions, or filled into a capsule, to alleviate one or more of the foregoing enumerated abnormal conditions and symptoms, especially anxiety, in a living animal body, whether human or domestic animal, for example, the afore-mentioned anxiety types. The compounds are subject to usual variations in optimum daily and unit dosages, due to patient body weight, condition, and ancillary factors, and the invention therefore should not be limited by the exact ranges stated. The exact dosage, both unit and daily, will of course as usual have to be determined according to established veterinary and medical principles.
It is to be understood that the invention is not to be limited to the exact details of operation or exact compounds, compositions, or procedures shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art, and the invention is therefore to be limited only by the scope of the appended claims.
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The present invention relates to 2'-(ortho-chlorobenzoyl)-4'-chloroglycylanilides, compositions thereof, and their use as medicaments, e.g., as anxiolytic agents.
The compounds of the invention have the general formula I ##STR1## in which R represents hydrogen or alkyl,
R 1 and R 2 may be identical or different and are selected from hydrogen, alkyl, hydroxyalkyl, alkenyl, and alkynyl, possibly substituted by alkyl, and cycloalkyl having three to six members, possibly substituted by alkyl, with the proviso that, when one of R 1 and R 2 represents hydrogen, the other is not lower alkyl or hydroxyalkyl; and with the further proviso that R 1 and R 2 may not simultaneously represent either hydrogen or lower-alkyl. R 1 and R 2 may furthermore form, with the nitrogen atom to which they are connected, a nitrogen heterocycle possibly containing a second heteroatom selected from oxygen and nitrogen.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a system of a connection between servers and devices, to a multi-path computer system by which devices are accessed via multi-path access paths, and, in particular, to a multi-path computer system in which reliability in multi-path device control is secured.
[0003] 2. Description of the Related Art
[0004] Recently, in a case where servers and devices are connected, multi-path device control in which not only a single server and a single device are connected simply, but also a plurality of servers and a plurality of devices are connected, has been regarded as importance, in order that a reliability is secured.
[0005] In the above-mentioned multi-path device control, a user sets a multi-path configuration in order to access devices, and, a multi-path control mechanism apportions access paths based on the above-mentioned multi-path configuration setting.
[0006] There are problems as will now be described when the above-mentioned multi-path environment is built:
[0007] (1) Data destruction may occur due to erroneous setting of multi-path configuration.
[0008] Because a user makes setting of a multi-path configuration, the setting may be made erroneously. When erroneous setting is made, different areas may be accessed via two paths, and, thereby, data may be destructed. Further, there may be a case where, for example, after access paths are set, an access path is erroneously re-connected while a maintenance work is performed. Also in such a case, data may be destructed.
[0009] In particular, recently, Fibre Channel has spread widely, and thereby, it becomes difficult to find out which devices are connected by access paths. Accordingly, multi-path setting may be easily made erroneously.
[0010] (2) A method of maintenance performed when a same path is used in common for a plurality of devices has not been clearly established.
[0011] For example, when a channel adapter of a device is exchanged, and an access path was set for another device using a channel adapter in a same exchange unit as that of the above-mentioned channel adapter to be exchanged, it is necessary to inform to the other device that the channel adapter of this other device will also be exchanged. Otherwise, the other device may not able to render a proper connection. In the related art, a method of dealing with such a situation has not been established clearly. Accordingly, it was not possible to perform a maintenance work efficiently.
[0012] (3) A long time is required for switching paths, and, thereby, a useless time of dealing with error/fault is required.
[0013] For example, when a channel adapter of a device has a fault, a path-fail-over function of a multi-path control mechanism functions, and, thereby, an access path using the channel adapter is prevented from being used. Thereby, when a plurality of access paths were set using this channel adapter, an error dealing-with operation starts each time an access is made via each access path thereof, and path switching is performed. Thus, a useless error dealing-with time is required. Especially, in a case of Fibre Channel, a long time is required for detecting error (for example, tens of seconds). Accordingly, for a system employing Fibre Channel, an efficient channel switching method has been demanded to be developed.
SUMMARY OF THE INVENTION
[0014] The present invention has been devised in consideration of the above-discussed situations, and, an object of the present invention is to solve a problem due to erroneous setting of multi-path configuration by a user, to shorten a time required for a recovery from a path-fail-over state, and, also, to shorten a time required for a maintenance work of a device, in a multi-path computer system.
[0015] [0015]FIG. 1 shows a general configuration of the present invention.
[0016] As shown in FIG. 1, host apparatuses 1 are connected with a plurality of input/output devices 3 via an interface 2 . As the interface 2 between the host apparatuses and plurality of input/output devices, the above-mentioned Fibre Channel network system may be used, for example. However, it is also possible to use a SCSI, a hub, or the like for the same purpose. In each host apparatus 1 , a plurality of host adapters 1 c are provided, and, a plurality of access paths are set for connection between the host adapters 1 c and channel adapters 3 a of the input/output devices 3 .
[0017] An I/O request from a host application 1 a of the host apparatus 1 is sent to a multi-path control part 1 b , which then apportions the I/O to a plurality of access paths. The thus-apportioned I/O is sent to the input/output device 3 via the host adapter 1 c , access path and channel adapter 3 a , and, then, is processed by the input/output device 3 . Then, response is sent to the host application 1 a via the same path.
[0018] In this system, the present invention solves the above-mentioned problems as follows:
[0019] (1) Each input/output device 3 includes a plurality of areas which the host apparatuses 1 can access; area information corresponding to each of the plurality of areas; device information for identifying this input/output device; and channel adapters 3 a , each of which renders permission or inhibition of access from the host apparatuses 1 for each one of the plurality of areas, according to the area information.
[0020] Further, each of the host apparatuses 1 includes the plurality of host adapters 1 c which are connected to the plurality of paths and perform access to the input/output devices 3 ; access path information indicating areas of the input/output devices which can be accessed by the respective ones of the plurality of host adapters; and the multi-path control part 1 b which selects a specific host adapter 1 c according to the access path information when access is made from a software operating in the host apparatus 1 , to a specific area of the input/output device 3 .
[0021] Further, each channel adapter 3 a of the input/output devices 3 includes an identification information responding part which responds to the host apparatuses 1 by identification information {circle over (1)} including the device information and area information, and each host apparatus 1 determines from the access path information and identification information {circle over (1)}, whether or not the plurality of paths are proper (or properly set).
[0022] Thus, erroneous setting of access paths is prevented from being accepted, by using the identification information {circle over (1)} specifying the area as mentioned above. Accordingly, it is possible to prevent different areas from being accessed via two paths erroneously. Thus, it is possible to prevent data from being destructed due to erroneous setting of access-path configuration.
[0023] Further, by obtaining the above-mentioned information from the channel adapters 3 a of the input/output devices 3 at a time of turning on of power, and periodically, it is possible to deal with an erroneous connection made also at a time of maintenance work.
[0024] (2) Each input/output device 3 includes device information for identifying this input/output device 3 , information of a number of each of the channel adapters 3 a in the input/output device 3 (adapter number information), and the channel-adapters 3 a , each of which renders permission/inhibition of access from the host apparatuses 1 connected with the plurality of paths.
[0025] Further, each of the host apparatuses 1 includes the plurality of host adapters 1 c connected with the plurality of paths and perform access to the input/output devices 3 therethrough; access path information indicating areas of the input/output devices 3 which can be accessed by the respective ones of the plurality of host adapters; and the multi-path control part 1 b which selects a specific host adapter 1 c , according to the access path information when access is to be made from a software operating in the host apparatus 1 .
[0026] Further, each of the channel adapters 3 a of the input/output devices 3 includes an identification information responding part which responds to the host apparatuses 1 by identification information {circle over (2)} including the above-mentioned device information and adapter number information, and, when detecting an error path, the host apparatus 1 sends the thus-responded identification information concerning the error path to the other multi-path control parts of the own apparatus and/or the multi-path control parts of the other apparatuses.
[0027] Thus, the identification information {circle over (2)} concerning the detected error path is sent to the other multi-path control parts of the own apparatus and/or the multi-path control parts of the other apparatuses. Thereby, the other multi-path control parts of the own apparatus and/or the multi-path control parts of the other apparatuses can terminate operation concerning the relevant access path and perform path-fail-over operation previously. Accordingly, it is possible to prevent a useless error dealing-with time from being required.
[0028] (3) Each of the input/output devices 3 includes device information for identifying this input/output device 3 ; information of component exchange units in this device (component exchange-unit information); and the channel adapters 3 a , each of which renders permission/inhibition of access from the host apparatuses 1 connected with the above-mentioned plurality of paths.
[0029] Further, each of the host apparatuses 1 includes the plurality of host adapters 1 c connected with the above-mentioned plurality of paths and performing access to the input/output devices 3 therethrough; access path information indicating areas of the input/output devices 3 which can be accessed by the respective ones of the plurality of host adapters; and the multi-path control part 1 b which selects a specific host adapter 1 c , according to the access path information when access is to be made from a software operating in the host apparatus 1 .
[0030] Further, each of the channel adapters 3 a of the input/output devices 3 includes an identification information responding part which responds to the host apparatuses 1 by identification information {circle over (3)} including the above-mentioned device information and the component exchange-unit information. Then, when a request for exchanging a channel adapter is given, the host apparatus 1 terminates operation of any path using this channel adapter, and, simultaneously, sends the identification information {circle over (3)} concerning this channel adapter to the other multi-path control parts of the own apparatus and/or the multi-path control parts of the other apparatuses, and, thereby, causes operation concerning the paths using the channel adapters having the same component exchange-unit information to be terminated.
[0031] Thus, when a request for exchanging a channel adapter is given, the path using this channel adapter is made to be terminated, and, simultaneously, as the identification information {circle over (3)} concerning this channel adapter is sent to the other multi-path control parts of the own apparatus and/or the multi-path control parts of the other apparatuses, operation is made to be terminated for the paths using the channel adapters having the same exchange-unit information. Accordingly, it is possible to perform exchange of channel adapters or the like of the input/output devices 3 without adversely affecting the other applications of the own apparatus and/or I/O requests of the other apparatuses.
[0032] Further, when re-start is performed after the exchange of components is finished, the same identification information {circle over (3)} is sent to the other multi-path control parts of the own apparatus and/or the multi-path control parts of the other apparatuses so as to inform them of recovery of the path. Thereby, it is possible to shorten a time required for the recovery after the exchange of components.
[0033] In a case where Fibre Channel is used as the interface, it is possible to utilize WWN (World Wide Name) of the Fibre Channel which each channel adapter has, as the above-mentioned identification information specifying/identifying the device. Further, it is also possible to utilize a node name of WWN, as the above-mentioned exchange component-unit information.
[0034] Other objects and further features of the present invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] [0035]FIG. 1 illustrates an outline of the present invention;
[0036] [0036]FIG. 2 is a block diagram showing a configuration of a multi-path device control system in each of first, second and third embodiment of the present invention;
[0037] [0037]FIG. 3 is a flow chart showing an outline of a process performed in the first embodiment of the present invention;
[0038] [0038]FIG. 4 illustrates the above-mentioned second embodiment of the present invention;
[0039] [0039]FIG. 5 is a flow chart showing a process in the above-mentioned second embodiment of the present invention;
[0040] [0040]FIG. 6A illustrates the above-mentioned third embodiment of the present invention;
[0041] [0041]FIG. 6B illustrates another aspect of the third embodiment of the present invention;
[0042] [0042]FIG. 7 is a flow chart showing an outline of a process in the above-mentioned third embodiment of the present invention;
[0043] [0043]FIG. 8 illustrates a relationship between a component exchange-unit and a node name of WWN which may be used in the above-mentioned third embodiment of the present invention; and
[0044] [0044]FIG. 9 is a block diagram showing a configuration of a computer which may be used as the host apparatus in each of the above-mentioned first, second and third embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] [0045]FIG. 2 is a block diagram showing a configuration of a multi-path device control system in each of first, second and third embodiments of the present invention. In FIG. 2, a host server # 100 corresponding to the above-mentioned host apparatus 1 includes a plurality of host adapters # 120 , # 121 , # 122 , from which a plurality of access paths to a plurality of channel adapters # 310 , # 311 , # 312 , # 410 of a plurality of devices # 300 and # 400 are set. In this system, it is assumed that the access paths # 200 , # 201 , # 202 , # 203 and # 204 are set.
[0046] An interface between the host server # 100 and devices # 300 and # 400 is not particularly prescribed, and, for example, may be of a hub or a SCSI. However, in this system, a Fiber Channel network, which has started spreading widely, is assumed to be used for this purpose. Thereby, a flexible setting of access paths can be rendered.
[0047] Respective areas A, B and C of the devices # 300 and # 400 can be accessed from the channel adapters. In this system, the area A can be accessed from the channel adapters # 310 and # 311 , the area B can be accessed from the channel adapter # 312 and the area C can be accessed from the channel adapter # 410 .
[0048] Flow of I/O requests in the system shown in FIG. 2 will now be described.
[0049] In the host server # 100 , a host application # 101 operates. An I/O request to the area A is sent to a multi-path device control mechanism # 102 from the host application # 101 . The multi-path device control mechanism # 102 apportions the I/O request to either one of the access paths # 200 and # 201 in order to access the area A.
[0050] The thus-apportioned I/O request is sent to the area A via a path of either one of host adapter # 120 —access path # 200 —channel adapter # 310 or host adapter # 121 —channel path # 201 —channel adapter # 311 , then, is processed, and, then, a response thereto is sent back to the host application # 101 via the same path.
[0051] How each embodiment of the present invention solves the above-mentioned problems will now be described.
[0052] (1) First Embodiment
[0053] The first embodiment of the present invention will now be described.
[0054] In the system shown in FIG. 2, setting of access paths from the multi-path device control mechanism # 102 is originally made by a user to the host server # 100 for multi-path device control, generally.
[0055] Specifically, in the example shown in FIG. 2, the user should make a setting such that a multi-path device control is configured by using the access paths # 200 and # 201 .
[0056] However, when the user erroneously makes a setting such that a multi-path device control is configured by using the access paths # 200 and # 202 , the different areas A and B are accessed via the two paths # 200 and # 202 . Thereby, the area B which is not relevant is damaged.
[0057] In order to make a protection against this erroneous setting, each of the channel adapters has an arrangement incorporated therein such as to send back information of a device name # 330 of the device # 300 , information of a serial number # 340 thereof, and information of the area to which the channel adapter is connected, in the first embodiment.
[0058] The host server # 100 reads this information sent back from the channel adapter, and, by combing this information, produces an area name unique in the world, and then uses the thus-produced area name as an identifier.
[0059] Specifically, the host server # 100 secures the information sent from the channel adapters # 310 , # 311 , # 312 , # 410 , and produces the following identifiers. In this case, it is assumed that the device name of the device # 300 is F6495, the serial number thereof is 0123, the device name of the device # 400 is F6495 and the serial number thereof is 0124.
[0060] (a) The above-mentioned information is secured sent from the channel adapter # 310 , and the following identifier is produced for the area A:
[0061] F6494-0123-A
[0062] (b) The above-mentioned information is secured sent from the channel adapter # 311 , and the following identifier is produced for the area A:
[0063] F6494-0123-A
[0064] (c) The above-mentioned information is secured sent from the channel adapter # 312 , and the following identifier is produced for the area B:
[0065] F6494-0123-B
[0066] (d) The above-mentioned information is secured sent from the channel adapter # 410 , and the following identifier is produced for the area C:
[0067] F6495-0124-C
[0068] Then, an arrangement is incorporated in the multi-path device control mechanism # 102 such as to reject specification/setting of access paths from which the same identifier cannot be produced, and, thereby, it is possible to prevent an erroneous multi-path device control from being performed.
[0069] Thus, in this example, from the channel adapters # 310 and # 311 , the same identifier is produced. Accordingly, a setting of the access paths using them are accepted. However, from the channel adapters # 310 and # 312 , the different identifiers are produced. Accordingly, a setting of the access paths using them are not accepted.
[0070] Further, there may be a case where, when a power of the host server # 100 is turned off once access paths are set, and, then, the access path # 201 is re-connected into the access path # 202 in a maintenance work, the area B is damaged similarly to the above-mentioned case.
[0071] In order to prevent such a problem from occurring, when the host server # 100 starts up, the multi-path device control mechanism # 102 obtains the identifiers for the respective settings of access paths as mentioned above and determines whether or not the settings of access paths used in multi-path device control are correct.
[0072] When the identifiers are different for the respective access paths set for an I/O request under multi-path device control, the multi-path device control mechanism # 102 does not perform the relevant multi-path process.
[0073] Furthermore, when the access path # 201 is erroneously re-connected into the access path # 202 while the power is maintained in the ON state in the host server # 100 , the area B is damaged similarly to the above-mentioned case.
[0074] In order to avoid such a situation, the multi-path device control mechanism # 102 of the host server # 100 periodically requests the channel adapters to send back the respective information, obtains the identifiers for the respective settings access paths similarly to the above-mentioned case, and determines whether the settings of access paths used in multi-path device control are correct.
[0075] When the identifiers are different for a setting of access paths used in multi-path device control, the multi-path device control mechanism # 102 stops the relevant multi-path process.
[0076] [0076]FIG. 3 is a flow chart showing an outline of a process performed by the multi-path device control mechanism # 102 in the first embodiment.
[0077] In FIG. 3, first, an access-path setting command input by a user is executed, and a setting of access paths is made in a step S 1 . Thereby, for example, the access paths # 200 and # 201 , shown in FIG. 2, are set.
[0078] Then, the multi-path device control mechanism # 102 secures, information of device name, information of serial number, and area information send back from each device, for each path, and produces the above-mentioned identifier therefrom, in a step S 2 . In the above-mentioned example, the identifier F6494-0123-A is produced for both access paths # 200 and # 201 , F6494-0123-B is produced for the access path # 202 , F6495-0124-C is produced for the access path # 203 and F6494-0123-B is produced for the access path # 204 .
[0079] When an I/O request is given for an area, the multi-path device control mechanism # 102 compares the identifiers of paths concerning the command, in a step S 3 . Then, when the identifiers compared do not coincide, the process is finished as an error in a step S 5 . When the identifiers coincide with each other, the process is finished normally, and the relevant multi-path process is then executed.
[0080] For example, when the user sets the access paths # 200 and # 201 for a multi-path device control, both identifiers thereof are F6494-0123-A, and thus, coincide. Accordingly, the multi-path device control is then continued. However, when the user erroneously sets the access paths # 200 and # 202 for the multi-path device control, the identifiers thereof are F6494-0123-A and F6494-0123-B, and thus, do not coincide. Accordingly, the multi-path device control is then interrupted.
[0081] Further, either at a time of power being turned on, or periodically, the multi-path device control mechanism # 102 also secures, information of device name, information of serial number, and area information sent back from each device, for each path, and produces the identifier therefrom, in the step S 2 . Then, when an I/O request is given for an area as mentioned above, the multi-path device control mechanism # 102 compares the identifiers of paths concerning the command, in the step S 3 . Thereby, it is possible to also appropriately deal with erroneous re-connection also made at a time of maintenance work.
[0082] (2) Second Embodiment
[0083] The second embodiment of the present invention will now be described.
[0084] A case is assumed such that, in a system shown in FIG. 4, the following multi-path configurations are set:
[0085] In the multi-path device control mechanism (for the area A) # 102 in the host server # 100 , a multi-path configuration using the access paths # 200 and # 201 to the area A of the device # 300 is set.
[0086] In a multi-path device control mechanism (for an area D) # 103 in the host server # 100 , a multi-path configuration also using the access paths # 200 and # 201 to the area D is set.
[0087] Then, while a process for the area A is being performed in this state, an error occurs in the channel adapter # 310 , thereby a path-fail-over function of the multi-path device control mechanism # 102 functions, operation concerning the access path # 200 is terminated, and, then, instead, the command is issued for the area A by using the channel adapter # 311 via the access path # 201 .
[0088] However, if a command is issued for the area D from the host application # 101 while the above-mentioned setting of access paths for the area D were maintained in the multi-path device control mechanism # 102 , also the multi-path device control mechanism (for the area D) # 103 would use the channel adapter # 310 via the access path # 200 .
[0089] However, the channel adapter # 310 is in the error state as mentioned above, and cannot be used actually. Thereby, a useless error dealing-with time would be required for the channel adapter # 310 . Especially, in the above-mentioned Fibre Channel network, a long time is required for detecting an error. Accordingly, this useless error dealing-with time would become problematic.
[0090] In order to avoid such a problematic situation, an arrangement is made such that the channel adapter having the error occurring therein can be recognized by the host server, in the second embodiment.
[0091] For this purpose, each channel adapter has an arrangement incorporated therein such that the information of device name # 330 , or the like of the belonging device, information of serial number # 340 , or the like, and adapter-number information unique in the device are sent back to the host server thereby.
[0092] The host server reads this information sent back from the channel adapters, produces channel-location identifiers each unique in the world by combining the information, and can use it.
[0093] Specifically, the host server # 100 secures this information sent back from the channel adapters, and generates the following identifiers, for example. In this example, it is assumed that the device name of the device # 300 is F6494, the serial number thereof is 0123, the device name of the device # 400 is F6495, the serial number thereof is 0124.
[0094] (a) The above-mentioned information sent back from the channel adapter # 310 (adapter No. 1 ) is secured, and the following identifier is produced:
[0095] F6494-0123-1
[0096] (b) The above-mentioned information sent back from the channel adapter # 311 (adapter No. 2 ) is secured, and the following identifier is produced:
[0097] F6494-0123-2
[0098] (c) The above-mentioned information sent back from the channel adapter # 312 (adapter No. 3 ) is secured, and the following identifier is produced:
[0099] F6494-0123-3
[0100] (d) The above-mentioned information sent back from the channel adapter # 410 (adapter No. 1 ) is secured, and the following identifier is produced:
[0101] F6495-0124-1
[0102] This information is secured previously by all the multi-path device control mechanisms for each path (in a step S 21 of FIG. 5) before path error is detected.
[0103] When detecting a path error, the multi-path device control mechanism informs of the above-mentioned channel-location identifier of the channel adapter concerning the error path to the other multi-path device control mechanisms in the belonging host server (in a step S 22 ).
[0104] In this example, the channel-location identifier is informed to the multi-path device control mechanism # 103 from the multi-path device control mechanism # 102 .
[0105] The multi-path device control mechanism # 103 , thus receiving the error identifier, examines whether or not the own settings include any access path concerning the thus-informed identifier. When the own settings include any access path concerning this identifier, the multi-path device control mechanism # 103 stops operation concerning this access path, and previously performs a path-fail-over operation (in a step S 23 ). Thereby, it is possible to prevent the multi-path device control mechanism # 103 from inadvertently accessing the relevant access path # 200 .
[0106] The above-described process is a process in one host server. However, this process can be performed exceeding the host server.
[0107] It is assumed that the host server # 100 and a host server # 500 are connected through a LAN # 600 , as shown in FIG. 4.
[0108] In this system, it is assumed that a multi-path configuration employing the access paths # 200 and # 201 is set for the area A of the device # 300 , a multi-path configuration also employing the access paths # 200 and # 201 is set for the area D of the device # 300 , and, also, the channel adapter 310 of the device # 300 is employed not only by the host server # 100 but also by the host server # 500 .
[0109] In this case, a fault of the channel adapter # 310 is detected also in the host server # 500 similarly. Accordingly, when a fault occurs in the channel adapter # 310 , error dealing-with operation is performed in the respective host servers # 100 and # 500 . Thereby, a useless (doubled) error dealing-with time is required.
[0110] In order to solve this problem, when a fault occurs in the channel adapter # 310 , for example, the above-mentioned error channel adapter identifier (F6494-0123-1) is also informed to the host server # 500 from the multi-path device control mechanism # 102 of the host server # 100 (in the step S 22 ). Thereby, it is possible to prevent the other host server # 500 from inadvertently performing useless error detection, and thereby to shorten a time required for recovery from the fault.
[0111] When receiving the above-mentioned error channel adapter identifier, a multi-path device control mechanism # 502 of the other host server # 500 having started up examines whether or not the own settings include any access paths concerning the same identifier. When any access path concerning the same identifier is included in the own settings, operation concerning this access path is terminated, and a path-fail-over operation is performed previously (in the step S 23 ).
[0112] (3) Third Embodiment
[0113] The third embodiment of the present invention will now be described.
[0114] In the above-described second embodiment, the process is performed when path error is detected. In the third embodiment, which will now be described, active exchange units in a device are considered, and termination of operation of an access path concerning an exchange unit is achieved in a host server.
[0115] In FIG. 6A, the channel adapters # 310 and # 311 are of a same package, and, are channel adapters in a same active exchange unit (referred to as an exchange unit 1 , hereinafter). Accordingly, when a channel adapter is exchanged, the channel adapters # 310 and # 311 are exchanged at the same time. Similarly, the channel adapters # 312 and # 313 are those in a same active exchange unit (referred to as an exchange unit 2 , hereinafter).
[0116] Further, the multi-path device control mechanism # 102 is set so that the area A of the device # 300 is accessed via the access paths # 200 and # 201 from the host server # 100 .
[0117] Further, a multi-path device control mechanism # 152 of the same host server # 100 is set so that the area B of the device # 300 is accessed via the access paths # 202 and # 203 from the host server # 100 .
[0118] The above-mentioned access paths # 200 and # 202 use the channel adapters # 310 and # 311 , respectively, in the same exchange unit 1 , while the above-mentioned access paths # 201 and # 203 use the channel adapters # 312 and # 313 in the same exchange unit 2 .
[0119] In this environment, when a fault occurs in the channel adapter # 310 , no influence thereof is given on the paths belonging to the multi-path device control mechanism # 152 .
[0120] However, when the channel adapter # 310 is exchanged in order to get lid off the fault of the channel adapter # 310 , the channel adapter # 311 is affected thereby because the channel adapter # 311 is in the same package with the channel adapter # 310 .
[0121] In order to solve such a problem, an arrangement is provided such that the operation performed using the channel adapter # 311 is previously stopped when the channel adapter # 310 is exchanged, in the third embodiment.
[0122] Specifically, each channel adapter has an arrangement incorporated therein such that the information of device name # 330 , for example, of the device, information of serial number # 340 , for example, and component exchange-unit identifier information unique in the device are sent back to the host server.
[0123] The host server reads this information sent back from the channel adapters, produces component exchange-unit identifiers each unique in the world by combining the information, and can use them.
[0124] Specifically, the host server # 100 secures the information sent back from the channel adapters, and generates the following component exchange-unit identifiers, for example. In this example, it is assumed that the device name of the device # 300 is F6494, the serial number thereof is 0123, the device name of the device # 400 is F6495, the serial number thereof is 0124.
[0125] (a) The above-mentioned information sent back from the channel adapter # 310 (in the exchange-unit 1 ) is secured, and the following identifier is produced:
[0126] F6494-0123-1
[0127] (b) The above-mentioned information sent back from the channel adapter # 311 (in the exchange-unit 1 ) is secured, and the following identifier is produced:
[0128] F6494-0123-1
[0129] (c) The above-mentioned information sent back from the channel adapter # 312 (in the exchange-unit 2 ) is secured, and the following identifier is produced:
[0130] F6494-0123-2
[0131] (d) The above-mentioned information sent back from the channel adapter # 313 (in the exchange-unit 2 ) is secured, and the following identifier is produced:
[0132] F6494-0123-2
[0133] In FIG. 6A, when the multi-path device control mechanism # 102 receives a command of exchanging the channel adapter # 310 from a user, the component exchange-unit identifier (in the above-mentioned example, F6494-0123-1) concerning this channel adapter # 310 is transferred to the other multi-path device control mechanism # 152 in the same host server # 100 .
[0134] When receiving this identifier, the multi-path device control mechanism # 152 stops operation concerning the access path # 202 concerning the same component identifier, and, thereby, exchange of the channel adapters # 310 -# 311 of the device # 300 can be performed without affecting any I/O request from a host application # 151 .
[0135] The above-described process is a process within one host server. However, the same process may be achieved exceeding the host server.
[0136] A case will now be described with reference to FIG. 6B where active exchange units in a device are considered, and operation concerning an access path is terminated exceeding a host server.
[0137] The multi-path device control mechanism # 102 is set so that the area A of the device # 300 is accessed via the access paths # 200 and # 201 from the host server # 100 . Further, a multi-path device control mechanism # 502 of the host server # 500 is set so that the area B of the device # 300 is accessed via the access paths # 202 and # 203 from the host server # 500 . The component exchange-unit identifiers are the same as those described above with reference FIG. 6A.
[0138] In FIG. 6B, when the multi-path device control mechanism # 102 receives a command of exchanging the channel adapter # 310 from a user, the component exchange-unit identifier (in the above-mentioned example, F6494-0123-1) concerning this channel adapter # 310 is transferred to the multi-path device control mechanism # 502 of the other host server # 500 .
[0139] When receiving this identifier, the multi-path device control mechanism # 502 terminates operation concerning the access path # 202 concerning the same component identifier, and, thereby, exchange of the channel adapters # 310 -# 311 in the same exchange unit of the device # 300 can be performed without affecting any I/O request from the host application # 501 .
[0140] Further, it is also possible to consider above-mentioned active exchange units in a device, and to re-start operation concerning the relevant access paths in the host server.
[0141] Specifically, in FIG. 6A, when the channel adapters # 310 -# 311 in the same exchange unit are exchanged, operation concerning the relevant access paths # 200 and # 202 are terminated by the multi-path device control mechanisms # 102 and # 152 .
[0142] Then, after the exchange is normally completed, a user may issue a command of re-starting operation concerning the relevant access path to the multi-path device control mechanism # 102 .
[0143] Thereby, the multi-path device control mechanism # 102 re-starts operation concerning the access path # 200 . Simultaneously, the exchange-unit identifier (F6494-0123-1) concerning this access path # 200 is informed of to the other multi-path device control mechanism # 152 in the same host server # 100 so that it is informed thereto that the path has been recovered. When receiving this information, the multi-path device control mechanism # 152 issues, to itself, a command of re-starting operation concerning the access path # 202 concerning the same exchange-unit identifier when operation concerning this access path was terminated. Thereby, re-starting of operation concerning the access path # 202 is also rendered automatically.
[0144] Similarly, it is also possible to consider active exchange units of a device, and to re-start operation concerning an access path exceeding a host server.
[0145] Specifically, in FIG. 6B, when the channel adapters # 310 -# 311 of the device # 300 are exchanged, operation concerning the access paths # 200 and # 202 are terminated by the multi-path device control mechanisms # 102 and # 152 .
[0146] Then, after the exchange is normally completed, a user issues a command of re-starting operation concerning the access path to the multi-path device control mechanism # 102 .
[0147] Thereby, the multi-path device control mechanism # 102 re-starts operation concerning the access path # 200 . Simultaneously, the exchange-unit identifier (F6494-0123-1) concerning this access path # 200 is informed of to the multi-path device control mechanism # 152 of the other host server # 500 so that it is informed thereto that the path has been recovered. When receiving this information, the multi-path device control mechanism # 152 issues, to itself, a command of re-starting operation concerning the access path # 202 concerning the same exchange-unit identifier when operation concerning this access path was terminated. Thereby, restarting of operation concerning the access path # 202 is also rendered.
[0148] Thereby, it is possible to simplify a command for multi-path device control when an active exchange unit is exchanged, exceeding a host server, to prevent an erroneous operation from being performed onto the multi-path device control, and to shorten a time required for recovery from termination due to exchange.
[0149] [0149]FIG. 7 is a flow chart showing an outline of the above-described third embodiment of the present invention.
[0150] In FIG. 7, first, the host server obtains the device name, serial number and information of component exchange units in the device from each channel adapter, and produces the above-mentioned component exchange-unit identifier therefrom, in a step S 11 .
[0151] Then, when a fault occurs in a channel adapter, the multi-path device control mechanism transfers the component exchange-unit identifier concerning the channel adapter to the other multi-path device control mechanisms of the own host server and/or of the other host servers, in a step S 12 .
[0152] The other multi-path device control mechanism receiving this identifier causes any access via the access paths concerning this component exchange-unit identifier to terminate, in a step S 13 .
[0153] Then, when an access re-starting command is issued, the multi-path device control mechanism transfers the component exchange-unit identifier of the relevant channel adapter to the other multi-path device control mechanisms of the own host server and/or the other host servers so as to inform thereto that the access path has been recovered, in a step S 14 , and re-starts access via the concerning access paths, in a step S 15 .
[0154] In the above-discussed embodiments, the serial numbers are used in the identifiers specifying the devices. However, when Fibre Channel network is used, instead of the serial numbers, WWN (World Wide Names) of the Fibre Channel which each channel adapters possesses may be used.
[0155] WWN of Fibre Channel is unique in the world. Accordingly, there is no problem in use thereof in each identifier in each of the above-discussed embodiments of the present invention. However, it is noted that WWN is used only in Fibre Channel connection environments. Especially, WWN is useful in a case where the serial number of a device cannot be read out.
[0156] As in each identifier in the above-mentioned third embodiment of the present invention, a node name of WWN may be utilized. The node name of WWN is unique in the world. Also, it is possible to utilize a plurality of port names given in a same node name, as shown in FIG. 8. Accordingly, it is possible to utilize them in identifiers specifying exchange components.
[0157] Although the first, second and third embodiments have been described separately, each thereof may be used alone, or all or some of the first, second and third embodiments may be combined in any manner.
[0158] [0158]FIG. 9 is a block diagram showing a configuration of a computer which may be used as any host server in any of the above-discussed first, second and third embodiments of the present invention.
[0159] The computer shown in FIG. 9 includes a display device 1001 (such as a CRT, a liquid crystal display device or the like), a CPU 1002 , a memory 1003 (such as a RAM, a ROM and so forth), a user operation (user input) device 1004 (such as a mouse, keyboard and so forth), a hard disk drive 1005 , a CD-ROM drive 1006 , and a communication device 1008 for connecting the computer to a network such as Fibre Channel network.
[0160] A software program for causing the computer to perform the processes described above with reference FIGS. 2 through 8 (especially, FIGS. 3, 5 and 7 ) described as being executed by each multi-path device control mechanism is previously recorded in a CD-ROM 1007 .
[0161] Then, when the CD-ROM 1007 is inserted into and driven by the CD-ROM driver 1006 , the program is read therefrom, and then, is stored in the hard disk drive 1005 .
[0162] Then, the CPU 1002 reads the program, and executes instructions thereof in cooperation with the memory 1003 , in response to commands input by a user via the user operation device 1004 . Thus, the computer shown in FIG. 9 performs the above-described process of host server/apparatus of multi-path device control system according to the present invention.
[0163] The present invention is not limited to the above-described embodiments, and variations and modifications may be made without departing from the scope of the present invention.
[0164] The present application is based on Japanese priority application No. 2000-248157, filed on Aug. 18, 2000, the entire contents of which are hereby incorporated by reference.
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In a multi-path computer system, a host apparatus and devices are connected via a plurality of paths, recorded therein. From channel adapters of the devices, device information of said devices, area information corresponding to a plurality of accessible areas, channel-adapter number information in said devices, and/or component exchange-unit information in said device are obtained. Properlity of the plurality of paths is determined from access path information and identification information comprising the device information and area information. Identification information is informed, concerning an error path, comprising the device information and channel-adapter number information, to the other multi-path control parts of the own apparatus or the multi-path control parts of the other apparatuses, when detecting the error path. Operation of a path employing a channel adapter is caused to stop, and, also, identification information is informed of, concerning said channel adapter, comprising the device information and component exchange-unit information, to the other multi-path control parts of the own apparatus and/or the multi-path control parts of the other apparatuses, when a request of exchanging said channel adapter is given.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 USC 119 based on Japanese patent Application No. 2004-229415, filed Aug. 5, 2004. The subject matter of this priority document is incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a shift controller for a continuously variable transmission. More specifically, the present invention relates to a shift controller for a continuously variable transmission including a shift actuator that changes a gear ratio regardless of engine speed.
[0004] 2. Description of the Background Art
[0005] There are many known hybrid vehicles. An electric vehicle powered by a motor offers the advantage of no air pollution, reduced noise pollution, and better response to acceleration and deceleration needs as compared with conventional vehicles powered by engines. A hybrid vehicle mounted with a motor and an engine has been put into practical use as an embodiment having these benefits.
[0006] Three types of such a hybrid vehicle are generally known: a “series hybrid system,” a “parallel hybrid system,” and a “series-parallel combined system.” Specifically, the series hybrid system is powered solely by the motor, with the engine being used for generating electricity for recharging a battery. The parallel hybrid system uses both the motor and the engine to drive the vehicle, each being used according to a running condition and the like. The series-parallel combined system uses the foregoing two systems, one being selected for use appropriately according to the running condition.
[0007] In many of these hybrid vehicles, a belt-type continuously variable transmission is adopted as an automatic transmission. The belt-type continuously variable transmission includes a driving side pulley, a driven side pulley, and an endless belt. The driving side pulley is connected to an output shaft of a power source. The driven side pulley is connected to a driving shaft. The endless belt is wound around the driving side pulley and the driven side pulley. The gear ratio is changed by displacing a radius of the driving side pulley using a centrifugal force generated by rotation of the output shaft.
[0008] Japanese Patent Laid-open No. 2004-116672 discloses an electronically controlled belt-type continuously variable transmission in the place of a conventional belt-type continuously variable transmission. The electronic controlled belt-type continuously variable transmission includes a separate shift actuator that displaces the radius of the driving side pulley called an electronic belt converter. The electronic belt converter is capable of arbitrarily controlling its gear ratio regardless of the speed of the output shaft.
[0009] FIG. 9 is a diagram showing a typical shift pattern of a conventional electronic belt converter. The relation among an engine speed Ne, a vehicle speed V, and a gear ratio R of the continuously variable transmission has been previously registered. The shift pattern includes a low ratio control range, a top ratio control range, and a shift control range. In the low ratio control range, the engine speed Ne is variably controlled at a low speed range with the gear ratio R set at a predetermined low ratio Rlow. In the top ratio control range, the engine speed Ne is variably controlled at a high-speed range with the gear ratio R set at a predetermined top ratio Rtop. In the shift control range, the gear ratio is variably controlled with the engine speed Ne fixed at a boundary between the low speed range and the high-speed range.
[0010] There is known a system, in which power of an engine is used to drive a generator for generating electricity which, in turn, is used to charge a battery. In such a system, the more a charging current, as a result of an amount of charge still available for use in the battery or a remaining charge of the battery, the greater a driving torque for the generator. This results in the engine mechanical load increasing. Thus, a rider is required to operate the vehicle with a relatively open throttle. Therefore, to obtain running performance equivalent to that associated with a sufficient remaining charge of the battery when the remaining charge of the battery is low, a rider needs to operate the vehicle with the throttle even more open. This gives the rider an impression different from that during ordinary operation. Consequently, there is still a need for a control apparatus for a continuously variable transmission that does not give the operator the above-mentioned different impression.
SUMMARY OF THE INVENTION
[0011] The present invention provides a shift controller for a continuously variable transmission ensuring an operating feel similar to that during ordinary running regardless of the remaining charge of the battery.
[0012] A shift control apparatus for a continuously variable transmission includes: a continuously variable transmission for transmitting power of an engine to a driving wheel; a shift actuator for changing a gear ratio of the continuously variable transmission; and a gear ratio controller for controlling the shift actuator such that the gear ratio of the continuously variable transmission exhibits a predetermined shift pattern.
[0013] According to a first aspect of the present invention, the shift controller further includes a battery monitor for detecting remaining charge of a battery charged by a generator connected to the engine, and the shift pattern is changed according to the remaining charge of the battery.
[0014] When the remaining charge of the battery is insufficient, if the gear ratio is shifted to a lower ratio side than when the remaining charge of the battery is sufficient, insufficient torque of the engine is supplemented with the gear ratio. This occurs even if a driving torque of the generator increases as a result of an insufficient remaining charge of the battery, and a mechanical load on the engine becomes greater. This gives the rider the same operating feel as that which occurs during ordinary running.
[0015] According to a second aspect of the present invention, the lower the remaining charge of the battery, the lower the gear ratio is selected. Insufficient torque of the engine is supplemented by adjustment of the gear ratio even if a driving torque of the generator increases as a result of an insufficient remaining charge of the battery, and a mechanical load on the engine becomes greater. This gives the rider the same operating feel as that which occurs during ordinary running.
[0016] According to a third aspect of the present invention, the shift control apparatus for the continuously variable transmission is characterized in that the shift pattern includes: a low ratio control range, in which an engine speed is variably controlled at a low speed range with the gear ratio set at a predetermined low ratio; a top ratio control range, in which the engine speed is variably controlled at a high speed range with the gear ratio set at a predetermined top ratio; and a shift control range, in which the gear ratio is variably controlled with the engine speed fixed at a boundary between the low speed range and the high speed range. In the shift control apparatus, the lower the remaining charge of the battery, the more the low ratio control range is expanded to the high speed range of the engine. As a result, the gear ratio in the shift control range is shifted on a low end. This gives the rider the same operating feel as that during ordinary running regardless of the remaining charge of the battery, particularly in the medium speed running range.
[0017] In a fourth aspect of the present invention, the shift pattern includes: a low ratio control range, in which an engine speed is variably controlled at a low speed range with the gear ratio set at a predetermined low ratio; a top ratio control range, in which the engine speed is variably controlled at a high speed range with the gear ratio set at a predetermined top ratio; and a shift control range, in which the gear ratio is variably controlled with the engine speed fixed at a boundary between the low speed range and the high speed range. In the shift control apparatus, the lower the remaining charge of the battery, the more the gear ratio of the low ratio control range is shifted to a low ratio side. Accordingly, in the low speed running range, when the remaining charge of the battery is insufficient the gear ratio can be made lower than the gear ratio when the remaining charge of the battery is sufficient. This gives the rider the same operating feel as that during ordinary running regardless of the remaining charge of the battery particularly in the low speed running range.
[0018] According to a fifth aspect of the present invention, the shift pattern includes: a low ratio control range, in which an engine speed is variably controlled at a low speed range with the gear ratio set at a predetermined low ratio; a top ratio control range, in which the engine speed is variably controlled at a high speed range with the gear ratio set at a predetermined top ratio; and a shift control range, in which the gear ratio is variably controlled with the engine speed fixed at a boundary between the low speed range and the high speed range; and that the lower the remaining charge of the battery, the more the gear ratio of the low ratio control range is shifted to a low ratio side, and the more the low ratio control range is expanded to the high speed range of the engine. In the shift apparatus, the lower the remaining charge of the battery, the more the gear ratio of the low ratio control range is shifted to a low ratio side, and the more the low ratio control range is expanded to the high speed range of the engine. Accordingly, in the low speed and medium speed running range, the gear ratio when the remaining charge of the battery is insufficient can be made lower than the gear ratio when the remaining charge of the battery is sufficient, giving the rider the same operating feel as that during ordinary running for both the low and medium speed running range.
[0019] According to a sixth aspect of the present invention, the continuously variable transmission is a belt type continuously variable transmission having an endless belt wound around a driving side pulley and a driven side pulley; and the shift actuator changes a belt winding diameter of at least either the driving side pulley or the driven side pulley. In an existing vehicle including a belt type continuously variable transmission and a shift actuator, simply changing a control system gives the rider the same operating feel as that during ordinary running regardless of the remaining charge of the battery.
[0020] According to a seventh aspect of the present invention, the shift pattern is not changed during running, even if the remaining charge of the battery becomes lower than a threshold value during running. There is, therefore, no likelihood that the running feel will be changed during running.
[0021] For a more complete understanding of the present invention, the reader is referred to the following detailed description section, which should be read in conjunction with the accompanying drawings. Throughout the following detailed description and in the drawings, like numbers refer to like parts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a side elevational view of a hybrid vehicle according to the present invention, showing a power unit including an engine and an electric drive motor operatively connected to the rear wheel.
[0023] FIG. 2 is a block diagram of the system configuration of the motorcycle shown in FIG. 1 .
[0024] FIG. 3 is a cross sectional view of the power unit of the motorcycle shown in FIG. 1 showing the engine above the rear wheel, and the drive motor to one side of the rear wheel.
[0025] FIG. 4 is an enlarged view of the shift motor and drive motor of the power unit shown in FIG. 3 .
[0026] FIG. 5 is a diagram showing a shift pattern according to the first embodiment of the present invention in which a broken line represents a shift pattern (a first pattern) when the remaining charge of the battery is sufficient, while a solid line represents a shift pattern (a second pattern) when the remaining charge of the battery is insufficient.
[0027] FIG. 6 is a flowchart showing shift pattern control processes.
[0028] FIG. 7 is a diagram showing a shift pattern according to the second embodiment of the present invention in which a broken line represents a shift pattern (a first pattern) when the remaining charge of the battery is sufficient, while a solid line represents a shift pattern (a second pattern) when the remaining charge of the battery is insufficient.
[0029] FIG. 8 is a diagram showing a shift pattern according to the third embodiment of the present invention in which a broken line represents a shift pattern (a first pattern) when the remaining charge of the battery is sufficient, while a solid line represents a shift pattern (a second pattern) when the remaining charge of the battery is insufficient.
[0030] FIG. 9 is a diagram showing a prior art shift pattern.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] A preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings. FIG. 1 is a side elevational view showing a scooter-type hybrid vehicle according to a preferred embodiment of the present invention.
[0032] The hybrid vehicle according to the preferred embodiment of the present invention includes a front fork 1 for journaling a front wheel WF at a point forward of a vehicle body. The front fork 1 is pivotally supported on a head pipe 2 . The front fork 1 can be steered through operation of a handlebar 3 . A down pipe 4 is fitted to the head pipe 2 so as to extend rearwardly and downwardly therefrom. An intermediate frame 5 is extended substantially horizontally from a lower end of the down pipe 4 . A rear portion frame 6 is formed rearwardly and upwardly from a trailing end of the intermediate frame 5 .
[0033] A vehicle body frame 10 as constructed above includes a power unit 11 including an engine and a driving motor as a power source. One end of the power unit 11 is pivotally secured to the vehicle body frame 10 . A rear wheel WR, functioning as a driving wheel, is rotatably mounted rearward and on the other end of the power unit 11 . The power unit 11 is suspended by a rear shock absorber (not shown) mounted on the rear portion frame 6 .
[0034] A vehicle body cover 13 covers the outer periphery of the vehicle body frame 10 . A seat 14 , on which a rider sits, is secured rearward and on a top surface of the vehicle body cover 13 . A step floor 15 , on which the rider rests his or her feet, is formed forward of the seat 14 . A storage box 100 is disposed below the seat 14 . The storage box 100 functions as a utility space for storing a helmet, luggage, and the like.
[0035] FIG. 2 is a block diagram showing a system configuration of the hybrid vehicle described above. The power unit 11 includes an engine 20 , an ACG starter motor 21 a, a continuously variable transmission (transmission power mechanism) 23 , a shift motor 77 , a starting clutch 40 , a driving motor 21 b, a one-way clutch 44 , and a reduction mechanism 69 . Specifically, the ACG starter motor 21 a functions as an engine starter and generator. The continuously variable transmission 23 is connected to a crankshaft 22 and transmits power of the engine 20 to the rear wheel WR. The shift motor 77 serves as a shift actuator that changes a shift position of the continuously variable transmission 23 . The starting clutch 40 connects or disconnects transmission power between the crankshaft 22 and an input shaft of the continuously variable transmission 23 . The driving motor 21 b functions as a motor or a generator. The one-way clutch 44 transmits power from the engine 20 and the driving motor 21 b to the rear wheel WR, but not from the rear wheel WR to the engine 20 . The reduction mechanism 69 transmits an output from the continuously variable transmission 23 at a reduced speed to the rear wheel WR. An engine speed sensor 36 detects an engine speed Ne of the engine 20 .
[0036] Power from the engine 20 is transmitted from the crankshaft 22 to the rear wheel WR via the starting clutch 40 , the continuously variable transmission 23 , the one-way clutch 44 , a driving shaft 60 , and the reduction mechanism 69 . Power from the driving motor 21 b, on the other hand, is transmitted to the rear wheel WR via the driving shaft 60 and the reduction mechanism 69 . That is, according to the preferred embodiment of the present invention, the driving shaft 60 serves as an output shaft of the driving motor 21 b.
[0037] A battery 74 is connected to the ACG starter motor 21 a and the driving motor 21 b. When the driving motor 21 b functions as a motor, and when the ACG starter motor 21 a functions as a starter, the battery 74 supplies power to the ACG starter motor 21 a and the driving motor 21 b. When the ACG starter motor 21 a and the driving motor 21 b function as a generator, the battery 74 is recharged by regenerative power generated by the ACG starter motor 21 a and the driving motor 21 b. A voltage sensor 37 detects a terminal data Vbat of the battery 74 .
[0038] A throttle valve 17 , for controlling the amount of intake air, is rotatably mounted in an intake pipe 16 of the engine 20 . The throttle valve 17 is rotated according to the amount of operation of a throttle grip (not shown) operated by the rider. The shift controller according to the preferred embodiment of the present invention may include a DBW (drive-by-wire) system 12 . The throttle valve 17 can thereby be automatically controlled according to the engine speed, a vehicle speed, and the like, irrespective of the operation performed by the rider. An injector 18 and a vacuum sensor 19 are disposed between the throttle Valve 17 and the engine 20 . The injector 18 injects fuel. The vacuum sensor 19 detects a negative pressure in the intake pipe.
[0039] A control unit 7 includes a gear ratio control portion 7 a, a battery monitoring portion 7 b, and a shift pattern registration portion 7 c. The gear ratio control portion 7 a controls the shift motor 77 such that the gear ratio of the continuously variable transmission 23 exhibits a predetermined shift pattern. The battery monitoring portion 7 b determines a charge state of the battery 74 based on the battery voltage Vbat detected by the voltage sensor 37 . The shift pattern registration portion 7 c stores the shift pattern of the continuously variable transmission 23 previously registered therein.
[0040] The construction of the power unit 11 including the engine 20 and the driving motor 21 b will be described with reference to FIG. 3 .
[0041] The engine 20 includes a piston 25 connected to the crankshaft 22 via a connecting rod 24 . The piston 25 can slide inside a cylinder 27 disposed in a cylinder block 26 . The cylinder block 26 is disposed such that an axis of the cylinder 27 runs substantially horizontally. A cylinder head 28 is secured to the front surface of the cylinder block 26 . The cylinder head 28 , the cylinder 27 , and the piston 25 constitute a combustion chamber 20 a for burning an air-fuel mixture.
[0042] The cylinder head 28 includes a valve (not shown) for controlling intake or exhaust of the air-fuel mixture to and from the combustion chamber 20 a, and a spark plug 29 . Opening or closing of the valve is controlled through rotation of a camshaft 30 journaled on the cylinder head 28 . A driven sprocket 31 is mounted on one end of the camshaft 30 . An endless cam chain 33 is wound around the driven sprocket 31 and a drive sprocket 32 disposed on one end of the crankshaft 22 . A water pump 34 for cooling the engine 20 is mounted on the one end of the camshaft 30 such that a rotational axis 35 of the water pump 34 rotates integrally with the camshaft 30 . Accordingly, rotating the camshaft 30 operates the water pump 34 .
[0043] A stator case 49 is connected on the right-hand side in a vehicle width direction of a crankcase 48 that journals the crankshaft 22 . The ACG starter motor 21 a is housed in the stator case 49 . The ACG starter motor 21 a is what is called an outer rotor type. A stator of the ACG starter motor 21 a includes a coil 51 , which is a conductive wire wound around teeth 50 secured to the stator case 49 . An outer rotor 52 is, on the other hand, secured to the crankshaft 22 . The outer rotor 52 is of a substantially cylindrical shape covering the outer periphery of the stator. A magnet 53 is disposed on an inner peripheral surface of the outer rotor 52 .
[0044] The outer rotor 52 includes a fan 54 a for cooling the ACG starter motor 21 a. When the fan 54 a rotates in synchronism with the crankshaft 22 , cooling air is drawn-in through a cooling air intake port formed in a side surface 55 a of a cover 55 of the stator case 49 . The cooling air is drawn-in in this manner.
[0045] A transmission case 59 is connected to the left-hand side, in the vehicle width direction, of the crankcase 48 . A fan 54 b, the continuously variable transmission 23 , and the driving motor 21 b are housed in the transmission case 59 . The fan 54 b is secured to a left end portion of the crankshaft 22 . The driving side of the continuously variable transmission 23 is connected to the crankshaft 22 via the starting clutch 40 . The driving motor 21 b is connected to a driven side of the continuously variable transmission 23 . The fan 54 b functions to cool the continuously variable transmission 23 and the driving motor 21 b, housed in the transmission case 59 . The fan 54 b is disposed on the same side as the driving motor 21 b relative to the continuously variable transmission 23 , that is, on the left-hand side in the vehicle width direction.
[0046] A cooling air intake port 59 a is formed forward and on the left of the vehicle body of the transmission case 59 . When the fan 54 b rotates in synchronism with the crankshaft 22 , an outside air is drawn in through the cooling air intake port 59 a located near the fan 54 b. The driving motor 21 b and the continuously variable transmission 23 are forcedly cooled by the outside air thus drawn in.
[0047] The continuously variable transmission 23 is a belt converter including a driving side transmission pulley 58 and a driven side transmission pulley 62 with an endless V-belt (endless belt) 63 wound therearound. The driving side transmission pulley 58 is mounted via the starting clutch 40 at a left end portion of the crankshaft 22 protruding in the vehicle width direction from the crankcase 48 . The driven side transmission pulley 62 is mounted via the one-way clutch 44 on the driving shaft 60 journaled with an axis running parallel with the crankshaft 22 on the transmission case 59 .
[0048] Referring to FIG. 4 that is an enlarged view of the starting clutch 40 , the shift motor 77 , and the driving motor 21 b, the driving side transmission pulley 58 is circumferentially rotatably mounted on the crankshaft 22 via a sleeve 58 d. The driving side transmission pulley 58 includes a driving side fixed pulley half 58 a and a driving side movable pulley half 58 c. The driving side fixed pulley half 58 a is fixed to the sleeve 58 d. The driving side movable pulley half 58 c is mounted on the sleeve 58 d such that the pulley half 58 c is axially slidable, but unable to make a circumferential rotation relative to the sleeve 58 d. A shift ring 57 is rotatably mounted via a bearing 56 to the driving side movable pulley half 58 c.
[0049] The shift ring 57 includes a gear 61 formed circumferentially on an outer peripheral large diameter portion thereof. The shift ring 57 also includes a trapezoidal screw 65 formed axially on an inner periphery thereof. Another trapezoidal screw 67 meshes with the trapezoidal screw 65 . The trapezoidal screw 67 is mounted so as to be circumferentially rotatable relative to the sleeve 58 d via a bearing 66 , but unable to slide axially.
[0050] A worm wheel 75 meshes with the gear 61 of the shift ring 57 . Further, a worm gear 76 meshes with the worm wheel 75 . The worm gear 76 is connected to a rotational axis of a shift motor 77 for controlling the gear ratio.
[0051] The driven side transmission pulley 62 , on the other hand, includes a driven side fixed pulley half 62 a and a driven side movable pulley half 62 b. The driven side fixed pulley half 62 a is circumferentially rotatably mounted on the driving shaft 60 via a sleeve 62 d, while being restricted in its axial sliding motion relative to the driving shaft 60 . The driven side movable pulley half 62 b is axially slidably mounted on the sleeve 62 d.
[0052] An endless V belt 63 is wound around each of belt grooves having substantially a V-shaped cross section formed between the driving side fixed pulley half 58 a and the driving side movable pulley half 58 c, and between the driven side fixed pulley half 62 a and the driven side movable pulley half 62 b.
[0053] A spring (elastic member) 64 is disposed on the backside (on the left-hand side in the vehicle width direction) of the driven side movable pulley half 62 b. The spring 64 urges the driven side movable pulley half 62 b toward the driven side fixed pulley half 62 a at all times.
[0054] When the gear ratio of the automatic continuously variable transmission 23 is to be changed, the shift motor 77 is driven in a direction of rotation corresponding to an upshift or downshift of the gear ratio. The driving force of the shift motor 77 is transmitted to the gear 61 of the shift ring 57 through the worm gear 76 and the worm wheel 75 . The shift ring 57 is thereby rotated. Since the shift ring 57 is in mesh with the sleeve 57 d through the trapezoidal screws 65 , 67 , the shift ring 57 moves to the left along the crankshaft 22 , as shown in FIG. 4 . This results in the driving side movable pulley half 58 c sliding toward the side of the driving side fixed pulley half 58 a. The driving side movable pulley half 58 c then comes closer to the driving side fixed pulley half 58 a by the amount of this sliding motion. This decreases a groove width of the driving side transmission pulley 58 . A position of contact between the driving side transmission pulley 58 and the V belt 63 is then deviated radially outwardly along the driving side transmission pulley 58 , causing the winding diameter of the V belt 63 to increase. This results in the following occurring in the driven side transmission pulley 62 . Specifically, a groove width formed by the driven side fixed pulley half 62 a and the driven side movable pulley half 62 b increases. That is, the winding diameter of the V belt 63 (a transmission pitch diameter) continuously varies according to the speed of the crankshaft 22 . This results in the gear ratio being automatically and steplessly varied.
[0055] The starting clutch 40 includes an outer case 40 a, an outer plate 40 b, a weight 40 c, a shoe 40 d, and a spring 40 e. The outer case 40 a of a cup shape is fixed to the sleeve 58 d. The outer plate 40 b is fixed on a left end portion of the crankshaft 22 . The shoe 40 d is mounted on an outer peripheral portion of the outer plate 40 b via the weight 40 c so as to face radially outwardly. The spring 40 e urges the shoe 40 d radially inwardly.
[0056] When the engine speed, or the speed of the crankshaft 22 is equal to, or less than, a predetermined value (e.g., 3000 rpm), transmission power between the crankshaft 22 and the continuously variable transmission 23 is disconnected through the starting clutch 40 . As the engine speed increases and the speed of the crankshaft 22 exceeds the predetermined value, the centrifugal force acting on the weight 40 c counteracts an elastic force acting radially inwardly by the spring 40 e, moving the weight 40 c radially outwardly. This causes the shoe 40 d to press an inner peripheral surface of the outer case 40 a with a force of a predetermined value or more. This causes rotation of the crankshaft 22 to be transmitted to the sleeve 58 d via the outer case 40 a. The driving side transmission pulley 58 fixed to the sleeve 58 d is thereby driven.
[0057] The one-way clutch 44 includes an outer clutch 44 a, an inner clutch 44 b, and a roller 44 c. The outer clutch 44 a is of a cup shape. The inner clutch 44 b is internally inserted in the outer clutch coaxially therewith. The roller 44 c allows power to be transmitted in one direction only from the inner clutch 44 b to the outer clutch 44 a. The outer clutch 44 a serves also as an inner rotor main body for the driving motor 21 b. The outer clutch 44 a is formed of the same member as the inner rotor main body.
[0058] Power from the side of the engine 20 transmitted to the driven side transmission pulley 62 of the continuously variable transmission 23 is transmitted to the rear wheel WR by way of the driven side fixed pulley half 62 a, the inner clutch 44 b, the outer clutch 44 a or the inner rotor main body, the driving shaft 60 , and the reduction mechanism 69 . Power from the side of the rear wheel WR generated as the vehicle is pulled by walking, during regenerative operation, or the like, on the other hand, is transmitted to the reduction mechanism 69 , the driving shaft 60 , and the inner rotor main body or the outer clutch 44 a. The power generated in the latter case is not, however, transmitted to the continuously variable transmission 23 and the engine 20 , since the outer clutch 44 a turns idly relative to the inner clutch 44 b.
[0059] The driving motor 21 b of an inner rotor type is disposed rearward of the transmission case 59 . The driving motor 21 b uses the driving shaft 60 as its output shaft. An inner rotor 80 includes the driving shaft 60 , an inner rotor main body or the inner clutch 44 b, and a magnet. The driving shaft 60 serves also as an output shaft for the continuously variable transmission 23 . The inner clutch 44 b is in splined engagement with the driving shaft 60 by a cup-shaped boss portion 80 b formed at a central portion thereof. The magnet is disposed on an outer peripheral surface on an open side of the inner clutch 44 b.
[0060] Referring back to FIG. 3 , the reduction mechanism 69 is disposed in a transmission chamber 70 that continues to the right-hand side at a trailing end portion of the transmission case 59 . The reduction mechanism 69 includes an intermediate shaft 73 that is journaled in parallel with the driving shaft 60 and an axle 68 of the rear wheel WR. The reduction mechanism 69 further includes a pair of first reduction gears 71 and a pair of second reduction gears 72 . The first reduction gears 71 are formed on the right end portion of the driving shaft 60 and a central portion of the intermediate shaft 73 , respectively. The second reduction gears 72 are formed on the intermediate shaft 73 and the left end portion of the axle 68 , respectively. Through such an arrangement, the speed of rotation of the driving shaft 60 is reduced at a predetermined reduction ratio. Rotation of the driving shaft 60 is then transmitted to the axle 68 of the rear wheel WR that is journaled in parallel with the driving shaft 60 .
[0061] In the hybrid vehicle having the arrangements as described in the foregoing, the ACG starter motor 21 a mounted on the crankshaft 22 is used to turn the crankshaft 22 when the engine is to be started. At this time, the starting clutch 40 is not engaged, meaning that transmission power from the crankshaft 22 to the continuously variable transmission 23 is shut off.
[0062] When the throttle grip is operated and opened, only the driving motor 21 b provides power as long as a throttle opening θ remains small according to the preferred embodiment of the present invention. Rotation of the driving shaft 60 through the driving motor 21 b is not transmitted to the driven side transmission pulley 62 through the functioning of the one-way clutch 44 . The continuously variable transmission 23 can then never be driven. Accordingly, running the vehicle by driving the rear wheel WR only with the driving motor 21 b enhances energy transmission efficiency.
[0063] As the throttle opening θ is made greater, the engine speed increases. When the speed of the crankshaft 22 thereafter exceeds a predetermined value (e.g., 3000 rpm), the rotational power of the crankshaft 22 is transmitted to the continuously variable transmission 23 through the starting clutch 40 and applied to the one-way clutch 44 . When the speed on an input side of the one-way clutch 44 coincides with the speed on an output side thereof, that is, the driving shaft 60 , power is switched from the driving motor 21 b to the engine 20 .
[0064] FIG. 5 is a diagram showing a typical shift pattern according to the first preferred embodiment of the present invention. In FIG. 5 , a broken line represents a shift pattern (a first pattern) when the remaining charge of the battery 74 is sufficient, while a solid line represents a shift pattern (a second pattern) when the remaining charge of the battery 74 is insufficient.
[0065] According to the first preferred embodiment of the present invention, if it is determined that the remaining charge of the battery is insufficient, a low ratio control range is expanded to include a high engine speed side. With an insufficient remaining charge of the battery 74 , the gear ratio is thereby made lower than the gear ratio with a sufficient remaining charge of the battery 74 , particularly in a medium speed running range.
[0066] FIG. 6 is a flowchart showing shift pattern control processes that change the shift pattern based on a remaining charge M of the battery 74 . FIG. 6 mainly shows operations performed by the control unit 7 .
[0067] In step S 1 , the battery monitoring portion 7 b of the control unit 7 detects the remaining charge M of the battery 74 based on the battery voltage Vbat detected by the voltage sensor 37 or a record thereof. In step S 2 , it is determined whether the vehicle is in a stationary state based on, for example, a vehicle speed V.
[0068] If it is determined that the vehicle is in the stationary state, the control proceeds to step S 3 . In step S 3 , the remaining charge M of the battery 74 is compared with a reference remaining charge Mref that has previously been registered as a threshold value of changing the shift pattern. If the remaining charge M of the battery 74 is lower than the reference remaining charge Mref, the control proceeds to step S 4 . In step S 4 , it is determined that the current shift pattern is the first pattern (the shift pattern indicated by the broken line in FIG. 5 ) adopted when the remaining charge is sufficient or the second pattern (the shift pattern indicated by the solid line in FIG. 5 ) adopted when the remaining charge is insufficient. If the current pattern is one other than the second pattern, the control proceeds to step S 5 . In step S 5 , the shift pattern is changed from the current first pattern to the second pattern. Accordingly, following this step, the gear ratio is controlled according to the second pattern indicated by the solid line in FIG. 5 .
[0069] If, in step S 3 , it is not determined that the remaining charge M of the battery 74 is lower than the reference remaining charge Mref, the control proceeds to step S 6 . In step S 6 , it is determined that the current shift pattern is either the first pattern or the second pattern. If the current pattern is one other than the first pattern, the control proceeds to step S 7 . In step S 7 , the shift pattern is changed from the current second pattern to the first pattern.
[0070] As described in the foregoing, according to the first preferred embodiment of the present invention, the shift pattern is changed from the first pattern to the second pattern as a result of the remaining charge M of the battery 74 decreasing. Even if this happens, if charging is thereafter promoted to allow the battery 74 to recover its charge, the shift pattern is returned from the second pattern to the first pattern. Accordingly, the gear ratio is hereafter controlled according to the first pattern indicated by the broken line in FIG. 5 .
[0071] FIG. 7 is a diagram showing a shift pattern according to a second preferred embodiment of the present invention. In FIG. 7 , again, a broken line represents a shift pattern (a first pattern) when the remaining charge of the battery 74 is sufficient, while a solid line represents a shift pattern (a second pattern) when the remaining charge of the battery 74 is insufficient.
[0072] According to the second preferred embodiment of the present invention, if it is determined that the remaining charge M of the battery 74 is insufficient, a gear ratio in the low ratio control range Rlow is lowered further than the level when it is determined that the remaining charge M of the battery 74 is sufficient. The gear ratio when the remaining charge M of the battery 74 is insufficient is thus made to be lower than the gear ratio when the remaining charge M of the battery 74 is sufficient particularly in a low speed running range.
[0073] FIG. 8 is a diagram showing a shift pattern according to a third preferred embodiment of the present invention. In FIG. 8 , too, a broken line represents a shift pattern (a first pattern) when the remaining charge of the battery 74 is sufficient, while a solid line represents a shift pattern (a second pattern) when the remaining charge of the battery 74 is insufficient.
[0074] According to the third preferred embodiment of the present invention, the lower the remaining charge M of the battery 74 , the more the gear ratio in the low ratio control range Rlow is shifted to the low ratio side as in the second preferred embodiment of the present invention. At the same time, the low ratio control range is expanded to include the high engine speed side as in the first preferred embodiment of the present invention. The gear ratio when the remaining charge M of the battery 74 is insufficient is thereby made to be lower than the gear ratio when the remaining charge M of the battery 74 is sufficient in both the low speed running range and the medium speed running range.
[0075] The present invention is not limited to the above embodiments in which the second shift pattern is selected when the remaining charge of the battery becomes insufficient. It is nonetheless appropriate that a plurality of shift patterns adopted according to the degree of insufficiency of the remaining charge of the battery is provided and the optimum shift pattern be adopted according to the remaining charge of the battery. An arrangement can thereby be made to control the shift pattern such that an even lower gear ratio can be selected when insufficiency of the remaining charge of the battery is serious.
[0076] Although the present invention has been described herein with respect to a limited number of presently preferred embodiments, the foregoing description is intended to be illustrative, and not restrictive. Those skilled in the art will realize that many modifications of the preferred embodiment could be made which would be operable. All such modifications, which are within the scope of the claims, are intended to be within the scope and spirit of the present invention.
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A shift control apparatus for a continuously variable transmission includes a continuously variable transmission for transmitting power of an engine to a driving wheel; a shift actuator for changing a gear ratio of the continuously variable transmission; and a gear ratio controller for controlling the shift actuator such that the gear ratio of the continuously variable transmission exhibits a predetermined shift pattern. The shift controller further includes a battery monitor for detecting remaining charge of a battery charged by a generator connected to the engine, and the shift pattern is changed according to the remaining charge of the battery. The shift control apparatus ensures an operating feel similar to that during ordinary running regardless of remaining charge of a battery. A method of controlling a continuously variable transmission in a vehicle is also disclosed.
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BACKGROUND OF THE INVENTION
The present invention relates to novel compounds, to methods for preparing the compounds, pharmaceutical formulations comprising these compounds, and the use of these compounds in therapy. In particular, the present invention relates to compounds that are useful in the treatment and prevention of primary and secondary arterial hypertension, ictus, myocardial ischaemia, cardiac and renal insufficiency, myocardial infarction, peripheral vascular disease, diabetic proteinuria, Syndrome X and glaucoma.
Arterial hypertension is a disorder whose causes generally remain unknown. Extrinsic factors which may participate include obesity, sedentary lifestyle, excessive alcohol or salt intake, and stress. Intrinsic factors suggested to play a role include fluid retention, sympathetic nervous system activity and constriction of blood vessels. Arterial hypertension can contribute directly or indirectly to diseases of the heart, the peripheral and cerebral vascular system, the brain, the eye and the kidney.
Treatment of arterial hypertension includes the use of diuretic agents, adrenergic blockers, inhibitors of angiotensin converting enzyme, angiotensin receptor antagonists, calcium antagonists and direct vasodilators. It is desirable to identify further compounds to treat arterial hypertension.
BRIEF DESCRIPTION OF THE INVENTION
The present inventors have identified novel compounds which are effective in reducing arterial hypertension and thus have utility in treating arterial hypertension and the diseases to which it indirectly and directly contributes.
Accordingly the invention provides the following compounds:
4,4′ dithiobis (sodium 3-aminobutane-1-sulfonic acid); 4,4′ dithiobis (2,2dimethypropyl)-3-aminobutane-1-sulfonate.
In another aspect, the present invention discloses a method for prevention or treatment of arterial hypertension and indirectly and directly related diseases, comprising administration of a therapeutically effective amount of a compound of this invention. In another aspect, the present invention provides pharmaceutical compositions comprising one or more compounds of the invention, preferably in association with a pharmaceutically acceptable diluent or carrier.
In another aspect, the present invention provides one or more compounds of the invention for use in therapy, and in particular, in human medicine.
In another aspect, the present invention provides the use of one or more compounds of the invention for the manufacture of a medicament for the treatment of arterial hypertension and indirectly and directly related diseases.
In another aspect, the present invention provides a method of treatment of a patient suffering from arterial hypertension and indirectly and directly related diseases comprising the administration of a therapeutically effective amount of one or more compounds of the invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 demonstrates the effect of the compound of Example 1 on blood pressure in hypertensive rats.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides methods of prevention or treatment of arterial hypertension and diseases to which arterial hypertension directly or indirectly contributes. Such diseases include diseases of the heart, the peripheral and cerebral vascular system, the brain, the eye and the kidney. In particular diseases include primary and secondary arterial hypertension, ictus, myocardial ischaemia, cardiac and renal insufficiency, myocardial infarction, peripheral vascular disease, diabetic proteinuria, Syndrome X and glaucoma.
As used herein, “a compound of the invention” means a compound described above or pharmaceutically acceptable salts or solvate thereof.
The person skilled in the art will recognize that stereocenters exist in the compounds of the invention. Accordingly, the present invention includes all possible stereoisomers and geometric isomers of the compounds of formula (I) and includes not only racemic compounds but also the optically active isomers as well. When a compound of formula (I) is desired as a single enantiomer, it may be obtained either by resolution of the final product or by stereospecific synthesis from either isomerically pure starting material or any suitable intermediate. Resolution of the final product, an intermediate or a starting material may be effected by any suitable method known in the art. See, for example, Stereochemistry of Carbon Compounds by E. L. Eliel (Mcgraw Hill, 1962) and Tables of Resolving Agents by S. H. Wilen. Additionally, in situations where tautomers of the compounds of formula (I) are possible, the present invention is intended to include all tautomeric forms of the compounds
The specialist in the art of organic chemistry will appreciate that many organic compounds can form complexes with solvents in which they are reacted or from which they are precipitated or crystallized. These complexes are known as “solvates”. For example, a complex with water is known as a “hydrate”. Solvates of the compound of formula (I) are within the scope of the present invention.
It will also be appreciated by the specialist in organic chemistry that many organic compounds can exist in more than one crystalline form. For example, crystalline form may vary from solvate to solvate. Thus, all crystalline forms of the compounds of the invention or the pharmaceutically acceptable solvates thereof are within the scope of the present invention.
It will also be appreciated by the person skilled in the art that as well as being used in the parent compound form the compounds of the present invention may also be utilized in the form of pharmaceutically acceptable salts or solvates thereof. The pharmaceutically acceptable salts of the compounds of the invention include conventional salts formed from pharmaceutically acceptable inorganic or organic acids or bases as well as quaternary ammonium salts. More specific examples of suitable acid salts include hydrochloric, hydrobromic, sulfuric, phosphoric, nitric, perchloric, fumaric, acetic, propionic, succinic, glycolic, formic, lactic, maleic, tartaric, citric, palmoic, malonic, hydroxymaleic, phenylacetic, glutamic, benzoic, salicylic, fumaric, toluenesulfonic, methanesulfonic, naphthalene-2-sulfonic, benzenesulfonic hydroxynaphthoic, hydroiodic, malic, steroic, tannic etc. Other acids such as oxalic, while not in themselves pharmaceutically acceptable, may be useful in the preparation of salts useful as intermediates in obtaining the compounds of the present invention and their pharmaceutically acceptable salts. More specific examples of suitable basic salts include sodium, lithium, potassium, magnesium, aluminium, calcium, zinc, N,N′-dibenzylethylenediamine, chloroprocaine, choline, diethanolamine, ethylenediamine, N-methylglucamine and procaine salts. References hereinafter to a compound according to the invention include both compounds of formula (I) and their pharmaceutically acceptable salts and solvates.
For example, preferred salt forms include:
4,4′ dithiobis (sodium 3-aminobutane-1-sulfonate) bis chlorohydrate;
4,4′ dithiobis (2,2dimethypropyl)-3-aminobutane-1-sulfonate), bis trifluoroacetate.
The compounds of the invention and their pharmaceutically acceptable derivatives are conveniently administered in the form of pharmaceutical compositions. Such compositions may conveniently be presented for use in conventional manner in admixture with one or more physiologically acceptable carriers or excipients. The carrier(s) must be “acceptable” in the sense of being compatible with the other ingredients of the formulation and not deleterious to the subject receiving them.
While it is possible that compounds of the present invention may be therapeutically administered as the raw chemical, it is preferable to present the active ingredient as a pharmaceutical formulation.
Accordingly, the present invention further provides for a pharmaceutical formulation comprising a compound of the present invention or a pharmaceutically acceptable salt or solvate thereof in association with one or more pharmaceutically acceptable carriers and, optionally, other therapeutic and/or prophylactic ingredients.
The formulations include those suitable for oral, parenteral (including subcutaneous e.g. by injection or by depot tablet, intradermal, intrathecal, intramuscular e.g. by depot and intravenous), rectal and topical (including dermal, buccal and sublingual) or in a form suitable for administration by inhalation or insufflation, although the most suitable route may depend upon for example the condition and disorder of the recipient. The formulations may conveniently be presented in unit dosage form and may be prepared by any of the methods well known in the art of pharmacy. All methods include the step of associating the compounds (“active ingredients”) with the carrier which constitutes one or more accessory ingredients. In general the formulations are prepared by uniformly and intimately associating the active ingredient with liquid carriers or finely divided solid carriers or both and then, if necessary, shaping the product into the desired formulation.
Formulations suitable for oral administration may be presented as discrete units such as capsules, cachets or tablets (e.g. chewable tablets in particular for paediatric administration) each containing a predetermined amount of the active ingredient; as a powder or granules; as a solution or a suspension in an aqueous liquid or a non-aqueous liquid; or as an oil-in-water liquid emulsion or a water-in-oil liquid emulsion. The active ingredient may also be presented as a bolus, electuary or paste.
A tablet may be made by compression or moulding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine the active ingredient in a free-flowing form such as a powder or granules, optionally mixed with a other conventional excipients such as binding agents, (for example, syrup, gum arabic, gelatin, sorbitol, tragacanth, mucilage of starch, polyvinylpyrrolidone or hydroxymethyl cellulose), fillers (for example, lactose, sucrose, microcrystalline cellulose, maize-starch, calcium phosphate or sorbitol), lubricants (for example, magnesium stearate, stearic acid, talc, polyethylene glycol or silica), disintegrants (for example, potato starch or sodium starch glycolate) or wetting agents, such as sodium lauryl sulfate. Moulded tablets may be made by moulding in a suitable machine a mixture of the powdered compound moistened with an inert liquid diluent. The tablets may optionally be coated or scored and may be formulated so as to provide slow or controlled release of the active ingredient therein. The tablets may be coated according to methods well-known in the art.
Alternatively, the compounds of the present invention may be incorporated into oral liquid preparations such as aqueous or oily suspensions, solutions, emulsions, and such as syrups or elixirs, for example. Moreover, formulations containing these compounds may be presented as a dry product for constitution with water or other suitable vehicle before use. Such liquid preparations may contain conventional additives such as suspending agents such as sorbitol syrup, methyl cellulose, glucose/sugar syrup, gelatin, hydroxyethylcellulose, carboxymethyl cellulose, aluminum stearate gel or hydrogenated edible fats; emulsifying agents such as lecithin, sorbitan mono-oleate or gum arabic; non-aqueous vehicles (which may include edible oils) such as almond oil, fractionated coconut oil, oily esters, propylene glycol or ethyl alcohol; and preservatives such as methyl or propyl p-hydroxybenzoates or sorbic acid. These preparations may also be formulated as suppositories, e.g., containing conventional suppository excipients such as cocoa butter or other glycerides.
Formulations for parenteral administration include aqueous and non-aqueous sterile injection solutions which may contain anti-oxidants, buffers, bacteriostats and solutes which render the formulation isotonic with the blood of the intended recipient; and aqueous and non-aqueous sterile suspensions which may include suspending agents and thickening agents. The formulations may be presented in unit-dose or multi-dose containers, for example sealed ampoules and vials, and may be stored in a freeze-dried (lyophilised) condition requiring only the addition of a sterile liquid carrier, for example, water-for-injection, immediately prior to use. Extemporaneous injection solutions and suspensions may be prepared from sterile powders, granules and tablets of the kind previously described.
Formulations for rectal administration may be presented as a suppository with the usual carriers such as cocoa butter, hard fat or polyethylene glycol.
Formulations for topical administration in the mouth, for example buccally or sublingually, include lozenges comprising the active ingredient in a flavoured excipient such as sucrose and gum arabic or tragacanth, and pastilles comprising the active ingredient in an excipient such as gelatin and glycerin or sucrose and gum arabic.
For topical administration to the epidermis, the compounds may be formulated as creams, gels, ointments or lotions or as a transdermal patch.
The compounds may also be formulated as depot preparations. These long acting formulations may be administered by implantation (for example subcutaneously or intramuscularly) or by intramuscular injection. Thus, for example, the compounds may be formulated with suitable polymeric or hydrophobic materials (for example as an emulsion in an acceptable oil) or ion exchange resins, or as sparingly soluble derivatives, for example, as a sparingly soluble salt.
For intranasal administration the compounds of the present invention may be used, for example as a liquid spray, as a powder or in the form of drops.
For administration by inhalation the compounds according to the present invention are conveniently delivered in the form of an aerosol spray presentation from a pressurised container or a nebuliser, with the use of a suitable propellant, e.g. 1,1,1,2-trifluoroethane (HFA 134A) and 1,1,1,2,3,3,3, -heptafluoropropane (HFA 227), carbon dioxide or other suitable gas. In the case of a pressurised aerosol the exact dosage may be determined by providing a valve adapted to deliver a metered amount. Capsules and cartridges of e.g. gelatin for use in an inhaler or insufflator may be formulated so as to contain a powder mix of a compound of the present invention and a suitable powder excipient such as lactose or starch.
In addition to the ingredients particularly mentioned above, the formulations may include other agents conventional in the art having regard to the type of formulation in question, for example those suitable for oral administration may include flavouring agents.
It will be appreciated by the person skilled in the art that reference herein to treatment extends to prophylaxis as well as the treatment of established diseases or symptoms. Moreover, it will be appreciated that the amount of a compound of the present invention required for use in treatment will vary with the nature of the condition being treated and the age and the condition of the patient and will be ultimately at the discretion of the attendant physician or veterinarian. In general, however, doses employed for adult human treatment will typically be in the range of 0.02–5000 mg per day, preferably 1–1500 mg per day. The desired dose may conveniently be presented in a single dose or as divided doses administered at appropriate intervals, for example as two, three, four or more sub-doses per day. The formulations according to the present invention may contain between 0.1–99% of the active ingredient, conveniently from 30–95% for tablets and capsules and 3–50% for liquid preparations.
The compound of the present invention for use in the present invention may be used in association with one or more other therapeutic agents for example, beta-adrenergic receptor antagonists, calcium channel blocking agents, thiazide diuretics, angiotensin receptor antagonists and angiotensin converting enzyme inhibitors. The present invention thus provides in a further aspect the use of a combination comprising a compound of formula (I) with a further therapeutic agent in the treatment of arterial hypertension.
When the compounds of the present invention are used in association with other therapeutic agents, the compounds may be administered either sequentially or simultaneously by any suitable route.
The associations referred to above may suitably be presented for use in the form of a pharmaceutical formulation and thus pharmaceutical formulations comprising a association as defined above optimally together with a pharmaceutically acceptable carrier or excipient comprise a further aspect of the present invention. The individual components of such associations may be administered either sequentially or simultaneously in separate or combined pharmaceutical formulations.
When combined in the same formulation it will be appreciated that the two compounds must be stable and compatible with each other and the other components of the formulation and may be formulated for administration. When formulated separately they may be provided in any suitable formulation, suitably in a manner known for such compounds in the art.
When a compound of the present invention is used in association with a second therapeutic agent active against the same disease, the dose of each compound may differ from that administered when the compound is used alone. Appropriate doses will be readily determined by the person skilled in the art.
The compounds of the present invention may be prepared by way of the following Examples which should not be construed as constituting a limitation thereto.
EXAMPLE 1
4,4′ dithiobis (sodium 3-aminobutane-1-sulfonate) bis chlorohydrate
Step 1: Synthesis of the Chlorohydrate of 2-amino-4-chloro-1-ethoxycarbonyl propane
A solution of 20 g L-homoserine in 50 mL of absolute ethanol was cooled to 0° C. and 121 mL (10 eq) SOCl 2 was added dropwise. The mixture was warmed to room temperature and then heated at reflux for 8 h. The solution was evaporated in vacuo and the residue was treated with Et 2 O. The precipitate was filtered and washed three times with Et 2 O. White solid: 31.2 g (92%). Rf (CH 2 Cl 2 /MeOH/AcOH: 7/3/0.5) 0.59.
Step 2: Synthesis of Ethyl 2-t-butoxycarbonylamino-4-chlorobutanoate.
The preceding compound (31.2 g), dissolved in 80 ml DMF was cooled to −10° C., then a solution of (Boc) 2 O (37.1 g) in 80 mL DMF and 23.8 ml Et 3 N was added. The mixture was stirred at room temperature overnight. The solution was evaporated in vacuo and the residue partitioned between H 2 O and Et 2 O. The organic layer was washed, dried over Na 2 SO 4 , filtered and evaporated in vacuo. Beige solid, 40.7 g (99%). Rf (EtOAc/nHex: 3/1) 0.66.
Step 3: Synthesis of Sodium, 3-tert-butoxycarbonylamino-3-ethoxycarbonyl-propane-1 sulfonate
The preceding compound (10.8 g) was dissolved in a mixture of 150 ml dioxane/150 ml H 2 O and 6.1 g Nal and 25.6 g Na 2 SO 3 were added. The mixture was heated at reflux for 15 hours, then, evaporated in vacuo. The residue was dissolved in EtOH (250 ml). The precipitate was eliminated and the filtrate was evaporated in vacuo. A white powder was obtained; 12 g (89%). Rf (CH 2 Cl 2 /MeOH: 8/2) 0.18.
Step 4: Synthesis of Sodium 3-tert-butoxycarbonylamino-4-hydroxy-butane-1-sulfonate
The preceding ester (10 g) was dissolved in 125 ml absolute EtOH and 125 ml anhydrous THF, then 5.1 g of anhydrous LiCl and 4.9 g NaBH 4 were added. The mixture was stirred for 17 h at room temperature. Acetic acid (60 ml) was added at 0° C. and the mixture was evaporated in vacuo. The crude product was purified by chromatography on silica gel using EtOAc/MeOH: 8/2 as eluent: White solid, 7.16 g (82%). Rf (EtOAc/MeOH: 7/3) 0.32.
Step 5: Synthesis of Sodium 4-acetylsulfanyl-3-tert-butoxycarbonylamino-butane-1-sulfonate.
A solution of 13 g triphenylphosphine in anhydrous THF (170 ml) was cooled at 0° C. and 10 ml of diisopropylazodicarboxylate were added. The solution was stirred for 45 min at the same temperature. A solution of the preceding alcohol (7 g) in THF (125 ml)+DMF (40 ml) was added, followed 15 min later by 4 ml CH 3 COSH and the mixture was stirred overnight at room temperature. After evaporation in vacuo, the residue was dissolved in EtOAc and washed with NaHCO 3 (10%), H 2 O, brine and dried over Na 2 SO 4 . After evaporation, n.Hex/EtOAc was added and the precipitate eliminated. The filtrate was evaporated and the residue purified by chromatography on silica gel using nHex/EtOAc: 4/1 as eluent. Oily product 8.4 g (80%) Rf(CH 2 Cl 2 //MeOH: 8/2) 0.20.
Step 6: Synthesis of 4,4′ dithiobis (sodium3-aminobutane-1-sulfonate) bis chlorhydrate.
350 mg of the preceding compound were heated at reflux with 15 ml HCl 6N for 3 h. The solution was evaporated in vacuo and the residue dissolved in EtOH/H 2 O: 1/4 and treated with a solution of iodine until a persistent yellow color was observed. The solution was evaporated and the final compound precipitated with Et 2 O. White solid highly hygroscopic 200 mg (80%).
Alternatively the parent compound can be prepared from the free thiol as follows:
7.0 g of EC33 are dissolved in 100 ml of methanol with stirring. A solution of 7.32 g iodine in 100 ml of methanol is added dropwise until decolouration ceases. The resulting precipitate is filtered and washed with 20 ml volumes of methanol until the liquid from washing is colourless. The precipitate is washed with ether and dried under reduced pressure to give 4.1 g of a white solid.
[α] D 20 =+194.5 water, c=1.33;
Calculated % C 26.07, H 5.47, N 7.60, O 26.05, S 34.81
Found % C 25.61, H 5.60, N 7.39, O 25.99, S 33.50;
NMR (D 2 O, 400 MHz): δ 2.1 (m, 2H, CH 2 β); 2.85 (dd, 1H, CH 2 γ); 2.95 (t, 2H, CH 2 β′); 3.10 (dd, 1H, CH 2 γ); 3.70 (m, 1H, CH α).
Rf=0.26 in isopropanol/water/acetic acid: 8/2/1, v/v/v
EXAMPLE 2
4,4′ dithiobis (2,2dimethypropyl)-3-aminobutane-1-sulfonate), bis trifluoroacetate
Step 1: Benzyloxycarbonyl-L-homocystine
L-homocystine (5 g) was dissolved in a mixture (80 ml) of dioxane/H 2 O. At 0° C. and under stirring, 1.52 g (2.1 eq) of NaOH and a solution of 7.8 g (2.4 eq) of benzylchloroformate in 40 ml dioxane were added. The pH was maintained at 9 by addition of a solution of NaOH 1M. After stirring for 2.30 h at room temperature, 100 ml H 2 O were added and the white precipitate was extracted by Et20 (2×50 ml). The aqueous phase was acidified to pH 1 and the precipitate was extracted by EtOAc (4×80 ml). The organic phase was washed, dried over Na 2 SO 4 , filtered and evaporated in vacuo. White solid 10.2 g (100%).
Step 2: Ethyl benzyloxycarbonyl-L-homocystinate.
Z-L-homocystine (10 g) was dissolved in 150 ml absolute EtOH. A solution of 1 ml SOCl 2 in CH 2 Cl 2 (17 ml) was added at 0° C. and the mixture was heated under reflux for 4 h. The mixture was evaporated in vacuo and the residue dissolved in CH 2 Cl 2 . The organic phase was washed, dried over Na 2 SO 4 , filtered and evaporated in vacuo. Yellow paste, 9 g (80%) Rf (EtOAc/cHex=1/1) 0.59
Step 3: Ethyl-2-benzyloxycarbonylamino-4-(2,2-dimethypropyl)-1-sulfonyl butanoate.
The preceding compound (9 g) was dissolved in a mixture CCl 4 /EtOH and Cl 2 gas was bubbled through the mixture for 45 min. After evaporation in vacuo, a yellow paste was obtained which was dissolved in 200 ml CH 2 Cl 2 . Then, 3.48 g neopentyl alcohol and 5.85 ml Et 3 N were added. The mixture was stirred overnight, evaporated in vacuo and purified by chromatography on silica gel, using EtOAc/cHex: 1/4 as eluent. 11.2 g of a white solid was obtained (90%). Rf (EtOAc/cHex: 1/4) 0.16.
Step 4: Ethyl-2-tert-butoxycarbonylamino-4-(2,2-dimethypropyl)-1-sulfonyl butanoate.
The preceding compound (5.2 g) was dissolved in 30 ml EtOAc and a solution of 4.07 g of Boc 2 O in 30 ml EtOAc and 400 mg of Pd/C 10% catalyst were added. The mixture was stirred under 250 kPa H 2 at 40° C. for 48 h. The mixture was filtered on Celite and the organic phase was evaporated in vacuo (100%) Rf (EtOAc/cHex: 1/4) 0.79.
Step 5: (2,2-dimethypropyl)-3-tert-butoxycarbonylamino-4-hydroxy-butane-1-sulfonate.
The preceding compound (2.44 g) was dissolved in 120 ml of 50/50 THF/EtOH. The solution was cooled to −10° C. under inert atmosphere and 1.09 g (4 eq) of LiCl and 0.97 g (4 eq) of NaBH 4 were added. After 15 min at −10° C., the mixture was stirred at room temperature for 60 h. Then 20 ml of AcOH were added and the mixture was evaporated in vacuo. The residue was dissolved in 400 ml EtOAc, washed with water, brine, and dried over Na 2 SO 4 . The crude product was purified by chromatography on silica gel using EtOAc/MeOH/cHex: 1/1/4 as eluent (Rf 0.20) 2.1 g (99%).
Step 6: (2,2-dimethypropyl)-3-tert-butyloxycarbonylamino-4-acetylsulfanyl-butane-1-sulfonate.
The preceding compound (0.965 g) in 10 ml CHCl 3 was cooled to −10° C. and 1.07 ml Et 3 N and 0.44 ml CH 3 SO 2 Cl in 4 ml CHCl 3 were successively added. The mixture was stirred at room temperature for 1.5 h. Then 40 ml CHCl 3 were added and the organic phase was washed at 0° C. with a solution of NaHCO 3 10%, H 2 O, HCl 1 N, H 2 O, brine and dried over Na 2 SO 4 . After filtration and evaporation, the crude product (Rf (EtOAc/AcOH/cHex: 1/1/4)=0.41) was dissolved in 15 ml DMF and at −10° C., 0.65 g CH 3 COSK was added. The mixture was stirred for two days at room temperature. The solvent was evaporated in vacuo and an orange residue was obtained.
Chromatography on silica gel; eluent EtOAc/cHex: 1/4 (Rf=0.15); white solid 0.64 g (57%).
Step 7: 4,4′ dithiobis ((2,2-dimethypropyl)-3-tert-butyloxycarbonylamino-butane-1-sulfonate).
The preceding compound (0.25 g) was dissolved in EtOH/THF: 2/1. Then 60 mg NaOH, dissolved in 1 ml H 2 O were added. The mixture was stirred under O 2 bubbling for 12 h. After evaporation in vacuo, the residue was dissolved in 40 ml H 2 O/40 ml EtOAc and was acidified to pH 1. The organic layer was isolated, washed, dried over Na 2 SO 4 , filtered and evaporated in vacuo. White solid: 0.178 g (80%). Rf (EtOAc/MeOH/cHex: 1/1/4) 0.28.
Step 8: 4,4′ dithiobis ((2,2-dimethypropyl)-3-aminobutane-1-sulfonate), bis trifluoroacetate.
The preceding disulfide (0.17 g) was dissolved in 6 ml CH 2 Cl 2 and 6 ml CF 3 CO 2 H were added. The mixture was stirred at room temperature for 2 h and evaporated in vacuo. The residue was washed with Et 2 O. White solid 0.17 g (100%) Rf(CH 2 Cl 2 /MeOH: 7/3) 0.47.
[α] D 19 =+24.8, c=0.995 in EtOH 95%
NMR 1 H (DMSO): δ 0.90 (s, 9H, tBu); 2.1 (m, 2H, CH 2 β); 2.70–2.75 (m, 1H, CH 2 β′); 2.80–2.90 (dd, 1H, CH 2 β′); 3.00–3.10 (dd, 1H, CH 2 α); 3.50 (m, 3H, CH α and CH 2 γ); 3.90 (s, 2H, CH 2 γ′), 8.1 (s, 2H, NH 3 + )
This compound can be converted to the parent molecule or other suitable salts by methods known in the art. For example, to convert to the parent molecule 40 mg of RB 151 are dissolved in 2 ml water. 5 ml of ether are added and then, dropwise, 0.12 ml of aqueous sodium hydroxide solution (1M). The aqueous phase becomes milky and then clarifies rapidly. The mixture is stirred for 30 minutes and the organic phase is separated. The aqueous phase is washed three times with 5 ml of ether. The combined organic phases are dried over sodium sulphate then concentrated under vacuum to give an amorphous powder with a 98% yield.
[α] D 19 =+42.3 c=0.992 in EtOH 95%
NMR 1 H (DMSO): δ 0.90 (s, 9H, tBu); 1.65–1.75 (m, 1H, CH 2 β; 1.90–2.00 (m, 1H, CH 2 β); 2.70–2.75 (m, 1H, CH 2 β′); 2.80–2.90 (m, 1H, CH 2 β′); 3.00–3.10 (m, 1H, CH 2 α); 3.35–3.50 (m, 2H, CH 2 γ); 3.80 (s, 2H, CH 2 γ′)
EXAMPLE OF BIOLOGICAL ACTIVITY
Effect on Blood Pressure in Rats
Deoxycorticosterone acetate (DOCA)-salt hypertensive rats were obtained according to Pham, I. et al (1993) J. Pharmacol. Exp. Ther. 265, 1339–1347 with the following modifications: under pentobarbital anaesthesia, unilateral nephrectomy was performed in male Wistar Kyoto rats (300 g) and a pellet of 50 mg of DOCA was implanted s.c. After surgery, the rats were fed on standard rat chow and the drinking water was supplemented with 0.9% NaCl and 0.2% KCl. Hypertension developed 3 weeks after surgery.
To record arterial blood pressure, DOCA-salt rats were anaesthetized with pentobarbital sodium (50 mg/kg i.p., Sentravet laboratory, Plancoët, France), a femoral artery catheter (PE 50 ) filled with heparinized saline (250 U/ml) was inserted, then brought under the skin and emerged at the nape of the neck. A flexible metal spring was attached to the skull and neck of the rat and connected to dual channel swivels mounted directly above the cage. This arrangement allowed the rat free movement inside the cage. Each rat was then given an intramuscular injection of 0.1 ml of penicillin-streptomycin (50 000 UI/ml, Boehringer Mannheim, GmbH-Germany) and allowed to recover for at least 24 h prior to the experiment. Mean arterial BP was continuously recorded throughout each experiment using a COBE CDX III pressure transducer (Phymep, Paris, France) connected to the MacLab system (Phymep, Paris, France) composed of a MacLab technology unit and Chart software running on a Macintosh computer.
The compound of Example 1 was administered to the rats by oral gavage in water at 15 mg/kg. As shown in FIG. 1 mean arterial blood pressure was decreased by 3680 Pa, 4.5 hours after administration.
The application of which this description and the claims are a part may be used as basis for priority with respect to any later application. The claims of such a later application may be directed to any new feature or association of new features described in the present document. Its claims may be in the form of product, composition, process or use claims and may comprise, by way of non-limiting example, one or more of the following claims.
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The invention relates to the bis-hydrochloride of 4,4′-dithiobis-(3-aminobutane-1-sodium sulphonate) and the bis-trifluoracetate of 4,4′-dithiobis-(3-aminobutane-1-sulphonate of 2,2-dimethylpropyl). The invention also relates to a pharmaceutical composition comprising one of said compounds and to the use of one of said compounds for the production of a medicament. The invention is suitable for use in a treatment method for hypertension and indirectly- or directly-linked illnesses.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to fiber optic communication systems, and particularly to the method of switchably or re-configurably adding/dropping the specific single wavelength channel to/from the multiplex of input wavelengths, and the associated device using the same.
[0003] 2. The Related Art
[0004] The optical ADD/DROP multiplexer is mainly used to add and drop one or more wavelength channels at a network node in a fiber optic communication system. With the increasing demands on the fiber optic communication systems, the optical network has been widely used in smaller systems, such as the local telephone or data networks, after proving its success on long haul point to point networks. It is noted that in the smaller system, communication signals are usually transmitted over a limited geographic area to various nodes into the network. A particular node can be re-configured to drop one or more channels from multiple channels, and/or add one or more channels with new information to the transmitted signals for transmission to other nodes in the network.
[0005] Current optical ADD/DROP devices are essentially passive components and lack availability of switching and power control thereof. To achieve the re-configuration capability, a 2×2 switch or two 1×2 switches are used to control the ADD and DROP port(s). This method and the corresponding device can be found in all the suppliers in the market. However, all the popularly used methods have disadvantages of uneven power distribution for the through and dropped channels.
[0006] Therefore, an object of the invention is to provide a new method for switchably or re-configurably add/drop channels to/from the transmitted signal of multiplex wavelength channels, and the corresponding device thereof. Therefore, one can use the device to specifically add and/or drop the selected channels, or allow all the channels to pass through with minimum insertion loss thereof.
SUMMARY OF THE INVENTION
[0007] According to an aspect of the invention, a switchable optical ADD/DROP device includes first and second same R-channel modules opposite to each other, two collimators performing in-and-out functions respectively, and a removable prism to commonly define switchable optical path. The R-channel module includes a GRIN lens with a DWDM filter. The multiplexed signal enters the first R-channel module with the specific wavelength channel passing through the filter and along a firstpath directing toward the second R-channel from the one side with the filter thereon while the rest of wavelength channels being reflected to a second path which enters the second R-channel from the other side opposite to the corresponding filter. The prism is adapted to be in a first position where the prism blocks the first path and guide the filtered/dropped specific wavelength channel toward the DROP collimator while simultaneously guide another added specific wavelength channel, if any, from the ADD collimator toward the filter side of the second collimator for entering the second collimator. Under this condition, the added wavelength channel will join the rest of wavelength channels from the second path to leave the second collimator via the OUT port. Alternatively, when the prism is moved to a second position without blocking the first path, the filter wavelength channel will enter the second collimator from the filter side, and join the rest of wavelength channels from the second path, leaving the second collimator via the OUT port. Therefore, the device essentially integrates the switching function and the optical ADD/DROP function together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a diagram to show a switchable optical ADD/DROP device according to the invention.
[0009] [0009]FIG. 2 is a diagram to show the R-channel used in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] References will now be in detail to the preferred embodiments of the invention. While the present invention has been described in with reference to the specific embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications to the present invention can be made to the preferred embodiments by those skilled in the art without departing from the true spirit and scope of the invention as defined by appended claims.
[0011] It will be noted here that for a better understanding, most of like components are designated by like reference numerals throughout the various figures in the embodiments. Attention is directed to FIGS. 1 and 2 wherein a switchable optical ADD/DROP device 1 generally comprises the R-channel assembly 10 , the collimator assembly 12 and the switchable prism 60 . The R-channel assembly 10 includes a first R-channel 20 and a second R-channel 30 spatially opposite to each other. The first R-channel 20 includes a GRIN lens 22 and a DWDM filter 24 . A first optical fiber 26 enters the IN port 100 of the first R-channel 20 , and a first path 70 is defined on the filter side (the near end) of the R-channel 20 toward the second R-channel 30 and a second path 80 is defined on the same side (the far end) of the IN port 100 .
[0012] Similarly, the second R-channel 30 includes a GRIN lens 32 and a DWDM filter 34 which is same with the DWDM filter 24 . A second optical fiber 36 is connected to the OUT port 200 of the second R-channel 30 . The first path 70 enters the second R-channel 30 through the filter 34 , and the second path 80 enters the second R-channel 30 on the same side of the OUT port 200 .
[0013] The collimator 12 includes a first collimator 40 and an opposite second collimator 50 being disposed around the first R-channel 20 and the second R-channel 30 , wherein the first collimator 40 , which is generally located on the same side of the first R-channel 20 , defines an ADD port 42 , and the second collimator 50 , which is generally located on the same side of the second R-channel 30 , defines a DROP port 52 .
[0014] A switchable prism 60 is removeably positioned among the first R-channel 20 , the second R-channel 30 , the first collimator 40 , and the second collimator 50 .
[0015] Therefore, in the condition of removal of the switchable prism 60 among the R-channel assembly 10 and the collimator assembly 12 , a multiplexed signal enters the first R-channel 20 from the IN port 100 with a specific wavelength channel penetrates the filter 24 to the first path 70 , while the rest of the wavelength channels are reflected to the second path 80 and directed to the second R-channel 30 around the side of the OUT port 200 . The filtered specific wavelength channel along the first path 70 further penetrates the filter 34 of the second R-channel 30 , entering the second R-channel 30 and further joining the rest of the wavelength channels from the second path 80 , then leaving the second R-channel 30 via the OUT port 200 . It is noted that under this situation the whole assembly functions as a transmission device without any change.
[0016] Differently, in the condition of positioning/existence of the switchable prism 60 , the filtered specific wavelength channel from the first R-channel 20 will hit the switchable prism 60 and be directed, along the dotted line path 90 , to the second collimator 50 and dropped from the DROP port 52 . Simultaneously, the same wavelength channel with new information signal may be added through the ADD port 40 of the first collimator 40 and hit the switchable prism 60 and be guided, along the dotted line path 92 , to the second R-channel 30 . The newly added wavelength channel penetrates the second filter 34 and joins the rest of the wavelength channels from the second path 80 and leaves the second R-channel 30 via the OUT port 200 . Under this situation, the whole assembly functions as a switchable ADD/DROP device.
[0017] In brief, if the prism 60 is present, the device 1 drops a single wavelength (λ drop ) to the DROP port 52 through the prism 60 . In the mean time, the same wavelength (λ add ) can be added through the ADD port 80 . In opposite if the prism 60 is removed, the dropped wavelength passes the second identical DWDM filter 34 and combined with the through channels from the second path 80 . In this case, the device 1 does not affect the spectra of the channels. Therefore, no wavelength is dropped or added. This is the so-called by pass mode.
[0018] The features and the advantages of the invention are as follows.
[0019] (1) The invention achieves the low insertion loss, the uniform bypass mode, even power distribution, the compact size, and the lower cost.
[0020] (2) The invention integrates the switch and optical add/drop function in a single piece. Understandably, the prism used in the invention is one feasible embodiment, and thus other means having the switching function may be applied thereto substitutionally.
[0021] While the present invention has been described with reference to specific embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications to the present invention can be made to the preferred embodiments by those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims.
[0022] While the present invention has been described with reference to specific embodiments, the description is illustrative of the invention and is not to be construed as limiting the invention. Various modifications to the present invention can be made to the preferred embodiments by those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims.
[0023] Therefore, person of ordinary skill in this field are to understand that all such equivalent structures are to be included in the scope of the following claims.
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A switchable optical add/drop device ( 1 ) includes a first R-channel ( 20 ) and a second R-channel ( 30 ) opposite to each other. A first path ( 70 ) and second path ( 80 ) are respectively defined between two near ends and two far ends of the first R-channel ( 20 ) and the second R-channel ( 30 ). A first collimator ( 40 ) with an ADD port ( 42 ) and a second collimator ( 52 ) with a DROP port ( 52 ) are disposed about said first R-channel ( 2 ) and said second R-channel ( 30 ). A prism ( 60 ) is removable disposed among the R-channels ( 20, 30 ) and the collimators ( 40, 50 ) for switchably adding/dropping the specific wavelength channel.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to European application No. EP16177271.0 having a filing date of Jun. 30, 2016, the entire contents of which are hereby incorporated by reference.
FIELD OF TECHNOLOGY
[0002] The following describes a method of handling a pitch bearing unit of a wind turbine rotor blade, a pitch bearing unit handling arrangement; and a wind turbine.
BACKGROUND
[0003] Wind turbines with several megawatts power output are generally very tall structures, since long rotor blades are required in order to achieve such power output levels. In order to extract the maximum amount of energy from the wind, the rotor blades of a wind turbine can be controlled by a pitch system so that each blade can be optimally pitched into the wind. To this end, the root end of a rotor blade is usually circular, so that it can be mounted to a circular pitch bearing. There are various ways of realizing a pitch bearing for a rotor blade. For example, a toothed ring may be mounted at the inside or outside of the rotor blade at the inner root end. The pinion gear of a pitch drive motor can engage with the toothed wheel, so that the drive motor can be actuated to turn the blade in the desired direction and by the desired amount. Alternatively, the pitch bearing can be realised as a roller bearing, a planetary bearing, etc.
[0004] The pitch bearing can be supplied as a self-contained unit. For example, the pitch bearing can be supplied as an annular or disc-shaped component that is realised to be mounted between the hub and the blade. For example, such a bearing unit can be secured to the hub by one or more annular arrangements of bolts extending from the bearing unit into the body of the hub and extending into the blade root end. Suitable connections can be made to one or more pitch drive motors, which may be arranged in the hub, to actuate the pitch bearing to pitch the blade by the desired degree about its longitudinal axis.
[0005] Any kind of pitch bearing is subject to wear and tear, and may eventually require maintenance or replacement. However, it is not easy to access a pitch bearing when installed in a large wind turbine, especially in the case of an offshore wind turbine. In a conventional approach, a large crane is brought into position at the base of the wind turbine tower, and the hub is turned to that the rotor blade with the defective bearing points downwards. The blade is dismounted and lowered to ground by the crane. The pitch bearing unit is then dismounted and lowered to ground by the crane. The crane then lifts a replacement bearing unit to hub height, and the bearing unit is mounted to the hub. Finally, the crane lifts the rotor blade again, so that the blade can be mounted to the bearing unit.
[0006] A “large crane” is to be understood as a crane that can reach to hub height of a wind turbine. An example of such a crane might be the type of crane used to install a wind turbine. For an offshore wind turbine, a large installation vessel may be necessary to support such a crane during an installation or maintenance manoeuvre. Crane time is expensive for this type of crane, so that repair and maintenance procedures that require their use are generally very costly.
SUMMARY
[0007] An aspect relates to providing a more economical way of removing the pitch bearing unit of a wind turbine rotor blade in a maintenance procedure.
[0008] According to embodiments of the invention, the method of handling the pitch bearing unit of a rotor blade mounted to the hub of a wind turbine comprises the steps of providing an extension assembly at the interface between the rotor blade and the hub; moving the rotor blade outward from the hub by means of the extension assembly to open a gap large enough to facilitate removal of a pitch bearing unit while maintaining a connection between the rotor blade and the hub; and removing the pitch bearing unit through the gap. The steps of the inventive method may be carried out in reverse, since the gap is large enough to facilitate insertion of a pitch bearing unit.
[0009] An advantage of the bearing unit handling method according to embodiments of the invention is that there is no need to use a large crane of the type described above. A defective bearing unit can therefore be removed and replaced by a replacement bearing unit in a cost-effective manner. In the case of an offshore wind turbine, a significant reduction in costs can be achieved by not having to pay for an installation vessel or a vessel big enough to support a large crane.
[0010] According to embodiments of the invention, the wind turbine rotor blade pitch bearing unit handling arrangement comprises an extension assembly at the interface between a wind turbine hub and a rotor blade, adapted to move the rotor blade outward from the hub to open a gap large enough to accommodate the removal and/or insertion of a pitch bearing unit while maintaining a connection between the rotor blade and the hub.
[0011] An advantage of the bearing unit handling arrangement is that it can be realized with relatively low cost effort. The bearing unit handling arrangement allows replacement of a defective bearing unit without actually having to completely detach the rotor blade from the hub. During the entire handling manoeuvre, the blade remains connected to the hub, and a bearing unit is removed or inserted through the gap.
[0012] According to embodiments of the invention, the wind turbine comprises a number of rotor blades mounted to a hub, a pitch bearing unit for each rotor blade, and such a pitch bearing unit handling arrangement to facilitate the removal and/or insertion of a pitch bearing unit.
[0013] The wind turbine according to embodiments of the invention is equipped with a means to facilitate the performance of maintenance procedures on the bearing unit(s), avoiding the need for an installation crane or other large crane, so that the costs of such manoeuvres can be kept to a favourably low level.
[0014] Particularly advantageous embodiments and features of the invention are given by the dependent claims, as revealed in the following description. Features of different claim categories may be combined as appropriate to give further embodiments not described herein.
[0015] A wind turbine can have one or more rotor blades mounted to a hub to face into the wind, and most wind turbine usually have three rotor blades. In the following, without restricting embodiments of the invention in any way, it may be assumed that wind turbine has three rotor blades mounted to a hub, and that each rotor blade is equipped with a pitch bearing unit and a pitch drive module so that the pitch angle of the blade can be adjusted as required during operation of the wind turbine in order to extract the maximum amount of energy from the wind. As already indicated above, there are various kinds of pitch bearing. In the context of embodiments of the invention, the “pitch bearing unit” may be assumed to be an annular or disc-shaped component of the type described in the introduction, realised for mounting between hub and blade. In the following, the pitch bearing unit may simply be referred to as the “bearing” or the “bearing unit”, and may be assumed to be a self-contained component for mounting between the blade and hub.
[0016] The bearing handling method according to embodiments of the invention allow a pitch bearing unit to be removed from the hub with a favourably low level of effort, and for a replacement pitch bearing unit to be inserted into the hub as required. As indicated above, a large crane such as the type of crane used on an installation vessel or the type of crane used to install a wind turbine is not required, so that the cost of the manoeuvre can be kept favourably low. Since the bearing unit is essentially at hub height when installed, it may be necessary to lower a defective pitch bearing unit from hub height to ground level. To this end, the bearing unit handling arrangement preferably comprises a hoist assembly mounted to the wind turbine, for example at hub height, and realized to lower a removed pitch bearing unit from the hub to ground level. The hoist assembly can of course also be used to raise a replacement pitch bearing unit from ground level to hub height. The hoist assembly can be a relatively small unit which need only be dimensioned to bear the weight of the pitch bearing unit as this is lowered or raised between ground level and hub height. The hoist assembly can be temporarily mounted at the outside of the nacelle or the outside of the hub, whichever is appropriate. After completion of the manoeuvre, the hoist unit can then be dismantled and stowed for future use. For example the hoist unit may be stowed inside the nacelle, and may be used to assist during other maintenance procedures as these become necessary.
[0017] Embodiments of the invention are based on the insight that it is possible for the rotor blade to remain connected in some way to the hub while the bearing unit is being dismounted. Therefore, in a preferred embodiment of the invention, the step of providing the extension assembly comprises inserting a number of extension elements into the root end of the rotor blade, wherein an extension element is realized to facilitate a displacement of the rotor blade in a direction radially outward from the hub while maintaining the connection between blade and hub. An extension element can be a rod or similar component, realised to extend into the body of the blade at the blade root end, preferably in a direction parallel to the blade longitudinal axis, and into the body of the hub. An extension element can also extend through the bearing unit as appropriate. If the extension element is realised as a threaded rod, with complementary threaded bushings in the blade root end and/or the bearing unit and/or the hub, the blade can be displaced radially outward in a favourably straightforward manner simply by turning the threaded rods. This step is preceded by a step of releasing the main mechanical connection between blade and bearing unit, for example by removing an annular arrangement of bolts that otherwise connect the rotor blade to the bearing unit. After releasing the blade from the bearing unit, the blade can be displaced outward from the hub along the extension rods. In other words, even when the bolts that otherwise connect the blade to the bearing unit have been removed, the blade is held in place relative to the hub by means of the extension elements. The extension elements can be inserted into the blade root end prior to beginning a bearing removal procedure. Equally, the extension elements may be permanently installed in the blade root end. Since the extension elements are only needed to hold the blade while in its downward pointing position, the number of extension elements can be significantly lower than the number connecting bolts required to mount a blade to the bearing unit. For example, for a rotor blade with a diameter of 3 m at its root end, eighty or more M36 connecting bolts may be required, whereas only eight extension rods may be sufficient to hold the blade during the initial stages of the bearing exchange manoeuvre.
[0018] A further aspect of the bearing unit handling arrangement according to embodiments of the invention is the provision of a number of holding blocks or fixation brackets that are initially mounted to the hub, and then also mounted to the rotor blade. A fixation bracket can be shaped at one end to match the outer shape of the hub, or an adapter may be placed between the hub and the fixation bracket. The step of mounting a fixation bracket can be performed with the rotor blade pointing upwards, so that a maintenance worker can mount the fixation brackets on the outside of the hub without undue risk. A fixation bracket is constructed to be connected to the hub, and also to the rotor blade, in such a way that the body of the fixation bracket maintains the gap defined by the extension elements between the hub and the blade. For example, an L-shaped fixation bracket can be mounted to the hub using a number of bolts at one end, and can be mounted to the blade root end using a number of bolts at the other end, as will become clear from the diagrams. Any number of fixation brackets may be deployed, depending on their structural form and load-bearing capacity. In a preferred embodiment of the invention, three fixation brackets are deployed, and are mounted to the hub so that an entire bearing unit can pass between them. To this end, the fixation brackets are preferably arranged within one half of the blade root end circumference. For example, with the blade axis of rotation as reference, neighbouring fixation brackets may be arranged to subtend an angle of at most 90°. Once the fixation brackets are in place, the extension elements can be removed, so that the rotor blade is no longer physically connected to the bearing unit and so that a space is created through which the bearing unit can pass.
[0019] Once the blade is securely held by the fixation brackets to maintain the gap created by the extension elements, the bearing unit can be released from the hub, and connected instead to a bearing unit displacement arrangement before being moved through the gap.
[0020] This can be achieved in a number of ways. In a preferred embodiment of the invention, the pitch bearing unit displacement assembly comprises a nacelle pivot mounted to the nacelle, and a pivot arm connected to the pivot and realized to extend into the gap. The pivot arm can be flat enough to be inserted into a space between the bearing unit and the hub, or into the gap between the rotor blade and the bearing unit. The bearing unit can be bolted or otherwise secured to the pivot arm. Once the bearing unit is secured to the pivot arm, the arm can be pivoted so that the bearing unit is removed from between the hub and blade. In one preferred embodiment of the invention, the pivot is mounted at a point underneath the nacelle, and a hoist unit is mounted at a point on top of the nacelle so that the bearing unit can be conveniently connected to the hoist unit, which can then lower the bearing unit to ground level. Here, the term “ground level” should not be construed in a limiting sense, and may also be understood to mean the deck of a vessel in the case of an offshore wind turbine, for example.
[0021] In a further preferred embodiment of the invention, the pitch bearing unit displacement assembly comprises a pivot arranged between the pitch bearing unit and the hub. Such a pivot is preferably arranged close to the outer edge of the bearing unit, so that a rotation of the bearing unit about its pivot has the effect of moving the bearing unit almost completely outside the space between hub and blade. Similarly to the approach described above, a hoist unit mounted to the nacelle or hub can then be used to lower the bearing unit to ground level.
[0022] In a further preferred embodiment of the invention, the pitch bearing unit displacement assembly comprises a number of rail assemblies arranged to slide the pitch bearing unit outward through the gap. A rail assembly may be understood to comprise an essentially horizontal rail extending outward from the hub, arranged to enclose or contain a complementary glider. The rail may be mounted to the bearing unit while the glider is mounted to the hub, or the other way around. One or more such rail elements may be used as required.
[0023] In addition to removing a bearing unit out through the gap, the embodiments described above can of course be used to introduce a replacement pitch bearing unit in through the gap, in which case the sequence of steps is reversed.
BRIEF DESCRIPTION
[0024] Some of the embodiments will be described in detail, with reference to the following figures, wherein like designations denote like members, wherein:
[0025] FIG. 1 shows a first stage of a pitch bearing exchange procedure using an embodiment of the bearing unit handling arrangement, in accordance with embodiments of the present invention;
[0026] FIG. 2 shows a second stage of a pitch bearing exchange procedure using an embodiment of the bearing unit handling arrangement, in accordance with embodiments of the present invention;
[0027] FIG. 3 shows a third stage of a pitch bearing exchange procedure using an embodiment of the bearing unit handling arrangement, in accordance with embodiments of the present invention;
[0028] FIG. 4 shows a further stage during the pitch bearing exchange procedure of FIGS. 1-3 , using a first embodiment of a bearing unit displacement assembly, in accordance with embodiments of the present invention;
[0029] FIG. 5 shows a further stage during the pitch bearing exchange procedure of FIGS. 1-3 , using a first embodiment of a bearing unit displacement assembly, in accordance with embodiments of the present invention;
[0030] FIG. 6 shows a further stage during the pitch bearing exchange procedure of FIGS. 1-3 , using a second embodiment of a bearing unit displacement assembly, in accordance with embodiments of the present invention;
[0031] FIG. 7 shows a further stage during the pitch bearing exchange procedure of FIGS. 1-6 , in accordance with embodiments of the present invention;
[0032] FIG. 8 shows a further stage during the pitch bearing exchange procedure of FIGS. 1-3 , using a third embodiment of a bearing unit displacement assembly, in accordance with embodiments of the present invention;
[0033] FIG. 9 shows the lowering of a bearing unit to ground level during a pitch bearing exchange procedure, in accordance with embodiments of the present invention.
[0034] In the diagrams, like numbers refer to like objects throughout. Objects in the diagrams are not necessarily drawn to scale.
DETAILED DESCRIPTION
[0035] FIGS. 1-3 show stages of a pitch bearing exchange procedure using an embodiment of the bearing unit handling arrangement 2 according to embodiments of the invention. A wind turbine 1 is shown, with three blades 10 mounted to a hub 11 , which in turn is mounted via a rotor shaft to a generator installed inside a nacelle 12 . The nacelle 12 is mounted atop a tower 13 , which may have a height exceeding 80 m, especially in the case of an offshore wind turbine.
[0036] FIG. 1 shows a stage early on in the exchange procedure. A defective bearing unit is to be replaced. Several L-shaped fixation brackets 20 have been mounted to the hub 11 in a previous step during which the blade may have been pointing upwards to facilitate the mounting step. The rotor blade 10 is now pointing downwards, and extension rods 21 have been inserted between the bearing unit 14 and the blade root end 100 . Prior to insertion and turning of the extension rods 21 , there is no gap between pitch bearing 14 and rotor blade root end 100 . However, once the extension rods 21 are in place, any bolts connecting the rotor blade 10 to the bearing unit 14 can be removed (corresponding bushings 141 are indicated in the diagram), and the extension rods 21 can be turned to gradually displace the rotor blade 10 radially outward from the hub 11 in the direction 10 V shown, until a sufficiently large gap G is opened. The gap G is at least as wide as the height of the bearing unit 14 .
[0037] FIG. 2 shows a next stage. Here, the fixation brackets 20 have been turned through 90° so that they can be bolted or otherwise secured to the blade root end 100 , for example by tightening bolts in the bushings that are normally used to secure the blade root end 100 to the bearing unit 14 .
[0038] FIG. 3 shows a next stage, observed from the other side of the nacelle. The diagram shows that the arrangement of three fixation brackets 20 inside one half of the circumference of the blade root end 100 will allow the bearing unit 14 to be removed. The diagram also shows a maintenance worker standing on a platform (not shown) inside the blade root end 100 , where he can easily access the connecting bolts, extension rods 21 , fixation brackets 20 etc. In this diagram, the bearing unit 14 is being disconnected from the hub 11 , as indicated by the space S between hub 11 and bearing unit 14 .
[0039] FIGS. 4-5 show further stages during the pitch bearing exchange procedure of FIGS. 1-3 , using a first embodiment of a bearing unit displacement assembly 22 , 220 . Here, a pivot 22 is permanently installed in the nacelle 12 . For a bearing exchange procedure, a pivot arm 220 is mounted to the nacelle pivot 22 . The pivot arm 220 can rotate about the nacelle pivot 22 in the direction 22 R shown, and can enter the space S between bearing unit 14 and hub 11 , so that a worker (inside the hub) can secure the bearing unit 14 to the pivot arm 22 . Alternatively, the pivot arm 220 can enter the gap G between blade root end 100 and bearing unit 14 , so that a worker inside the blade root end can secure the bearing unit 14 to the pivot arm 22 .
[0040] In FIG. 5 , a hoist unit 25 , for example a small crane 25 , is shown in place on top of the nacelle 12 . This hoist unit 25 can be stowed in the nacelle 12 when not in use. A cable or chain can be secured to the bearing unit 14 , for example by a maintenance worker inside the hub or blade root end. The hoist unit 25 can then lower the defective bearing unit 14 to ground level, where it is detached. If the pivot arm 220 was mounted to the bearing unit 14 from below, the entire pivot arm 220 may be detached from the nacelle pivot 22 and lowered to ground level along with the bearing unit 14 . A replacement bearing unit 14 ′ can then be attached to the hoist unit 25 (and pivot arm 220 , as the case my be) and raised to hub height, where the steps described above are performed in the reverse order to install the replacement bearing unit 14 ′ between hub 11 and rotor blade 10 . After completion of the exchange manoeuvre, any temporary apparatus such as the extension rods, fixation brackets, pivot arm, hoist unit etc. may be stowed in the nacelle 12 for later use, or removed and used in a bearing exchange procedure carried out on another wind turbine. FIG. 6 shows a further stage during the pitch bearing exchange procedure of FIGS. 1-3 , using a second embodiment of a bearing unit displacement assembly. Here, a pivot 23 is installed between the bearing unit 14 and the hub 11 so that the bearing unit 14 can be rotated out of the gap G towards the hoist unit 25 . The remainder of the procedure can be carried out as described above and as shown in FIG. 7 , which shows a bearing unit 14 , 14 ′ being lowered to ground level or raised to hub height by the hoist unit 25 . This diagram also clearly shows the opening formed by the three fixation brackets 20 to allow an entire defective bearing unit 14 to be removed, and an entire replacement bearing unit 14 ′ to be inserted while keeping the blade 10 attached to the hub 11 .
[0041] FIG. 8 shows a further stage during the pitch bearing exchange procedure of FIGS. 1-3 , using a third embodiment of a bearing unit displacement assembly. Here, rail assemblies 24 are mounted between the bearing unit 14 and the hub 11 , so that the bearing unit 14 can slide outwards, essentially horizontally in the direction 24 H shown (a slight upwards tilt of the generator rotational axis may be assumed to exist to avoid tower/blade collisions). In this embodiment, a hoist unit 25 is temporarily mounted on top of the hub 11 , so that it can be connected by cable or wire to the bearing unit 14 in order to lower the bearing unit 14 to ground level.
[0042] FIG. 9 shows the lowering of a bearing unit 14 to “ground level” during a pitch bearing exchange procedure, in this case to a marine vessel 90 near the tower of an offshore wind turbine. A defective bearing 14 at the interface 101 between blade 10 and hub 11 can be replaced with a minimum of cost and effort since a crane, large enough to reach to hub height, is not needed. The procedure can be carried out for one or more of the bearing units 14 .
[0043] Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.
[0044] For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements. The mention of a “unit” or a “module” does not preclude the use of more than one unit or module.
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A method of handling the pitch bearing unit of a rotor blade mounted to the hub of a wind turbine, the method including the steps of providing an extension assembly at the interface between the rotor blade and the hub, moving the rotor blade outward from the hub by means of the extension assembly to open a gap large enough to accommodate the pitch bearing unit while maintaining a connection between the rotor blade and the hub, and removing the pitch bearing unit through the gap.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the treatment of a group of physiological disorders known as complex regional pain syndrome, which is a multi-system, multi-symptom, syndrome usually affecting one or more extremities (but can affect any other part of the body) by the electrical stimulation of the corresponding cluster of nerves and/or ganglia in the sympathetic chain, adjacent to the corresponding vertebrae.
2. Description of the Prior Art
Within the field of neurosurgery, the use of electrical stimulation for the treatment of pathologies, including such disorders as uncontrolled movement, such as Parkinson's disease and essential tremor, as well as chronic pain and eating disorders, has been widely discussed in the literature. It has been recognized that electrical stimulation holds significant advantages over alternative methods of treatment, for example lesioning, inasmuch as successful lesioning destroys all nerve activity. Collateral damage to non-targeted tissues is also a significant risk in lesioning treatments. In many instances, it is, therefore, the preferred effect is to stimulate or reversibly block nervous tissue. Electrical stimulation permits such stimulation of the target neural structures, and equally importantly, it does not require the destruction of the nervous tissue (it is a reversible process, which can literally be shut off or removed at will). In addition, stimulation parameters can be adjusted so that benefits are maximized, and side effects are minimized.
The particular application which the present invention is directed to, is the treatment of complex regional pain syndromes. Complex regional pain syndrome (CRPS) type I, commonly known as reflex sympathetic dystrophy syndrome, or RSDS, was described 25 years ago. Several synonyms have been commonly employed in describing parts or all of this syndrome, including Raynaud's syndrome, vasomotor instability, occupational digital thrombosis, arteriosclerotic obliterative disease, etc. CPRS Type II, on the other hand, also known as causalgia, is a regional pain syndrome that develops after injury to a peripheral nerve, as first described during the Civil War by Dr. W. Mitchell. Spontaneous pain develops in the territory of the affected nerve which may then spread beyond that region. Vasomotor abnormalities and focal edema may occur alone or in combination in both CRPS types I and II. These are a severely disabling group of illness with simultaneous involvement of nerve, skin, muscle, blood vessels, and bones. While there are many symptoms associated with CRPS, the only common denominator is pain. The pain usually appears in one or more extremities, and is described as chronic, burning, and constant in nature. A syndrome of total body pain due to CRPS has been described as well. The remainder of symptoms may or may not occur. These symptoms include swelling, limited motor function which may lead to atrophy or dystrophy, tremor, focal dystonia or spasm, skin changes such as atrophy, dryness, and scaling, as well as bony changes with joint tenderness and swelling. In addition, vasomotor instability consisting of Raynaud's phenomenon (e.g. color changes and pain in fingers when exposed to cold), vasoconstriction or dilatation leading to cold and warm extremities respectively, as well as increased sweating.
The cause of the condition is currently not well understood and is often unrecognized. A number of precipitating factors have been associated with CRPS including minor trauma, cerebral or spinal cord lesions, ischemic heart disease and/or myocardial infarction, and repetitive cumulative trauma, such as carpal tunnel syndrome. However, in many of the patients a definite precipitating event can not be identified. Duration of CRPS varies, in many cases the pain continues on for at least two years and in some cases, indefinitely. Some patients experience periods of remissions and exacerbations. Periods of remission may last for weeks, months or years. The mean age of onset is in the mid thirties and there is increasing evidence that the incidence of CRPS in adolescents and young adults is on the rise. In Germany alone, for example, the annual incidence of RSD is estimated at 15000 [Dertwinkel, 1998]. Both sexes are affected, but the incidence of the syndrome is higher in women. Nonsurgical treatment consists of medicinal therapy, physical therapy, various peripheral or sympathetic nerve blocks, transcutaneous electrical nerve stimulation, or surgical sympathectomy. Patient response to therapy directly correlates to early diagnosis and treatment. However, the overall response rate to treatment is poor with over 50% of patients having significant pain and/or disability years later.
Abnormalities of autonomic function are present in both CRPS types I and II. Autonomic dysfunction results in localized sweating and changes in blood flow that may result in temperature asymmetries between affected and unaffected limbs. The changes in blood flow and sweating may result from localized noradrenergic and cholinergic hypersensitivity. Each body area has a regional cluster of nerve cells extending along the outside of the spinal column, and forming the sympathetic nervous system.
For example, the sympathetic outflow to the upper extremity lies in the inferior portion of the stellate or cervicothoracic ganglion down to the third thoracic ganglion. Similarly for the lower extremity, the sympathetic outflow passes through the second through fourth sympathetic ganglia. In general terms, the sympathetic, along with the parasympathetic, nervous system is part of the autonomic, or vegetative, nervous system. The effects of the autonomic system are extensive, and range from the control of blood pressure, heart rate, sweat, and body heat, to blood glucose levels, sexual arousal, and digestion.
While there are a variety of different techniques and mechanisms which have been designed to focus the lesioning means directly onto the target nerve tissue, collateral damage is inevitable. Were it even possible to direct all lesioning energy onto the target nerve cluster, it is a significant drawback that other functioning of these nerves is lost, even when such functioning may not be pathological. In addition, there are several common side effects described in the medical literature, including an ipsilateral Horner's syndrome (drooping eyelid and smaller pupil), compensatory sweating (increased sweating in other areas), and gustatory sweating (sweating, particularly of the face, at the smell of certain foods). It is because of the development of these and other side effects, including the poor response of medical or surgical therapy especially after a delay in treatment, that thoracic or lumbar sympathectomy has not enjoyed a greater popularity among physicians.
These complications, however, can be minimized to a large extent, or possible eliminated, by the use of chronic electrical stimulation or continuous drug infusion. The reasons are many, and include the possibility of changing which contacts of a multipolar lead are stimulated to minimize stimulating the superior portion of the stellate ganglion which can lead to a Horner's syndrome, to adjusting the parameters such as frequency or pulse width to affect changes in compensatory and gustatory sweating, should they arise. In addition, parameters may be intermittently adjusted if, and when, clinical efficacy is worsening in order to maximize therapeutic benefit
It is therefore the principle object of the present invention to provide a less destructive and fully reversible and adjustable method of treating complex regional pain syndromes by electrically or chemically stimulating/inhibiting the appropriate portion(s) of the sympathetic chain.
SUMMARY OF THE INVENTION
The preceding objects are provided in the present invention, which comprises new and novel methods of treating complex regional pain syndromes by implantation of stimulation electrodes at specific locations along the sympathetic chain. More particularly the present invention comprises a method of therapeutically treating upper or lower extremity CRPS Type I or II by surgically implanting an electrode adjacent to a predetermined site along the sympathetic chain on the affected side of the body, or if clinically indicated, bilaterally. For upper extremity reflex sympathetic dystrophy (CRPS Type I), for example, this involves the surgical implantation of a stimulating electrode over the inferior portion of the stellate ganglion, and over T2-4. The most commonly employed surgical approach is aided by video-assisted thoracoscopy, which involves the placement of 2-4 small incisions or ports in the chest wall, through which instruments may traverse en route to the lateral aspect of the vertebral bodies where the sympathic chain lies extrapleurally. The distal end of the lead can be secured to surrounding tissues and be placed either directly over the sympathetic chain or over the internal aspect of the parietal pleura. The proximal end of the lead can be passed out of the thoracic cavity via one of the neighboring surgical ports, and tunneled subcutaneously to an electrical signal source which, in turn, is operated to stimulate the predetermined treatment site over the sympathetic ganglia, such that the clinical effects of the pain disorder are reduced with minimal side effects.
Alternatively, a catheter with either end- or side-apertures placed over the ganglia of interest is connected in a similar fashion to a infusion pump. In addition, this embodiment is extended to include a combination electrical contact and drug delivery system, as well as a system which has the capacity to sense or record electrical or chemical activity in the region of interest.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a patient lying in the lateral decubitus position having one visualization port in the fifth intercostal space at the mid-axillary line and two instrument ports at the fourth and fifth intercostal space at the anterior and posterior axillary lines, respectively;
FIG. 2 is an axial cross section view of the upper thoracic region including one visualization port and two instrument ports wherein the two instrument ports have disposed therethrough endoscopic instruments accessing the ipsilateral paravertebral region where the sympathetic chain lies;
FIG. 3 is an exposed view of the left hemithorax displaying one instrument tenting the parietal pleura while the second endoscopic instrument is incising the parietal pleura to expose the sympathetic chain; and
FIG. 4 is a side view of an exposed superior thoracic ganglia in which an electrical stimulation lead is disposed adjacent thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
There are many several approaches described in the literature that have been employed in the lesioning of the stellate and superior thoracic sympathetic ganglia, as well as other ganglion groups, such as the second through fourth lumbar sympathetic ganglia. With respect to this embodiment, any one or a combination of these methods, as well as modifications of this technique not herein described, may be possible without deviating from the broad spirit and principle of the present invention. Specifically, it will be apparent to those skilled in the art that variations and modifications are possible without deviating the scope of the current embodiment which describes the technique of changing the functional state of the upper thoracic and cervicothoracic (stellate) sympathetic ganglia or lumbar sympathetic ganglia via chronic electrical stimulation or infusion of drug known to modulate its function.
Referring now to FIG. 1, in which a patient 100 is illustrated in the decubitus position, having been prepared by the surgical insertion of three ports 102 , 104 , 106 into the left hemithorax. This preparation is anticipation of a thoracoscopic approach, which is a typical and feasible surgical technique utilized for lesioning of these ganglia. More specifically, this approach commonly involves positioning the patient in the lateral decubitus position, with the hips below the flexion joint of the operating room table. Subsequent flexion of the table allows some separation of the ribs by dropping the patient's hips and therefore increasing the intercostal space to work through. The ipsilateral arm is abducted on an arm holder. Rotating the table somewhat anteriorly and using reverse Trendelenburg positioning further maximizes the exposure to the superior paravertebral area by allowing the deflated lung (see FIGS. 2 and 3) to fall away from the apical posterior chest wall. The patient is under placed under general anesthesia and intubated via a double lumen endotracheal tube. This allows for ventilation of one lung, and collapse of the lung on the side to be operated upon without using carbon dioxide insufflation. Three 2 cm incisions for the thoracoscopic sympathectomy are ordinarily used. One incision is in the midaxillary line in the fifth intercostal space and is used as the telescopic video port 104 . The second incision, performed under endoscopic observation, is placed in the third or fourth intercostal space at the anterior axillary line and is used as one of two instrument channels 106 . The third incision is made at the posterior axillary line just below the scapular tip in the fifth interspace, and it is used as the second instrument channels 102 . Additional incisions/ports can be made as necessary.
Referring now also to FIGS. 2 and 3, in which axial cross section and exposed views of the surgical field are provided, respectively, the surgical exposure and preparation of the relevant portion of the sympathetic chain for the treatment of hyperhidrosis is described. After the lung 110 is collapsed, and if necessary, retracted down by a fanning instrument via one of the working ports, the sympathetic chain 112 is visualized under the parietal pleura 114 as a raised longitudinal structure located at the junction of the ribs 116 and the vertebral bodies 118 . The parietal pleura 114 is grasped between the first and second ribs in the region overlying the sympathetic chain 112 and the endoscopic cautery or scissors 120 is used to incise the pleura 114 in a vertical manner just below the first rib thereby exposing the sympathetic chain 112 .
Referring now also to FIG. 4, in which the placement of the multichannel electrode adjacent to the symnpathetic chain is shown, the implantation of the stimulation electrode is now described. Once the sympathetic chain 112 has been exposed, a multipolar electrode 122 is placed over sympathetic chain of interest, typically the inferior third of the stellate ganglion to the T3 ganglion, and sutured in place to the nearby tissue or parietal pleura 114 .
Alternatively one may prefer not to incise the parietal pleura 114 if electrical stimulation is used, as the current which is generated may modulate the functioning of the ganglia through the pleural surface. Pending the preference and comfort level of the surgeon, a temperature probe may be placed on the ipsilateral arm, and electrical stimulation (or in the case of the alternate drug infusion embodiment) testing may be performed prior to closure of the chest cavity to maximize the probability of future effective therapy.
This procedure can most easily be accomplished by using existing electrode configurations, or modifications thereof, with the distal tip being more superior, and the proximal tip and the connection cable being more inferior. The lead can be inserted into the thoracic cavity and held in place via the posterior axillary line incision and sutured by using the other working port. The proximal connecting cable can be left at the posterior axillary line port after the lead has been secured with some remaining 'slack of connecting cable being left in the inter-pleural space. The proximal end of the connecting cable/tube can be brought out of the thoracic cavity, and via an extension cable/tube, be tunneled subcutaneously and connected to an electrical pulse generator or infusing pump. The pulse generator or pump may be placed in the subcutaneous tissues of the flank area, abdominal wall area, or buttock area, etc. Any excess fluid is suctioned from the thoracic cavity and the lung is reinflated. A suctioning chest tube may or may not be used depending on the presence or absence of damage to the visceral pleura of the lung. The incisions are closed, and a chest X-Ray is obtained in the recovery room to ensure the lung has reinflated. Electrical stimulation or drug infusion therapy may be started immediately, or after a delay, allowing for some healing to occur first.
Alternative approaches include posterior open extrapleural techniques, posterior percutaneous approaches, the anterior supraclavicular method, as well as the open transthoracic approach. For the lower extremities, an open or videoscopically-assisted transabdominal approaches are most viable. Alternatively, posterior or modified percutaneous approaches are feasible. However, while there has been described and illustrated specific embodiments of new and novel methods of treatment for complex regional pain disorders, and it will be apparent to those skilled in the art that variations and modifications are possible, such alterations shall be understood to be within the broad spirit and principle of the present invention which shall be limited solely by the scope of the claims appended hereto.
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A method for treating complex regional pain syndromes by applying an oscillating electric field to appropriate sympathetic ganglia. The method includes the steps of inserting an electrode into the vicinity of the sympathetic ganglion, for example the stellate and upper thoracic ganglia, such that the necessary electric field may be applied to the ganglion. The necessary field oscillation frequency and strength, as well as other characteristics of the signal are determined individually for each patient. Continued driving of the pathological activity of the ganglion into the normal function is the long-term, reversible palatative remedy for the condition.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application is a Continuation of U.S. application Ser. No. 12/414,744, filed Mar. 31, 2009, titled “Food Preparation Sink”, which is incorporated herein by reference in its entirety, which claims priority from U.S. Provisional Application Ser. No. 61/042,818, filed Apr. 7, 2008, titled “Food Preparation Sink”, which is incorporated herein by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
Not Applicable.
BACKGROUND OF THE INVENTION
The present invention relates to a sink that facilitates the preparation of food and the efficient and hands-free disposal of food waste and other kitchen waste from a sink work area to a garbage disposal.
Various types of preparation steps are typically performed on food items prior to cooking and/or serving. For example, vegetables and fruit may be peeled and/or have seeds, stems or other portions removed from them. The user will typically push the waste portions of the food off a cutting board into a sink by scraping the board with a knife or by hand. The user may then push the waste into the disposal with a tool or other item, sometimes by also using a manually held sprayer to help drive the food towards the drain.
Moving the waste portions in this manner is time consuming and somewhat messy, and the need to push the waste through the disposer entry can require the use of a separate implement to avoid using a hand for that purpose.
Accordingly, there exists a need for addressing these problems.
SUMMARY OF THE INVENTION
In one aspect the invention provides a food preparation sink. The sink has a basin having a lower drain outlet connectable to a garbage disposal, and a bottom surface elevated above the drain outlet. There is also a rim extending around an upper edge of the basin, and a nozzle mounted to the basin below the rim and configured to direct water onto the bottom surface if the nozzle is connected to a water supply. A flange may extend radially outwardly from rim of the basin. If there is food waste in the sink, and if water is directed by the nozzle onto the bottom surface, the sink can be rinsed by the nozzle so as to drive the food waste to an area of the basin above the drain outlet.
The sink provides its own confined, raised work area for cutting/food preparation. The water from the nozzle can rinse the food in this area, and/or carry unneeded waste or scraps to a drain portion of the basin, from which the waste ultimately can go to a garbage disposal. Thus, no separate cutting board is needed (albeit the sink can be used with one), and the food waste can be disposed of more efficiently and, as will be described below, in a hands free/tool free manner.
In a preferred form the bottom surface/work area is an elongated essentially rectangular area that slopes downwardly for a majority of its length. The area may have a concavely sloped entry area (to facilitate smooth flow of entering water and avoiding splashing), and this could transition to a convexly sloped region between the concavely sloped entry area and an area of the basin adjacent the drain outlet (to help food waste move off the work area without getting caught up on it).
In another preferred form the work area terminates at a vertical shoulder that defines in part a sump area over the drain opening. The nozzle is positioned at an end of the work area opposite an end of the work area adjacent the drain opening outlet, and the nozzle directs water essentially along a longitudinal axis of the work area.
In another aspect the food preparation sink may have a basin having a lower drain outlet connectible to a garbage disposal and a work area elevated above the outlet. In this form there are two nozzles mounted to the basin and configured to direct water onto the work area if the nozzles are connected to a water supply. There is a diverter capable of altering (to at least some extent) flow of water between the nozzles if the diverter is linked to a water supply. This altering optimizes the force of the entering water along different portions of the work area, to help optimize the cleaning effect.
This can be implemented with a diverter that has a movable valve member having a first position in which a first flow path is provided between a diverter inlet and a first diverter outlet linked to a first of said nozzles, and a second position in which a second flow path is provided between the diverter inlet and a second diverter outlet linked to a second of said nozzles. For example, in the first position the valve member may also block the second flow path, and wherein in the second position the valve member may also block the first flow path.
In yet another aspect the food preparation sink may have a basin having a lower drain outlet connected to a garbage disposal and a work area elevated above the outlet. In this form there will be a nozzle mounted to the basin and configured to direct water onto the work area if the nozzle is connected to a water supply, and also a conical baffle positioned in the outlet for controlling entry of items into the garbage disposal. If there is food waste in the work area, and if water is directed by the nozzle to the work area, the work area can be rinsed by the nozzle so as to carry the food waste to an area of the basin above the outlet, and weight of the water and food waste can automatically cause the baffle to open to permit the food waste to enter the garbage disposal. This allows the option of completely hands free/tool free operation.
Most preferably, a sump area is provided in the basin above the drain opening that is suitable to develop a head of water and waste above the drain opening so as to facilitate automatic movement of the food waste past the baffle. The sump region is relatively small so that a small amount of water can create an adequate pressure head, and further so that food waste does not get easily hung up on the drain floor remote from the drain.
Other preferred features of the present invention include an electrical controller for controlling the supply of water to the sink and the operation of the garbage disposal. For example, the controller could provide an automatic shut-off of the water and/or garbage disposal after a period of operation.
The sinks of the present invention are particularly useful as food preparation sinks. In the most preferred embodiments, they facilitate the efficient and hands-free movement of food waste from the work area to the garbage disposal. This can be achieved without requiring a faucet mounted on top of the sink or elsewhere on top of the counter, or requiring a hand sprayer. Hence, scarce counter space can be used for other purposes.
The foregoing and other advantages of the present invention will become apparent from the following description. In that description reference will be made to the accompanying drawings which form a part thereof, and in which there is shown by way of illustration example embodiments of the invention. The example embodiments do not limit the full scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top, frontal, right perspective view of a first embodiment of a food preparation sink according to the invention, mounted on the top of a kitchen counter top in drop-in configuration;
FIG. 2 is a view similar to FIG. 1 , but of the sink alone, and depicting water flow paths;
FIG. 3 is a cross-sectional view taken along line 3 - 3 of FIG. 1 ;
FIG. 4 is a cross-sectional view 1 taken along line 4 - 4 of FIG. 3 ;
FIG. 5 is a cross-sectional view taken along line 5 - 5 of FIG. 4 ;
FIG. 6 is a view similar to FIG. 1 , but showing the sink mounted in an under counter configuration;
FIG. 7 is an exploded perspective view of a second embodiment of a food preparation sink according to the invention;
FIG. 8 is a cross-sectional view of the second embodiment in assembled form; and
FIG. 9 is an enlarged top view of a valve portion of the FIG. 7 embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a food preparation sink 10 for preparing food items and disposing of waste. As shown in FIGS. 2 and 3 , the sink 10 includes a bottom wall 12 , a first side wall 14 , a second side wall 15 disposed opposite the first side wall 14 , a first end wall 17 , and a second end wall 22 disposed opposite the first end wall 17 . The first side wall 14 , the second side wall 15 , the first end wall 17 , and the second end wall 22 extend upwardly from the bottom wall 12 to define a basin. One non-limiting example version of the food preparation sink 10 measures about twenty-eight inches (711 millimeters) between the end walls, and about six inches (152 millimeters) between the side walls.
The food preparation sink 10 has a rim extending around an upper edge of the basin. In the construction shown in FIG. 1 , flanges 24 , 25 , 26 and 27 extend radially outwardly from the side walls 14 , 15 and end walls 17 , 22 at the rim. These flanges 24 , 25 , 26 and 27 are suitable to sit on a counter surface 28 of a counter top 29 when mounting the food preparation sink 10 in drop-in fashion. As shown in FIG. 6 , the flanges can instead facilitate under counter style installation. In addition, the sink may be formed as a continuous one piece construction with the countertop.
The sink is preferably formed from a conventional kitchen sink material such as stainless steel, ceramics, or polymers. In some aspects, and in some constructions, it may be desirable that the material be resistant to nicking or scratching by a cutting knife.
The bottom wall 12 of the food preparation sink 10 slopes downwardly as the bottom wall extends from the first end wall 17 toward the second end wall 22 along the bottom surface of the basin there between. As shown in FIGS. 2 and 3 , the bottom wall 12 has a varying non-uniform slope with a concavely sloped region 31 near the first end wall 17 , which then transitions into an elongated convexly sloped region 33 , and ultimately drops down to a drain floor 35 . FIG. 3 illustrates a junction 37 which indicates the transition from the concavely sloped region 31 to the convexly sloped region 33 . Junction 39 indicates the transition of the bottom wall 12 between convexly sloped region 33 and floor 35 .
A shoulder portion 41 extends vertically downwardly from the convexly sloped region 33 to the drain floor 35 . The shoulder portion 41 , along with lower portions of the end wall 22 and first and second side walls 14 , 15 , at least partially define a sump 43 at the bottom of the basin. A drain opening 45 is provided in the drain floor 35 to permit water and waste items to exit the basin. Passage through the drain opening 45 is controlled by a flexible baffle having a conical lower end 47 with vertical slits 48 .
The conical lower end 47 covers an entrance passage 49 to a garbage disposal 90 (see the schematic depiction in FIG. 3 ). Rubber, or another elastomeric material, is particularly well suited for formation of the conical lower end 47 . The garbage disposal 90 is preferably a conventional garbage disposal having a motor driving a rotating element to cut waste passing through the drain into smaller pieces.
In one example, the shoulder portion 41 is about one inch (25.4 millimeters) high creating a one inch deep sump 43 . Water may accumulate in this sump 43 to create a body of water that provides a pressure difference and helps move waste down into and through the conical lower end 47 without the need for manual assistance to push the waste through. Compared to conventional kitchen sinks, the surface area of the drain floor 35 within the sump 43 is relatively small in relation to the drain opening. This permits even a relatively small amount of water to build up as a significant head within the sump 43 , and provides additional pressure beyond that which would be supplied by the same amount of water in a conventional kitchen sink. Also, initiation of the garbage disposal 90 can, depending on the configuration of the garbage disposal, create a slight vacuum that helps suck and thus facilitate entry of the waste.
It is particularly desirable that the slope of the convexly sloped region 33 continuously increases as the waste approaches the drain opening 45 . This helps maintain and/or increase the speed of the water flow and move the waste towards the drain floor 35 with sufficient force to stop the waste from getting hung up near the shoulder portion 41 . Also, the shoulder portion 41 allows water flowing down the bottom wall 12 to be launched off the convexly sloped region 33 and carry waste toward the drain opening 45 .
Referring next to FIGS. 4 and 5 , the first end wall 17 includes an upper portion 18 and a lower portion 19 with a rectangular water inlet 20 . The food preparation sink 10 has a first nozzle 51 for delivering water in a first flow path F 1 along the bottom wall 12 of the food preparation sink 10 . The food preparation sink 10 also has a second nozzle 57 for delivering water in a second flow path F 2 along the bottom wall 12 of the food preparation sink 10 .
Water delivery to the first nozzle 51 and the second nozzle 57 is controlled by a valve system 70 having a manifold 74 . The manifold 74 is in fluid communication with a first port 76 , a second port 78 , and an inlet port 80 and directs fluid flow of the water between these ports 76 , 78 and 80 . A valve member 82 is positioned in the manifold 74 from controlling water delivery to the first and second nozzles 51 , 57 as described below. The valve member 82 preferably has a cylinder driven piston that drives a diverter plate in response to a solenoid. This either turns the water flow on or off to the nozzles 51 , 57 . Movement of the diverter plate of valve member 82 may be controlled by an actuator 95 .
In some aspects and in some constructions, the diverter plate of valve member 82 swings in directions V 1 and V 2 in the manifold 74 to provide a variable water flow to the nozzles 51 , 57 . Movement of the diverter plate of the valve member 82 in directions V 1 and V 2 in the manifold 74 can be controlled by the actuator 95 .
The valve system 70 also includes a fitting 86 having a first end 87 that is coupled to the inlet port 80 of the manifold and a second end having a coupler 88 . As shown in FIG. 3 , a coupler flange 89 attached to the bottom wall 12 can permanently or temporarily retain the coupler 88 to the bottom wall 12 . The coupler 88 joins the fitting 86 to a water line 91 from a water source.
A switch 93 can be actuated by the user to provide a signal to an electronic control module 94 . The electronic control module 94 controls introduction of water into the inlet port 80 of the valve system 70 via another solenoid 96 (e.g. a conventional solenoid volume valve), controls the actuator 95 of the valve system 70 to direct the flow of the water, and controls operation of the garbage disposal 90 .
Turning now to FIG. 6 , there is shown a under counter mounted food preparation sink 110 according to a second example embodiment of the invention. This is similar to the first embodiment except for using conventional under counter mounting hardware.
Regardless of whether the installation follows the principles of FIG. 1 or FIG. 6 , it should be appreciated that no further faucet or hand spray is required to be mounted on the counter top in the preferred embodiments. This saves considerable space.
Having described the primary features of the food preparation sink 10 , its preferred operation can be explained as follows. A user pushes on switch 93 . This signals the electronic control module 94 to begin delivery of water from water line 91 through fitting 86 and into the inlet port 80 of the valve system 70 . This can also signal the garbage disposal 90 to begin operation to dispose of the waste, either immediately or with a slight time delay.
Looking next at FIG. 5 , the water flows in direction I into the inlet port 80 and into the manifold 74 of the valve system 70 . Depending on the position of the valve member 82 , the water takes different flow paths from the manifold 74 . The diverter plate of the valve member 82 is movable back-and-forth in a first direction V 1 and a second direction V 2 to direct the water flow through the valve system 70 between a first path P 1 and a second path P 2 .
When the valve member 82 is in a first position at the end of movement in first direction V 1 (as shown in FIG. 5 ), water generally flows along the second path P 2 between the inlet port 80 and the second port 78 , and water may be blocked from flowing from the inlet port 80 to the first port 76 . Water flowing along the second path P 2 through the second port 78 exits the valve system 70 through the second nozzle 57 and enters the basin of the sink 10 . Water passing through the second nozzle 57 will generally flow along the second flow path F 2 (see FIG. 2 ) on the bottom wall 12 of the sink 10 .
When the valve member 82 is in a second position at the end of movement in the second direction V 2 , water generally flows along the first path P 1 between the inlet port 80 and the first port 76 , and water may be blocked from flowing from the inlet port 80 to the second port 78 . Water flowing along the first path P 1 through the first port 76 exits the valve system 70 through the first nozzle 51 and enters the basin of the sink 10 . Water passing through the first nozzle 51 will generally flow along the first flow path F 1 (see FIG. 2 ) on the bottom wall 12 of the sink 10 .
The actuator 95 preferably cycles the valve member 82 in directions V 1 and V 2 in the manifold 74 so that the water varies between the first flow path F 1 and the second flow path F 2 . The varying water flow paths F 1 and F 2 serve to more efficiently move waste along the bottom wall 12 to the sump 43 . As shown in FIG. 2 , the water flow paths F 1 and F 2 are directed longitudinally on the bottom wall 12 in side by side relationship. However, complete coverage from the front side wall 14 to the rear side wall 15 of the upper surface 54 of the bottom wall 12 of the food preparation sink 10 can be provided by each of the water flow paths F 1 and F 2 . The valve member 82 may also be positioned at all points between the directions V 1 and V 2 to provide a continuously variable water flow in the sink 10 along water flow paths F 1 and F 2 .
In some aspects and in some constructions, the electronic control module 94 is connected to a conventional power outlet box 99 (shown schematically in FIG. 3 ). The electronic control module 94 (also shown schematically in FIG. 3 ) preferably has its own power outlet (not shown, in addition to the shown control line to the garbage disposal), and the garbage disposal 90 is plugged into that power outlet (rather than taking up a second linkage at the power outlet box 99 ). This allows a conventional garbage disposal to be easily connected to the food preparation sink system. It also facilitates the control of the electronic control module 94 relative to activation of the garbage disposal 90 when desired.
The electronic control module 94 may include various settings to control the water flow into the sink 10 and operation of the garbage disposal 90 . For example, the electronic control module 94 may receive a signal from the switch 93 to initiate water flow into the sink 10 and then start the garbage disposal 90 after a delay of a set period of time following the water flow. This allows the water to enter the sink 10 and flow down to the sump 43 before the garbage disposal 90 is started. The water flow and the garbage disposal 90 may instead be started simultaneously. In addition, the electronic control module 94 may be set to turn the garbage disposal 90 off after a period of time of operation.
Also, the electronic control module 94 may be configured to sense operation of the garbage disposal 90 to determine when the disposal 90 is finished disposing of the waste. This may be accomplished by sensing output voltage to the garbage disposal 90 (e.g. sensing the RPMs of the garbage disposal 90 ) or by sensing the turbidity of the water exiting the sink 10 , or by other sensing means.
In some embodiments the food preparation sink may have only one nozzle. The pressure of the water from the single nozzle may be spread across the entire bottom wall 21 . Instead, a single nozzle may be mounted to oscillate and vary the water flow path along the bottom wall 12 . However, by using the pulsing varying flow of a dual nozzle construction shown in FIGS. 2 and 5 , the cleaning effects of both pulsation, and having a given pressure need to be spread over only half an area to be cleaned at a time, provide effective movement of waste along the bottom wall 12 .
The above description has been that of example embodiments of the present invention. It will occur to those that practice the art, however, that still other modifications may be made without departing from the spirit and scope of the invention. For example, FIGS. 7 and 8 show an alternative sink 210 that uses a valve 212 to split the flow well upstream of a nozzle 214 . In this construction the nozzle can direct the water into the basin.
In other embodiments the sink need not be rectangular and the work area/raised bottom wall need not be at a side of the drain area. In this regard, a circular basin could be provided with an outside concentric ring area of the basin being the work area. Hence, the scope of the invention should not be entirely judged by just the example embodiments.
INDUSTRIAL APPLICABILITY
The present invention provides a sink for food preparation or the like that facilitates the efficient and hands-free movement of food waste from the sink basin to the garbage disposal.
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Food preparation sinks are disclosed which have an integral raised work area that is rinsed by an automatic system. Food waste or the like present in that area can be washed into a sump above a drain, and the weight of the waste and water in the sump is enough to automatically drive them through a baffle to a garbage disposal, without requiring the baffle to be manually opened. An automatic controller system coordinates water flow and garbage disposal operation, and the water supply can be linked to the sink below the sink rim to save counter top space. In some forms multiple rinsing nozzles are provided which pulse in altering fashion.
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FIELD OF THE INVENTION
This invention pertains to a blank and a carton for packaging ice cream and the like. The carton and blank have many characteristics and features of end filled ice cream cartons now presently on the market such as lip seal, for top and bottom end flaps, the tamper-evident feature including a tear-away strip on the front panel of the carton, and a deep hood which pivots upwardly upon removal of the tear-strip and which can be readily replaced on top of the carton after a serving of ice cream has been extracted from the opened carton. The carton generally also includes a break-away feature designed to maintain seal on the carton prior to removal of the tear-strip and the lifting of the hood. Another general feature of this invention is the incorporation of a single glue line at either end of the carton sleeve when the flaps are in-folded in the filling operation.
BACKGROUND OF THE INVENTION
In the past, ice cream cartons which are end-filling and top-opening, have had problems with leakage at the corners. During the filling operation, the ice cream is in a semi-viscous form and has not been solidly frozen as you would find in the stores. After leaving the filling machine, the ice cream carton is placed in a chiller which freezes the contents solid. During the solid freezing operation, the ice cream tends to leak from the carton ends at the corners and various areas where the flaps overlap. Thus, testing for leakage in a carton would be done by taking filled cartons and leaving them on a shelf at room temperature until ice cream begins to ooze from the bottom of the carton. Because of the susceptibility of leakage, it is important that the cartons reach the chiller as soon as possible in order to prevent leakage from starting at the ends. Different dairies have different packaging conditions and temperatures vary widely in different parts of the country. Thus the longer that leakage can be prevented, the less likelihood of rejection of certain cartons because of excess build-up of ice cream on the outside thereof. The purchaser does not want to see the ice cream on the outside of the carton and rejects those that are found packaged in this fashion.
It should also be noted, that different types of ice cream have different consistencies. Sherbet, for example, tends to melt much faster than heavier types of ice cream. Thus chilling of sherbet in the package becomes more critical than a heavy ice cream. The longer a leak can be prevented, the fewer rejects there are. Packing a large number of cartons adjacent each other in the chiller also creates a problem in that those cartons that are centrally located in a chiller, do not freeze as quickly as outer perimeter cartons. Contrary to popular belief, the ice cream carton itself is not sealed all around by some type of bonding agent such as glue or the like. The flaps, upon in-folding, are secured in an overlying manner by means of glue which is applied only to certain flaps and in a line. The glue is provided to prevent the flaps from flying open after closing. The glue does not overlie a seam in the carton as might be expected.
It should be stated, that the carton blank is formed into a sleeve which does have a glue line running the length of one panel thereof which bonds that panel to the flap having the tear-strip thereon. Thus leakage is not around the central portion of the carton but at the ends. Bosses have been used in the past to provide for proper closing of cartons so that when glue is applied, an adjacent flap surface will not be lower than the glue application surface of the initial flap portion; i.e. the adjacent flap area to which glue will be applied to and extended over onto the next flap. This can be readily seen in the use of bosses such as embosses in Buttery U.S. Pat. Nos. 3,524,581 and 3,735,916, De Paul 4,756,470.
Many patents have been granted to provide features which will delay leakage such as Froom U.S. Pat. Nos. 4,555,027, 4,712,689, 4,712,730, DePaul U.S. Pat. Nos. 4,756,470, 4,872,609, Capuano 4,819,864 and Hutchinson, et al. 4,757,902.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved carton and blank for ice cream which will delay leakage of a semi-viscus ice cream for a substantial period to enable chilling to harden the ice cream in the container prior to leakage setting in.
Yet another object of this invention is to provide a carton and blank which will conform to standard filling machines.
Yet a further object of this invention is to provide a carton blank which in the manufacture thereof can be nested in such a manner as to produce the maximum number of blanks from a piece of board with a minimum amount of waste.
Yet another object of this invention is to provide a carton and blank which will be attractive and commercially appealing to the dairies who fill the cartons.
Still a further object of this invention is to provide a carton blank which can be readily color printed and which when assembled in carton form will produce an attractive carton with a minimum number of irregular lines in the carton itself.
Another object of this invention is to provide a carton which has tight fitting corners upon erection of the carton from the blank thereby reducing leakage.
Yet another object of this invention is to provide a carton which incorporates means for reducing leakage along lines of gap.
In summary, the present invention discloses a novel configuration for carton blanks and for cartons which includes means for improving the seal and the overall appearance of the carton. These and other objects of the invention will be apparent from the following:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of the interior of the carton blank. Various bosses are shown at the top or the bottom of the blank.
FIG. 2 is an interior top plan view of a modified blank showing various bosses incorporated therein.
FIG. 3 is a side elevational view of the carton when erected with the first end flat shown in position.
FIG. 4 is a side elevational view of the erected carton with the first and second end flaps shown in position.
FIG. 5 is a side elevational view of the erected carton with the first, second and third end flaps shown in position.
FIG. 6 is a side elevational view of the erected carton with the first, second, third and fourth end flaps in position and the hood tab positioned over the third-end flap.
FIG. 7 is a side elevational view of the carton from one end showing in phantom lines where the glue is applied and where the bosses are positioned.
FIG. 8 is a fragmentary cross sectional view taken along the lines 88 in FIG. 7 and viewed in the direction of the arrows.
FIG. 9 is an enlarged fragmentary view of modification of the carton as shown in the upper portion circular dash lines of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, the blank B is made from standard carton board or other materials as desired by the trade. The blank B includes rectangular panels 2, 4, 6 and 8. The panels are folded on fold lines 10, 12, 14 and 16 to make a rectangular sleeve. Panels 2, 4, 6 and 8 have respectively lower flaps 18, 20, 22 and 24 and upper flaps 26, 28, 30 and 32. Flaps 24 and 32 as well as panel 8 to which these flaps are attached, have lips 34, 36 and 38 respectively. The lips 34, 36 and 38 are well known in the art and include cutouts 40 and 42. Hinges 44, 46 and 48 are provided on flaps 24, panel 8, and flap 32 respectively for infolding purposes known in the art.
Tear strip flap 50 is secured to panel 2 at the hinge or fold line 10 and includes tear strip 52 and fold back tabs 54 and 56 which are folded back over flaps 18 and 26 respectively and glued thereto in the assembled carton.
Flaps 20 and 28 include breakaway tabs 58 and 60 with tear lines 62 and 64. Glue line embosses 66 and 68 are provided on respective flaps 22 and 30.
Referring to the bottom of the blank B, it will be noted that flap 18 incorporates a deboss 70 and flap 22 incorporates an emboss 72. If the deboss 70 extends below the inside surface of the blank B a thickness equalled to the carton board, then the emboss 72 will not be necessary. However, in order to prevent tearing or cutting of the board material during boss operations, the deboss 70 may be of a slight depth less than the thickness of the board which then permits the emboss 72 to cooperate therewith to provide the additional thickness required. Thus, bosses 70 and 72 overly each other when the blank is folded into a carton. As shown in phantom lines in the upper portion of the blank B, deboss 70' and emboss 72' work in the same manner as bosses 70 and 72. It will be noted that panel 2 has deboss 74 thereon in the lower right hand corner and a deboss 74' shown in the upper right hand corner of panel 2. Either debosses 70 and 70' or 74 and 74' may be used alone or in conjunction with each other and with embosses 72 and 72'. In the preferred embodiment, debosses 70 and 70' and cooperating embosses 72 and 72' are used without the debosses 74 and 74'.
Flap fold lines 76, 78, 80, 82, 84, 86, 88 and 90 are provided for their respective flaps 18, 20, 22, 24, 26, 28, 30 and 32. It should be noted in FIG. 1, that the cut throughs 92 and 94 between the flaps 18 and 20 and 26 and 28 respectively are offset to the right of the fold line 12. This allows for additional material on the flaps 18 and 26 so that when infolded, they will form with the infolded flaps 20 and 28 respectively, a tight corner reducing leakage at the corner. Such tight corners are also provided between adjacent flaps which are provided with overlap on one of the flaps beyond the fold line of the panels as will be noted between adjacent flaps 20 and 22, 22 and 24, 28 and 30, and 30 and 32.
FIGS. 3-8
FIG. 3 shows the first end flap 22 with the embosses 66 and 72. A gap 96 is created between the top edge of the flap 22 and the inside surface of the cover panel 2. This gap is about the thickness of the board from which the blank B is constructed. It should be noted that the emboss 72 borders on the edge of the flap 22 and that the gap 96 continues across the top edge emboss 72.
Referring now to FIG. 4, it will be noted that the flap 24 overlies the flap 22 and becomes the second-in flap. The lip 34 as best shown in FIG. 1 is folded in and into the gap 96 to seal the first portion of the gap 96 on the right hand side but it does not seal the second portion of the gap 96 on the left hand side which is the area adjacent the emboss 72. It should also be noted that the left hand edge of the flap 24 cooperates with the edge of the emboss 66 and the emboss 72 and abuts both these embosses 66 and 72.
In FIG. 5, the third-in end flap 18 now overlies the flaps 22 and 24 and deboss 70 overlies and is in contact with emboss 72. A glue line G is shown with glue in the areas 98 and 100 on emboss 66, flap 24 and flap 18.
Referring now to FIG. 6, flap 20 is now positioned to overlie flaps 22, 24 and 18 and is bonded to these flaps by the glue line G and glue portions 98 and 100. Tab 54 is bonded to the flap 18 by glue 102 as shown in FIG. 5. The overlying effect is also shown by FIG. 7. The opposite end of the carton C would be formed in the same manner with a similar glue line G incorporated for securing the end flaps 26, 28, 30 and 32 (not shown in folded position).
FIG. 8 is enlarged to show the cooperating deboss 70 and emboss 72 on the respective panels 18 and 22.
FIG. 9
Referring now to FIG. 9 is enlarged and is taken from FIG. 2. It will be noted that the cut-through 104 is angled between about 3 degrees and 5 degrees and that flap 26 extends beyond the fold line 12. The purpose of this cut through 104 at an angle about 3 degrees to about 5 degrees is to provide additional material in the corner when flap 28 is folded over flap 26. This crowds the corner and provides an excellent seal for the corner to avoid leakage. Obviously the same arrangement is made on the lower portion of the blank as in the upper portion as shown. Note in FIG. 2 the angle cut 104 is shown at the bottom.
OPERATION
It will now be observed that by gluing (not shown) the flap 50 onto the panel 8, a tube or sleeve is formed which can then be erected for filling purposes. It will also be observed that the various bosses such as the debosses 70 and 70' and 74 and 74' can be used by themselves or in conjunction with the embosses 72 and 72' to effectively provide a mechanism for preventing leakage out the second portion of the gap 96 which is not covered by the infolding lips 34 and 38. Ice cream attempting to get through the second portion of the gap 96 which is adjacent the debosses 70 and 70' or the debosses 74 or 74' will be prevented from coming down between flap 22 and the overlying flap 20 or flap 30 and its overlying flap 28. Furthermore, it will be noted that the tight corners formed by the angled cut throughs 104 and 104' as well as the offset arrangement such as illustrated by the cut throughs 92 and 94 will additionally prevent leakage.
While this invention has been described as having a preferred design it is understood that it is capable of further modifications, uses and/or adaptations of the invention following in general the principle of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention of the limits of the appended claims.
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A leak preventing carton and blank for ice cream and the like in which the first-in and flap substantially closes the opening of the carton but leaves a gap along the top edge of the first-in flap which gap is prevented from becoming a leaking area by a boss such as a deboss which may or may not be used in conjunction with an emboss. The boss or bosses cooperate to seal the area of the gap from leakage. In addition, the carton is designed to provide for very tight corners in which excess material is provided in the blank for closing tightly the corners when the carton is erected for receiving ice cream.
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FIELD OF INVENTION
This invention relates to both biological engineering and medical fields. In particular, it relates to a method of diagnosing and treating dentinogenesis imperfecta type II using human dentin sialophosphoprotein or DSPP gene and the coded product, and a pharmaceutical composition containing DSPP gene and/or protein.
TECHNICAL BACKGROUND
The odontoblasts produce the dentin, which consists in mature tooth or the tooth during tooth development phase. During dentinogenesis, the odontoblasts form dentinal tubules. Dentin cell processes in these tubules make dentin a living tissue. During the primary stage of dentinogenesis, the odontoblasts synthesize, secrete and re-absorb the dentin matrix components. Protein synthesis occurs within cells. Exocytosis and endocytosis occurs mainly in cell processes. The first material formed is unmineralized mantle dentin matrix, mainly including collagen secreted by cells and non-collagenous components. The fasciculata collagen fibers congregate to a ball structure. Due to the continual increase of new fibrils, collagen becomes closer and closer. As a result, these prophase collagen fibers change into collagen fibers. Thus predentin characterized by collagen matrix is formed. Later, the mineralization crystals gradually deposited to become dentin at some distance away from cells.
The mature dentin contains more inorganic minerals than the bone. 65 wt. % of dentin are minerals, mostly hydroxyapatite crystals. Organic materials are 20%, mainly collagenous proteins and non-collagenous proteins. These collagens offer braces to the deposition of hydroxyapatite plate like crystalline.
Type I collagen is predominant (about 97%) in dentin collagens, 10%-15% of which is type I collagen trimer. Different from other connective tissue, type III collagen is lacking in dentin. Moreover, there are types V and VI collagens in dentin, but the contents are small. Although the contents of non-collagenous proteins in dentin are small, there are various kinds. According to the source of proteins, the dentin noncollagenous proteins can be divided to four kinds: dentin specific protein, mineralized tissue specific protein, aspecific protein, and blood serum source protein (or dentin affinity protein). Dentin specific protein is the only one which is synthesized and secreted by odontoblasts and exists only in dentin. Mineralized tissue specific proteins means those that are found and exist not only in dentin but also in cementum and bone. They are synthesized and secreted by osteoblasts, odontoblasts and cementoblasts. The non-specific proteins exist both in dentin and other tissues, including parenchyma, and synthesized and secreted by odontoblasts and other kinds of cells. Blood serum source proteins are those which are synthesized by other cells in the body, mainly by liver cells, and secreted to serum. These proteins have a high affinity to dentin, though they are not synthesized by dentin. They can enter dentin by blood circulation, so they are also called dentin affinity proteins. Proteoglycans or PGS are other primary non-collagenous proteins in dentin. They are large covalent molecules formed by many anylose side chains and one core protein. These side chains are composed of repeating disaccharide chain units, each of which consists of one glycuronic acid and one N-acetamidoacetose. One function of PGS in dentinogenesis is to affect or even control the systematism of collagen skeleton in predentin. The dentin proteoglycans fixed on the solid bracket can induce the formation of hydroxyapatite in vivo and in physiologic pH and ionic condition in vitro. On the contrary, the liquid proteoglycans restrain the form of mineral components in vitro. The combination of PGS and Ca 2+ is the precondition of inducing the formation of hydroxyapatite.
Dentinogenesis imperfecta or DGI is an autosomal dominant dental genetic disease that has a prevalence of 1/8000. There are three types according to clinical taxonomy (1) (The number in brackets shows the relative literature.). Dentinogenesis imperfecta Type I is also named DGI-I. Except for dentinogenesis imperfecta, patients usually have osteogenesis imperfecta The pathogeny is broad mutations in collagen type I gene (2) . Type II or DGI-II is also called hereditary opalescent dentin. DGI-II has a relationship with the improper mineralization of dentin and its penetrance is nearly 100% (3) . Type III or DGI-III is also called dentinogenesis imperfecta Brandywine type or isolate hereditary opalescent dentin. It is a special hereditary opalescent dentin, only found in three isolates in Washington, D.C., the State of Maryland, USA. Witkop first reported this illness in 1956 (4) and there is no related report in China till now. DGI-III has an obviously genetic heterogeneity. Its pathogeny is related to malamineralization. Because the gene causing DGI-I has been found and DGI-III is only found in the isolates in the State of Maryland, USA, DGI-II becomes the focus of tooth endodontics.
The clinical symptoms and pathology changes of DGI-II are as follows. The malajustment and turbulence of mineralization result in embryonic layer dysplasia in dentin. Both the primary dentition and permanent dentition are affected, with a more serious damage in primary dentition. A predominant feature is a blue-gray or amber brown discoloration of the teeth. The improper mineralized dentin is soft and the crown is prone to be worn. Moreover, compensatory hyperplasia of matrix increases in improperly mineralized dentin, leading to small or obliterated pulp chambers. Radiographs reveal that the affected teeth have bulbous crowns, narrow roots and small or obliterated pulp chambers and root canals. The pathology shows that the enamel surface is normal, but hypoplasia and hypocalcification can be found in about ⅓ of the patients. The enamel dentin junction changes greatly. Some teeth have a non-obvious sector structure in the enamel dentin junction. However, others are especially obvious. Dentin is lamellar with nearly normal outerdentin and dentinal tubules having subdivisional branches. In other parts, the dentin is obviously abnormal. Some short tubules or tubules with abnormal form distribute in dentin matrix disorderly. The predentin zone is very wide. Along the plywood, the remaining embedded cell can be seen, similar to embedded odontoblast and bloods. Observation under electron microscope indicates that the form and size of hypoplastic dentin micro-crystal are unchanged, but the quantity is small. Uncalcified or partly calcified transverse collagen fasciculi and volumes of crystal space can be seen discontinuously.
For the mapping of DGI-II gene, in 1969, Bixler et al. (5) tried to use some protein polymorphic markers, such as ABO, Rh, MNSs, Kell, Fy, JK, HP, ACP1, PGM1 and PTC, to perform a linkage analysis in DGI-II families, but they failed to get the linkage evidence. In 1977, Mikkelsen et al. (6) mapped a group of specific components (GC) in Vitamin D conjugated protein to 4q11-q13. In the next year, Kühnl identified that GC included six phenotypes: GC2/2, 2/1+, 2/1−, 1+/1−, 1+/1+, and 1−/1−. Later, Ball. S. P. et al. (7) analyzed the linkage in a DGI-II big family named Family MRC4000 with the polymorphic markers of GC and found that DGI-II had a close linkage with GC (Lod=+7.9, θ=0.13). In 1992, Crall et al. (8) mapped DGI-II to interval defined by two protein polymorphic markers: GC and interferon-inducible cytokine INP-10. The relative chromosome location was 4q12-21. The results above only offered a gross orientation of disease gene of DGI-II. Under that condition, it was almost impossible to clone the disease gene in this region.
In 1995, Crosby A.H et al (9) analyzed the linkage in two big DGI-II families with 9 short tandem repeat polymorphic markers (STRP) and mapped the disease gene to the 4q21-23 region defined by two STRPs of D4S2691 and D4S2692. Multipoints linkage analysis suggested that the disease gene might be in the region within about 3.2 cM around SPP1. Recently, Aplin H. M et al. (10) genotyped two big families used by Crosby A. H with 5 hyperdense STRPs. The linkage analysis showed that the disease gene of DGIII located between two STRPs of GATA62A11 and D4S1563 with a genetic distance of 2 cM. Moreover, this research group established the YACs Contigs in this region. They also identified that DMP1, IBSP, SPP1 and DSPP are all in this candidate region by PCR technology.
However, the mechanism of dentinogenesis imperfecta type II is still unclear so far. Also the direct relationship between dentinogenesis imperfecta type II and some special kind of protein is not reported.
In addition, there is still no effective method to diagnose DGI-II early and/or antenatally and to cure DGI-II by non-operative treatment in the art.
Therefore, there is an urgent need to develop new and efficient methods to diagnose and cure DGI-II, the relative pharmaceuticals, and diagnostic technology and reagents.
SUMMARY OF INVENTION
One purpose of the invention is to provide a new diagnostic method and detection kit, especially for antenatal and/or early diagnosis of dentinogenesis imperfecta type II (DGI-II) and dentinogenesis imperfecta type II with deafness (DGI-II with deafness).
Another purpose is to provide a new method to treat DGI-II and DGI-II with deafness.
Still another purpose is to provide a pharmaceutical composition to treat DGI-II and DGI-II with deafness.
In the first aspect, the invention provides a method for determining the susceptibility of DGI-II and/or DGI-II with deafness in a subject comprising the steps of:
detecting the DSPP gene, transcript and/or protein in said subject and comparing it with the normal DSPP gene, transcript and/or protein to determine whether there is any difference, wherein said difference indicates that the possibility of suffering DGI-II and/or DGI-II with deafness in said subject is higher than the normal population.
In a preferred embodiment, the DSPP gene or transcript is detected, and compared with the normal DSPP nucleotide sequence to determine the difference. More preferably, said difference is selected from the group consisting of: in position 1 of Exon 3, G1→T1; in position 1 of Intron 3, G1→A1.
In the second aspect, the invention provides a method for treating DGI-II and/or DGI-II with deafness comprising the step of administrating a safe and effective amount of normal DSPP and/or DSP protein to the patient in need of said treatment. Preferably, the DSPP and/or DSP protein are administrated topically to periodontal tissues.
In the third aspect, the invention provides a pharmaceutical composition comprising a safe and effective amount of DSPP and/or DSP protein and a pharmaceutically acceptable carrier. Preferably, said pharmaceutical composition is injection.
In the fourth aspect, the invention provides a kit for detecting DGI-II and/or DGI-II with deafness comprising the primers which specifically amplify the DSPP gene or transcript. Preferably, the kit further comprises a probe that binds to the site of mutation.
In view of the technical teaching of the invention, the other aspects of the invention will be apparent to the skilled in the art.
DESCRIPTION OF DRAWINGS
FIG. 1 shows the gene structure of DSPP. This gene contains 5 exons and 4 introns. The full length is 8210 bp. Exon 1 (7-98), Exon 2 (2359-2437), Exon 3 (3577-3660), Exon 4 (3794-4780) and Exon 5 (5257-8201) encode DSPP. Exons 1-4 and part of Exon 5 (5257-5520) encode DSP, while another part of Exon 5 (5521-7893) encodes DPP.
FIG. 2 shows the haplotype construction of STRP markers in 4q21 region in a dentinogenesis imperfecta type II family.
FIG. 3 shows the haplotype construction of STRP markers in 4q21 region in a DGI-II with deafness family. A square represents a male. A filled suuare represents a DGI-II or DGI-II with deafness male patient. An open square represent a normal male. A circle represents a female. A filled circle represents a DGI-II or DGI-II with deafness female patient. An open circle represents a normal female. A bracketed circle or square represents a person not affected by DGI-II or DGI-II with deafness but by other disease. A bracketed circle or sausre that is lined through represents a dead person. The long bars represent the same chromosome from different persons. The numbers adjacent to the bars represent markers.
FIG. 4A and 4B show mutations in DSPP gene. FIG. 4A shows G1→T1 in position 1 of Exon 3, which causes codon GTT change into TTT, resulting in a corresponding amine acid change of Val→Phe. The change of splicing site is shown in SEQ ID NO: 45, wherein n is G or T. A part of DSPP amino acid sequence is shown in SEQ ID NO: 47. FIG. 4B shows G1→A1 in position 1 of Intron 3, which causes the mutation of splicing site. The change of splicing site is shown in SEQ ID NO: 46, wherein n is A or G. A part of DSPP amino acid sequence is shown in SEQ ID NO: 48.
DETAILED DESCRIPTION OF INVENTION
After studying for several years, the inventors of the invention have, for the first time found and proved dentin sialophosphoprotein (DSPP) and/or dentin sialoprotein (DSP) have a close relationship with dentinogenesis imperfecta type II (DGI-II). In addition, the new function of DSPP/DSP was found, i.e., the changes of DSPP or DSP will cause DGI-II directly. Based on this discovery, the inventors accomplished the invention.
Firstly, the inventors collected two genetic families affected by dentinogenesis imperfecta or dentinogenesis imperfecta with progressive hearing loss in China. Then they localized the disease gene of dentinogenesis imperfecta to the 4q21-22 region in Chromosome 4 by genotyping and linkage analysis with microsatellite markers Then, the inventors identified the candidate genes by the following steps:
(1) Finding all of the genes mapped in 4q21-22 region, i.e., making the transcription map in 4q21-22 region;
(2) Checking the expression situation of all of the genes in 4q21-22 region;
(3) Determining the genes mapped in 4q21-22 region and expressed in dental pulp as the candidates for dentinogenesis imperfecta.
The results showed that the candidate genes included DMP1, IBSP, SPP1, DSP, DPP and DSPP.
Further, the inventors used PCR-SSCP technique to screen all candidate genes for mutation and found that the mutations in DSPP have a direct causality with dentinogenesis imperfecta, while other genes do not.
Finally, the mode and site of DSPP mutation in two genetic families were identified by sequence analysis. In DGI-II family, sequencing revealed a G1→T1 mutation at position 1 of Exon 3 (position 3577 in SEQ ID NO:1). The mutation results in not only an amino acid change, but also a splicing site change which may cause the expression of intron, termination of translation in advance or frame shifting ( FIG. 4A ). Therefore, the normal DSPP (or DSP) protein is unable to be expressed.
In another DGI-II with deafness family, the mutation is a G1→A1 mutation in position 1 of Intron 3 (position 3661 of SEQ ID NO:1). The mutation was predicted to result in splicing site change, which may cause the expression of intron, termination of translation in advance or frame shifting ( FIG. 4B ). Therefore, the normal DSPP (or DSP) protein is unable to be expressed. Further, it may influence the translation of signal peptide so that DSPP can not be correctly localized. Surprisingly, this mutation causes the patient affected with both DGI-II and deafness, suggesting that DSPP mutation is associated with deafness. It is possible to diagnose deafness, especially DGI-II with deafness, by detecting whether DSPP is normal or not.
On the basis of this invention, one can design and exploit new drugs based on DSPP gene and its products (e.g., transcripts and proteins) as well as the interacting molecule. In addition, one can use DSPP gene in vitro to reconstruct teeth or remodel some tooth structure, such as dentin.
Human DSPP mutation causes human dentinogenesis imperfecta type II. Based on the DSPP gene and its expression products, one can develop new drugs and diagnosis/treatment techniques for detecting and treating human DGI-II.
Human DSPP Gene and Protein
The detailed sequences of human DSPP gene and protein are available in Genbank (The accession number is AF163151) and some references, such as Gu, K., Chang, S., Ritchie, H. H., Clarkson, B. H. and Rutherford, R. B., Eur. J. Oral Sci. 2000 Feb: 108 (1):35-42. In Sequence Listing, human DSPP nucleotide sequence and amino acid sequence are shown in SEQ ID NO:1 and SEQ ID NO: 2, respectively. FIG. 1 shows the introns and exons of human DSPP.
Exon 1
7-98
mRNA
join (7-98, 2359-2437, 3577-3660, 3794-4780,
5257-8201)
Exon 2
2359-2437
CDS
join (2387-2437, 3577-3660, 3794-4780, 5257-7896)
sig_peptide
2387-2431
mat_peptide
join (2432-2437, 3577-3660, 3794-4780, 5257-7893)/
Product “DSPP”
mat_peptide
join (2432-2437, 3577-3660, 3794-4780, 5257-5520)/
Product “DSP”
Exon 3
3577-3660
Exon 4
3794-4780
Exon 5
5257-8201
mat_peptide
5521-7893
misc_feature
5596-5604 /note = “Region: cell binding domain”
PolyA_signal
7988-7993
PolyA_signal
8171-8176
The DSPP and/or DSP protein or polypeptide have various uses including but not limited to: curing disorders caused by low or no activity of DSPP and/or DSP protein (using directly as a medicine), and screening out antibodies, polypeptides or ligands which promote the function of DSPP and/or DSP. The expressed recombinant DSPP and/or DSP protein can be used to screen polypeptide library to find therapeutically valuable polypeptide molecules which activate the function of DSPP and/or DSP protein.
In another aspect, the invention also includes polyclonal and monoclonal antibodies, preferably monoclonal antibodies, which are specific for polypeptides encoded by human DSPP DNA or fragments thereof. By “specificity”, it is meant an antibody that binds to the human DSPP gene products or fragments thereof. Preferably, the antibody binds to the human DSPP gene products or fragments thereof and does not substantially recognize nor bind to other antigenically unrelated molecules. Antibodies that bind to human DSPP and block human DSPP protein and those which do not affect the human DSPP function are included in the invention.
The present invention includes not only intact monoclonal or polyclonal antibodies, but also immunologically-active antibody fragments, e.g., a Fab′ or (Fab) 2 fragment, an antibody heavy chain, an antibody light chain, a genetically engineered single chain Fv molecule (Lander, et al., U.S. Pat. No. 4,946,778), or a chimeric antibody, e.g., an antibody which contains the binding specificity of a murine antibody, but the remaining portion of which is of human origin.
The antibodies in the present invention can be prepared by various techniques known to those skilled in the art. For example, purified human DSPP gene products, or its antigenic fragments can be administrated to animals to induce the production of polyclonal antibodies. Similarly, cells expressing human DSPP or its antigenic fragments can be used to immunize animals to produce antibodies. The antibodies of the invention can be monoclonal antibodies which can be prepared by using hybridoma technique (See Kohler, et al., Nature, 256; 495,1975; Kohler, et al., Eur. J. Immunol. 6: 511,1976; Kohler, et al., Eur. J. Immunol 6: 292, 1976; Hammerling, et al., In Monoclonal Antibodies and T Cell Hybridomas, Elsevier, N.Y., 1981). Antibodies of the invention comprise those which block human DSPP function and those which do not affect human DSPP function. Antibodies in the invention can be produced by routine immunology techniques and using fragments or functional regions of human DSPP gene product. These fragments and functional regions can be prepared by recombinant methods or synthesized by a polypeptide synthesizer. The antibodies binding to unmodified human DSPP gene product can be produced by immunizing animals with gene products produced by prokaryotic cells (e.g., E. coli ), and the antibodies binding to post translationally modified forms thereof (e.g., glycosylated or phosphorylated polypeptide) can be acquired by immunizing animals with gene products produced by eukaryotic cells (e.g., yeast or insect cells).
The antibody against human DSPP and/or DSP protein can be used in immunohistochemical method to detect the presence of DSPP and/or DSP protein in the biopsy specimen.
The polyclonal antibodies can be prepared by immunizing animals, such as rabbit, mouse, and rat, with human DSPP and/or DSP protein. Various adjuvants, e.g., Freund's adjuvant, can be used to enhance the immunization.
The substances that act with DSPP and/or DSP protein, e.g., inhibitors, agonists and antagonists, can be screened out by various conventional techniques, using the protein of the invention.
The protein, antibody, inhibitor, agonist or antagonist of the invention provides different effects when administrated in therapy. Usually, these substances are formulated with a non-toxic, inert and pharmaceutically acceptable aqueous carrier. The pH typically ranges from 5 to 8, preferably from about 6 to 8, although pH may alter according to the property of the formulated substances and the diseases to be treated. The formulated pharmaceutical composition is administrated in conventional routine including, but not limited to, intramuscular, intravenous, subcutaneous, or topical administration. The topical administration at periodontal tissues is preferred.
The normal DSPP and/or DSP can be directly used for curing disorders, e.g., DGI-II. The DSPP and/or DSP protein of the invention can be administrated in combination with other medicaments for DGI-II.
The invention also provides a pharmaceutical composition comprising safe and effective amount of DSPP and/or DSP protein in combination with a suitable pharmaceutical carrier. Such a carrier includes but is not limited to saline, buffer solution, glucose, water, glycerin, ethanol, or the combination thereof. The pharmaceutical formulation should be suitable for the delivery method. The pharmaceutical composition of the invention may be in the form of injections which are made by conventional methods, using physiological saline or other aqueous solution containing glucose or auxiliary substances. The pharmaceutical compositions in the form of tablet or capsule may be prepared by routine methods. The pharmaceutical compositions, e.g., injections, solutions, tablets, and capsules, should be manufactured under sterile conditions. The active ingredient is administrated in therapeutically effective amount, e.g., from about 1 ug to 5 mg per kg body weight per day. Moreover, the polypeptide of the invention can be administrated together with other therapeutic agents.
When using pharmaceutical composition, the safe and effective amount of the DSPP and/or DSP protein or its antagonist or agonist is administrated to mammals. Typically, the safe and effective amount is at least about 0.1 ug/kg body weight and less than about 10 mg/kg body weight in most cases, and preferably about 0.1-100 ug/kg body weight. Of course, the precise amount will depend upon various factors, such as delivery methods, the subject health, and the like, and is within the judgment of the skilled clinician.
The human DSPP and/or DSP polynucleotides also have many therapeutic applications. Gene therapy technology can be used in the therapy of abnormal cell proliferation, development or metabolism, which is caused by the loss of DSPP and/or DSP expression or the expression of abnormal or non-active DSPP and/or DSP. The methods for constructing a recombinant virus vector harboring DSPP and/or DSP gene are described in the literature (Sambrook, et al.). In addition, the recombinant DSPP and/or DSP gene can be packed into liposome and then transferred into the cells.
The methods for introducing the polynucleotides into tissues or cells include: directly injecting the polynucleotides into tissue in the body, in vitro introducing the polynucleotides into cells with vectors, such as virus, phage, or plasmid, and then transplanting the cells into the body.
The invention further provides diagnostic assays for quantitative and in situ measurement of DSPP and/or DSP protein level. These assays are well known in the art and include FISH assay and radioimmunoassay. The level of DSPP and/or DSP protein detected in the assay can be used to illustrate the importance of DSPP and/or DSP protein in diseases and to determine the diseases associated with DSPP and/or DSP protein.
A method of detecting the presence of DSPP and/or DSP protein in a sample by utilizing the antibody specifically against DSPP and/or DSP protein comprises the steps of: contacting the sample with the antibody specifically against DSPP and/or DSP protein; observing the formation of antibody complex which indicates the presence of DSPP and/or DSP protein in a sample.
The polynucleotide encoding DSPP and/or DSP protein can be used in the diagnosis and treatment of DSPP and/or DSP protein related diseases. In respect of diagnosis, the polynucleotide encoding DSPP and/or DSP can be used to detect whether DSPP and/or DSP is expressed or not, and whether the expression of DSPP and/or DSP is normal or abnormal, e.g., in the case of diseases. DSPP DNA sequences can be used in the hybridization with biopsy samples to determine the expression of DSPP. The hybridization methods include Southern blotting, Northern blotting and in situ blotting, etc., which are public and sophisticated techniques. The corresponding kits are commercially available. A part of or all of the polynucleotides of the invention can be used as probe and fixed on a microarray or DNA chip for analyzing the differential expression of genes in tissues and for the diagnosis of genes. The DSPP and/or DSP specific primers can be used in RNA-polymerase chain reaction and in vitro amplification to detect the transcripts of DSPP and/or DSP.
Further, detection of the mutation of DSPP and/or DSP gene is useful for the diagnosis of DSPP and/or DSP protein related diseases. The mutation forms of DSPP and/or DSP include site mutation, translocation, deletion, rearrangement and any other mutations compared with the normal wild-type DSPP and/or DSP DNA sequence. The conventional methods, such as Southern blotting, DNA sequencing, PCR and in situ blotting, can be used to detect mutation. Moreover, mutation sometimes affects the expression of protein. Therefore, Northern blotting and Western blotting can be used to indirectly determine whether the gene is mutated or not.
The invention is further illustrated by the following examples. It is appreciated that these examples are only intended to illustrate the invention, but not to limit the scope of the invention. For the experimental methods in the following examples, they are performed under routine conditions, e.g., those described by Sambrook et al., in Molecule Clone: A Laboratory Manual, New York: Cold Spring Harbor Laboratory Press, 1989, or as instructed by the manufacturers, unless otherwise specified.
EXAMPLE 1
DGI-II family had 42 members, and DGI-II with deafness family had 14 members. All individuals were subjected to careful clinical examination and recorded in details by experienced dentists. The patients with deafness were examined carefully by otologists and identified by pure tone audiogram and brain stem evoked potential. 5 ml blood samples in the families were collected by standard venipuncture and stocked by ACD solution. DNA was extracted using the following method:
Preparation of Blood DNA Sample
Blood DNA samples were extracted by Qiagen kit according to manufacturer's instructions. The steps were as follows:
a. Add 20 ul Proteinase K, 200 ul blood sample and 200 ul Buffer AL into a 1.5 ml microcentrifuge tube. Mix by pulse-vortexing for 15 seconds.
b. Incubate for digestion at 56° C. for 10 minutes. Add 210 ul 100% ethanol to the sample, and briefly centrifuge for 10 seconds.
c. Carefully apply the mixture onto a QIAamp spin column and centrifuge at 8000 rpm for 1 minute.
d. Discard the filtrate and transfer the QIAamp spin column in another 2 ml collection tube.
e. Add 500 ul Buffer AW1 into QIAamp spin column, centrifuge at 8000 rpm for 1 minute.
f. Discard the filtrate and add 500 ul Buffer AW2 into QIAamp spin column, centrifuge at 14000 rpm for 3 minutes.
g. Discard the filtrate and place the QIAamp spin column in a new 1.5 ml microcentrifuge tube. h. Add 200 ul Buffer AE into QIAamp spin column, incubate at room temperature for 5 minutes, and centrifuge at 8000 rpm for 1 minute. The filtrate collected in the tube was DNA solution from blood sample. i. DNA quality was determined by 1% agarose gel electrophoresis. The DNA quantity was determined by UV spectrophotometer. The DNA samples were stored at −20° C.
EXAMPLE 2
1 Genotyping:
The sequences of high polymorphic STR markers in region 4q21 were obtained from Genome Database and markers A-G were D4S2691, D4S1534, GATA62 μl 1, DSP, DMP1, SPP1, D4S451, respectively. PCR amplifications were carried out following LI-COR company manual for the touchdown program and using PTC-225 DNA Engine Tetrad (MJ-Research Inc.). PCR reactions were in 10 ul system containing 20 ng genomic DNA template, 2.0 mM dNTP, 1.0 pmol M13-tailed forward primer and reverse primer, 1.0 pmol fluorescent M13 primer, 1.5 mM MgCl 2 , 10 mM Tris-HCl, and 1U AmpliTaq Gold Taq Polymerase (Perkin-Elmer Corp.). The reaction system was initially denatured at 95° C. for 8 minutes, followed by 4 cycles of denaturing at 95° C. for 45 seconds, annealing at 68° C. for 2 minutes with a drop of 2° C. per cycle until 60° C., and extending at 72° C. for 1 minute, and by a second set of 2-4 cycles of denaturing at 95° C. for 45 seconds, annealing at 58° C. for 1 minute with a drop of 2° C. per cycle until 50-54° C., and extending at 72° C. for 1 minute, and then by 20-30 cycles of denaturing at 95° C. for 30 seconds, annealing at 50-54° C. for 30 seconds and extending at 72° C. for 30 seconds. Finally the samples were extended at 72° C. for 15 minutes. PCR products and fluorescent-labeled standard size DNA markers were electrophoresed on a LI-COR automated sequencer on a polyacrylamide gel. Data were collected and analyzed by Base Image 4.1 and Gene Image 3.12 software, while linkage ready pedigree files were generated. These files were used for linkage analysis and haplotype analysis.
2. Linkage Analysis and Haplotype Analysis
DGI-II hereditary locus was modeled as an autosomal dominant inheritance with 100% penetrance in a two-allele system. The frequency of disease gene was set to 0.0001, the frequencies of STRs were assumed to be uniformly distributed. Two-point linkage analysis was performed by using MLINK and ILINK program from the LINKAGE version 5.10 software package. Haplotype construction was performed using SIMWALK2 version 2.31 and Cyrillic version 2.02 software.
The pedigree data are shown in Tables 1-2 and FIGS. 2-3 .
TABLE 1
Disease locus in DGI-II pedigree and STRP two-point linkage analysis in
4q21 region
Loca-
tion
Lod score at θ
Maximum
marker
0.0
0.01
0.05
0.1
0.2
0.3
0.4
Lod
θ
A
−∞
−0.11
2.19
2.76
2.59
1.81
0.83
2.76
0.1
B
1.65
1.62
1.51
1.37
1.09
0.78
0.42
1.65
0.0
C
7.63
7.50
6.96
6.25
4.74
3.09
1.36
7.63
0.0
D
6.06
5.96
5.53
4.98
3.82
2.57
1.24
6.06
0.0
E
8.24
8.11
7.54
6.80
5.22
3.49
1.67
8.24
0.0
F
8.38
8.24
7.67
6.93
5.32
3.55
1.64
8.38
0.0
G
7.34
7.23
6.77
6.16
4.87
3.44
1.84
7.34
0.0
TABLE 2
Disease locus in DGI-II with deafness pedigree and Lod score in 4q21
region
Loca-
tion
Lod score at θ
Maximum
marker
0.0
0.01
0.05
0.1
0.2
0.3
0.4
Lod
θ
A
−∞
−2.86
−1.48
−0.92
−0.42
−0.18
−0.05
−0.05
0.4
B
−∞
0.67
1.19
1.25
1.04
0.65
0.21
1.25
0.1
C
1.20
1.8
1.07
0.93
0.63
0.33
0.08
1.20
0.0
D
−0.14
−0.09
−0.05
−0.02
−0.00
−0.00
−0.00
−0.00
0.2
E
0.91
0.92
0.91
0.86
0.67
0.41
0.14
0.92
0.01
F
2.71
2.66
2.46
2.21
1.65
1.02
0.37
2.71
0.0
G
2.11
2.07
1.91
1.70
1.24
0.73
0.23
2.07
0.0
The results suggested that the disease genes in DGI-II and DGI-II with deafness pedigrees were linked with STRP markers in 4q21 region.
EXAMPLE 3
Mutation Screening of Candidate Genes
Using Primer 5.0 software, we designed primers to amplify exons and the splice junctions between exons and introns of DSP gene (Table 3). PCR-SSCP technique was used to screen DSP gene for mutation. PCR products were electrophoresed on 10% polyacrylamide gel and 9.3% polyacrylamide gel with 4% glycerol. Then, the gels were silver stained according to standard protocol.
Primers were as follows:
TABLE 3
Primer Sequences in DSPP Coding Region
Primer
Name
Sequence
No.
bp
DSPP-E1 F
5′-TGCAAAAGTCCATGACAGTG-3′
SEQ ID
128
NO:3
DSPP-E1 R
5′-TCAGTTGGTTCTGAGTAAAAAGGA-3′
SEQ ID
NO:4
DSPP-E2 F
5′-AAGTAATTTTGTGCTGTTCCTTT-3′
SEQ ID
149
NO:5
DSPP-E2 R
5′-AACAAAGTGAAGAGGTTTTCT-3′
SEQ ID
NO:6
DSPP-E3 F
5′-AAGAACCTTTTCAATTGCTAGT-3′
SEQ ID
189
NO:7
DSPP-E3 R
5′-TGGAGAAGTTAATGGAATGTAGCA-3′
SEQ ID
NO:8
DSPP-E4 F
5′-TGCAATTTGCTTTCCTTCAA-3′
SEQ ID
205
NO:9
DSPP-E4 R
5′-CCTCTTCGTTTGCTAATGTGG-3′
SEQ ID
NO:10
DSPP-E5 F
5′-TCACAAGGTAGAAGGGAATG-3′
SEQ ID
226
NO:11
DSPP-E5 R
5′-GTTTGTGGCTCCAGCATTGT-3′
SEQ ID
NO:12
DSPP-E6 F
5′-GGGACACAGGAAAAGCAGAA-3′
SEQ ID
243
NO:13
DSPP-E6 R
5′-TGTTATTGCTTCCAGCTACTTGAG-3′
SEQ ID
NO:14
DSPP-E7 F
5′-CAATGAGGATGTCGCTGTTG-3′
SEQ ID
206
NO:15
DSPP-E7 R
5′-TATCCAGGCCAGCATCTTCT-3′
SEQ ID
NO:16
DSPP-E8 F
5′-CACCTCAGATCAACAGCAAGAG-3′
SEQ ID
226
NO:17
DSPP-E8 R
5′-TCTTCTTTCCCATGGTCCTG-3′
SEQ ID
NO:18
DSPP-E9 F
5′-ATGAAGAAGCAGGGAATGGA-3′
SEQ ID
232
NO:19
DSPP-E9 R
5′-ATTCTTTGGCTGCCATTGTC-3′
SEQ ID
NO:20
DSPP-E10 F
5′-TGATGGAGACAAGACCTCCAA-3′
SEQ ID
205
NO:21
DSPP-E10 R
5′-TGCCATTGAAAGAAATCAGC-3′
SEQ ID
NO:22
DSPP-E11 F
5′-TTCTTTCCTCCATCCTTCCA-3′
SEQ ID
194
NO:23
DSPP-E11 R
5′-TTCTGATTTTTGGCCAGGTC-3′
SEQ ID
NO:24
DSPP-E12 F
5′-GGCAATGTCAAGACACAAGG-3′
SEQ ID
236
NO:25
DSPP-E12 R
5′-TCTCCTCGGCTACTGCTGTT-3′
SEQ ID
NO:26
DSPP-E13 F
5′-TGCAAGGAGATGATCCCAAT-3′
SEQ ID
231
NO:27
DSPP-E13 R
5′-TGTCATCATTCCCATTGTTACC-3′
SEQ ID
NO:28
DSPP-E14 F
5′-CAAAAGGAGCAGAAGATGATGA-3′
SEQ ID
243
NO:29
DSPP-E14 R
5′-TGCTGTCACTGTCACTGCTG-3′
SEQ ID
NO:30
DSPP-E15 F
5′-GCAGTGATAGTAGTGACAGCAGTG-3′
SEQ ID
205
NO:31
DSPP-E15 R
5′-TTGCTGCTGTCTGACTTGCT-3′
SEQ ID
NO:32
DSPP-E16 F
5′-CAAATCAGACAGTGGCAAAGG-3′
SEQ ID
508
NO:33
DSPP-E16 R
5′-GCTCTCACTGCTATTGCTGCT-3′
SEQ ID
NO:34
DSPP-E17 F
5′-GCAAGTCAGACAGCAGCAAA-3′
SEQ ID
598
NO:35
DSPP-E17 R
5′-CTGCTGTCGCTATCACTGCT-3′
SEQ ID
NO:36
DSPP-E18 F
5′-ATAGCAACGACAGCAGCAAT-3′
SEQ ID
583
NO:37
DSPP-E18 R
5′-TCGCTGCTATTGCTATCACTG-3′
SEQ ID
NO:38
DSPP-E19 F
5′-GCAACAGCAGTGATAGTGACA-3′
SEQ ID
598
NO:39
DSPP-E19 R
5′-CTGCTGTCGCTGCTTTCA-3′
SEQ ID
NO:40
DSPP-E20 F
5′-AGCAGCGACAGCAGTGATAT-3′
SEQ ID
500
NO:41
DSPP-E20 R
5′-TTGTTACCGTTACCAGACTTGC-3′
SEQ ID
NO:42
DSPP-E21 F
5′-TGACAGCACATCTGACAGCA-3′
SEQ ID
261
NO:43
DSPP-E21 R
5′-TCCCCCAGTTGTTTTTGTTT-3′
SEQ ID
NO:44
PCR products were sequenced to determine the type and location of mutations.
1. The DNA fragments that showed a changed electrophoresis pattern in SSCP analysis were amplified by standard PCR.
2. PCR products were purified with Millipore spin column.
3. Sequencing Reaction:
(1)
Reaction system
Reaction mixture
2 ul
Primers (0.8 mM)
2 ul
Purified PCR products
3 ul
(2)
Reaction conditions:
96° C.
30 sec
96° C.
30 sec
50° C.
5 sec
60° C.
4 min
60° C.
4 min
Total 35 cycles
(3) Precipitation of the Product of Sequencing Reaction
Add 9 volumes of 70% ethanol into the sequencing product, incubate at 4° C. for 3 minutes.
Centrifuge at 4° C. at 4000 rpm for 30 minutes.
Place the centrifuge tube upside down and continue to centrifuge until the speed reaches 1300 rpm at 4° C.
(4) Loading and Sequencing Samples
Add 2 ul Loading Dye buffer into precipitated products of sequencing reaction.
Incubate at 90° C. for 2 minutes and place it on ice immediately.
Load samples into ABI PRISM automated DNA sequencer to sequence.
The sequencing results were shown in FIGS. 4A and 4B . In DGI-II family, sequencing revealed a G1→T1 mutation at position 1 of Exon 3 (position 3577 in SEQ ID NO:1). This mutation resulted in not only an amino acid change, but also a splicing site change that might cause the expression of intron, termination of translation in advance or frame shifting ( FIG. 4A ). Therefore, the normal DSPP (or DSP) protein was unable to be expressed.
In another DGI-II with deafness family, the mutation was a G1→A1 mutation in position 1 of Intron 3 (position 3661 of SEQ ID NO:1). This mutation was predicted to result in splicing site change which may cause the expression of intron, termination of translation in advance or frame shifting ( FIG. 4B ). Therefore, the normal DSPP (or DSP) protein was unable to be expressed. Further, it might influence the translation of signal peptide so that DSPP could not be correctly localized. Surprisingly, this mutation caused the patient affected with both DGI-II and deafness, suggesting that DSPP mutation was associated with deafness. It is possible to diagnose deafness, especially DGI-II with deafness, by detecting whether DSPP is normal or not.
Discussion
1. Linkage and Haplotype Analysis
We used seven STR markers in 4q21 region to genotype DGI-II and DGI-II with deafness families. Linkage and haplotype construction showed that the disease gene in DGI-II family was linked with 4q21 and the maximum LOD score was 8.38 at SPP1 locus (θ=0.00) (Table 1, FIG. 2 ) and the disease gene in DGI-II with deafness was also linked with STR markers in 4q21 region and the maximum LOD score was 2.71 (0=0.00) (Table 2, FIG. 3 ).
2. Mutation Screening of Candidate Genes and Confirmation by Sequencing
We designed 22 primers overlapping the DSPP gene to screen for mutations and identify mutations by sequencing. We found the disease gene in DGI-II family was linked with the STR markers in 4q21 region, while the disease gene in DGI-II with deafness was also linked with STR markers in this region. These mutations were not observed in 100 normal and unaffected individuals. It suggests that these mutations should be the cause of DGI-II disease.
DPP and DSP are two small polypeptides which have specific chemical properties and are cleaved from a single transcripts of DSPP gene. Both of them are expressed specifically in dental pulp tissue and may also be expressed in cochleae. DSP is a Glu-, Ser- and Gly-rich protein with many phosphorylation sites, which are predicted to be involved in dentin mineralization. DPP affects mineralization in two ways. Low concentration of DPP protein is able to bind to interspace of collagen I and initiate formation of phosphorum apatite crystals, while high concentration of DPP protein binds to the growing crystals, affects the size and form of crystals, and decreases the growth of crystals. It is necessary to further study the mechanism that the mutations in DSPP gene cause dentinogenesis imperfecta and deafness.
All the documents cited herein are incorporated into the invention as reference, as if each of them is individually incorporated. Further, it would be appreciated that, in the above teaching of the invention, the skilled in the art could make certain changes or modifications to the invention, and these equivalents would still be within the scope of the invention defined by the appended claims of the present application.
REFERENCES
1. Witkop C J et al. Hereditary defects in enamel and dentin. Acta Genet 1957;7:236˜239
2. Cetta G et al. Third international conference on osteogenesis imperfecta. Ann NY Avad Sci, 1998
3. Takagi Y et al. Matrix protein difference between human normal and dentinogenesis imperfecta dentin. In the chemistry and biology of mineralized connective tissues. Veis A, editor, New York: Elsevier/North-Holand. 1981
4. Witkop C J, et al. Medical and dental findings in the Brandywine isolate. AL J Med Sci 1966;3:382˜403
5. Bixler D, et al. Dentinogenesis imperfecta: genetic variation in a six-generation family. J. Dent. Res. 1968;48:1196˜1199
6. Mikkelsen, M et al. Possible localization of Gc-system on chromosome 4. Loss of long arm 4 material associated with father-child incompatibility within the Gc-system. Hum. Hered. 1988;27: 105˜107
7. Ball. S P, et al. Linkage between dentinogenesis imperfecta and Gc. Ann. Hum. Genet. 1982;46:35˜40
8. Crall M G. Genetic marker study of dentinogenesis imperfecta. Proc Finn Dent Soc. 1992;88:285˜293
9. Crodby A H, et al. Genetic mapping of dentinogenesis imperfecta type II Locus. Am. J. Hm. Genet. 1995;57:832˜839
10. Aplin H. M, et al. Refinement of the dentinogenesis imperfecta type II locus to an interval of less than 2 centimorgans at chromosome 4q21 and the creation of a yeast artificial chromosome contig of the critical region. J. Dent. Res. 1999;78(6):1270˜1276
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The invention has disclosed a method for diagnosis of dentinogenesis imperfecta type II (DGI-II) and/or dentinogenesis imperfecta type II with deafness (DGI-II with deafness). Said method comprises the steps of detecting the DSPP gene, transcript and/or protein in said subject and comparing it with the normal DSPP gene, transcript and/or protein to determine whether there is any variation, wherein said variation indicates that the possibility of suffering DGI-II and/or DGI-II with deafness in said subject is higher than the normal population. The present invention also discloses the method and pharmaceutical composition for treating DGI-II and/or DGI-II with deafness.
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BACKGROUND OF THE INVENTION
The present invention relates to a valve control arrangement. More particularly, it relates to a valve control arrangement for controlling closing and opening time of a valve in a displacement piston-internal combustion engine, the valve actuatable by a valve control cam of a cam shaft via an axially displaceable valve plunger.
Valve control arrangements of the above mentioned general type are known in the art. One of the valve control arrangements is disclosed in the German document DE-OS No. 3,125,650 and designed so that at the beginning of the stroke of the valve control cam which acts for valve opening, the opening of the stroke transmitting chamber is blocked. By the pressure of the valve control cam upon the stroke transmitting chamber, on which also the valve plunger abuts under the force of the valve closing spring in an opposite direction, no pressure medium can discharge from the stroke transmitting chamber. Thereby, the stroke movement of the valve control cam which is produced by the rotary movement of the cam shaft is completely transmitted to the valve plunger which in turn lifts the valve member from the valve seat and opens the valve.
The closing of the valve is performed at a predetermined point of time so that the opening of the stroke transmitting chamber is performed in a shock-like manner. Under the action of the valve control cam which presses on the stroke transmitting chamber, on the one hand, and the valve seat which presses on the stroke transmitting chamber, on the other hand, the pressure medium flows out of the pressure transmitting chamber and therefore its axial extension reduces. Despite further stroke movement of the valve control cam in direction of the valve opening, the valve plunger can move under the action of the valve closing spring in direction toward the valve control cam, and thereby close the valve. The stroke of the valve plunger or the valve member is shown in FIG. 2 vs the rotary angle of the valve control cam. The curve I represents the course with closed opening of the stroke transmitting chamber, and the curve II represents the course with release of the opening of the stroke transmitting chamber at point of time φ SII . In dependence upon the fixation of the closing point of time φ SII , the quantity of fuel aspirated into the cylinder can be adjusted in correspondence with different consumption in different operational conditions.
As can be seen from curve II in FIG. 2, after closing of the valve in point time φ SII , a relatively long evacuation phase takes place, in which with the valve closed, the piston moves further downwardly in the cylinder and thereby a negative pressure is produced in the cylinder. Because of this negative pressure, the fuel cools relatively too much, the fuel evaporates poorly and as a result a poor mixture preparation takes place. The poor mixture preparation is a cause for a high hydrocarbon content in waste gas. In addition, the lower temperature fuel results in reduced temperature in exhaust, whereby the post-combustion of the waste gas in the exhaust is lower and the hydrocarbon content additionally increases. During idle running or in the lower partial load direction, the worsening of the mixture preparation because of the additional low flow turbulence with the fuel mixture aspiration and the shorter valve opening time is especially high.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a valve control arrangement which avoids the disadvantages of the prior art.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a valve control arrangement which is designed so that at the beginning of the stroke of the valve control cam which acts for valve opening, the controllable opening of the stroke transmitting chamber is adjusted to an unloading cross-section so that to the closing point of time of the valve a partial quantity of pressure medium can flow out of the stroke transmitting chamber.
When the valve control arrangement is designed in accordance with the present invention, it has the disadvantage that with the same fuel quantity flowing into the cylinder, the valve opening time is considerably increased and thereby the evacuating stroke in the cylinder after closing of the valve is considerably reduced. The above-described problems with the fuel cooling and poor mixture preparation are essentially improved and the hydrocarbon content in waste gas is considerably reduced. Since a smaller inner cross-section is available for the fuel mixture quantity during longer valve opening time, the flow speed is increased and thereby the mixture preparation is improved also during idle running and in the lower partial load region.
The longer valve opening time for fuel mixture filling is obtained by the unloading cross-section in the opening of the stroke transmitting chamber, adjustable with the beginning of the valve opening stroke. Thereby a partial quantity of the pressure medium can flow out during the cam stroke of the valve control cam acting for the valve opening. The finally adjusted dynamic pressure in the stroke transmitting chamber is sufficient to open the valve with the desired opening course along the rotary angle φ SII , as can be seen in FIG. 2 on the curve III.
In accordance with another feature of the present invention a change-over switch is provided for converting the electromagnets from partial to full excitement, and it is controlled in dependence on a load signal obtained advantageously on the drive pedal of a vehicle and on the motor rotary speed. The limitation to the operational region of the internal combustion engine is advantageous since here a maximum reduction of the hydrocarbon waste gas can be obtained. In full load region because of the considerably higher flow turbulence, the fuel preparation also during short valve opening time or longer evacuating phase is so good that the hydrocarbon content in fuel is increased only insigificantly. On the other hand, with the longer valve opening time in accordance with the present invention, increased throttle losses are taken into account with constant fuel mixture filling because of the reduced inlet cross-section of the valve. In the idle running and in the lower partial load region, the absolute fuel consumption is so low that this influence is not noticeable. With the higher fuel consumption in full load and partial load region, the throttle losses are significant and their adverse influence has no reasonable relation to the relative low gain of hydrocarbon reduction in waste gas. By the inventive conversion of the stroke transmitting chamber-opening to blocking of the unloading cross-section in full load and upper partial load region, these throttle losses are avoided.
In accordance with a further feature of the present invention the point of time of closing of the valve is corrected in dependence on the running quietness of the internal combustion engine. By this feature, the unacceptable variations in the fuel mixture filling of the individual cylinders during the valve opening phase are avoided. These variations can take place because of tolerances in the magnet valve which is used for controlling the stroke transmitting chamber-opening as well as because of temperature influence. With the inventive correction of the time point of closing of the valve, the filling quantity can be maintained constant with high accuracy.
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 drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a view showing a longitudinal section of a valve control arrangement for an inlet valve of displacement piston-internal combustion engine;
FIG. 2 is a diagram of an inlet valve-stroke in dependence on the rotary angle of a valve control cam;
FIG. 3 is a view showing a longitudinal section of a magnetic valve of the valve control arrangement of FIG. 1 in connection with a block diagram of a magnetic valve control; and
FIG. 4 is a diagram of the spring force versus the valve needle stroke in the magnetic valve of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A valve control arrangement for an inlet valve 10 of an internal combustion engine, here a combustion motor, is arranged between a valve plunger 12 which carries a valve member 11, and a valve cam 14 rotatable on a cam shaft 13. The valve plunger 12 is axially displaceably guided in a valve housing 15, and sits with the valve member 11 on a valve seat 18 in the valve housing 15 under the action of two valve closing springs 16 and 17. A valve inlet opening 19 is formed in the valve housing 15.
The valve control arrangement has a housing 20 which is arranged on the valve housing 15. A housing chamber 21 is formed in the housing 20 so that it is in alignment with a spring chamber 22 in the valve housing 15 which accommodates the coaxial valve closing springs 16 and 17. A housing block 23 is inserted from below into the housing chamber 21 and has a central axially throughgoing housing opening 24. A valve piston 25 and a piston part 26 of a cam piston 27 are axially displaceable in the housing opening 24. The cam piston 27 is pressed against the valve control cam 14 by a return spring 28 which is supported on the housing block 23. The piston part 26 is either fixedly connected with the cup-shaped cam piston 27 or retained in abutment against the cam piston 27 via the same return spring 28.
The valve piston 25 and the piston part 26 limit a stroke transmitting chamber 29 which is filled with a pressure medium, here oil. The effective axial length of the stroke transmitting chamber 29 between the cam piston 27 and the piston part 26 can be changed by relative movement of the pistons relative to one another. The stroke transmitting chamber 29 communicates via conduits 30, on the one hand, with a spring accumulator 31 and, on the other hand, with a supply container 32. A check valve 33 and a filling pump 34 are arranged between the conduit 30 and the supply container 32. The conduit 30 permits displacement of the oil volumes available in the stroke transmitting chamber 29 into the spring accumulator 31 and vice versa. Leakage losses in oil volumes are compensated by the feeding pump 34 and the check valve 33 from the supply container 32. For controlling the oil volume and thereby the axial expansion of the stroke transmitting chamber 29, a magnetic valve 35 is arranged in the conduit 30. The magnetic valve 35 is reached by a bypass conduit 36. A check valve 37 is arranged in the bypass conduit 36 so that the oil can flow from the spring accumulator 31 with bypassing of the magnetic valve 35, into the stroke transmitting chamber 29.
The magnetic valve 35 is shown in a longitudinal section in FIG. 3. The magnetic valve 35 is connected with its valve inlet 38 to the conduit portion connected with the stroke transmitting chamber 29, and with its valve outlet 39 with the conduit portion connected with the spring accumulator 31, the conduit portion being connected to a portion of the conduit 30. The valve inlet 38 and the valve outlet 39 are connected by a throughflow conduit 40 which inner cross-section is controlled by a valve needle 41. The valve needle 41 is connected with an armature 42 of an electromagnet 43 and guided displaceably in an axial opening 44. At the end of the valve needle 41 which faces toward the throughflow opening 40, a return spring 46 engages an annular flange 45 which is formed of one-piece with the valve needle 41. The return spring 46 holds the valve needle 41 in the valve opening position in condition of not energized electromagnet 43. The spring characteristic of the return spring 46 which provides a small tensioning is shown in FIG. 4 as a curve a.
The end of the valve needle 41 which faces toward the throughflow opening 40 has a recess 47. A bush 49 is displaceable on a guiding rod 48 and extends into the recess 47. The bush 49 is supported on an abutment 51 under the action of a second return spring 50. The abutment 51 is arranged so that the valve needle 41 must cover a displacement path s 1 before the bottom of the recess 47 comes into contact with the bush 49. The total stroke of the valve needle 41 from its opening position in condition of not energized electromagnet 43 to its closing position in which its end side is pressed against a valve seat 52 which surrounds the throughflow opening 40, is identified in FIGS. 3 and 4 with s ges . The spring characteristic of the second return spring 50 is identified in FIG. 4 with reference letter b, the second return spring 50 is also pretensioned. However, its tensioning force, as can be seen in FIG. 4, is considerably higher than the tensioning force of the first return spring 46.
An exciting winding 53 of the electromagnet 43 is connected with a changeover switch 54. The changeover switch 54 has three switching positions. In both outer switching positions the exciting winding 53 is connected with a direct current source 55, and because of differently dimensioned resistors 56, 57 the electromagnet 43 can be once fully excited and once partially excited. The partial excitation is selected so that the valve needle 41 can cover the displacement path s 1 against the force of the first return spring 46, but cannot overcome the spring force of the second return spring 50. The full excitation is selected so that the valve needle 41 can cover the total stroke s ges against return force of both return springs 46, 50. The magnet valve 35 is formed pressure equalized, in other words, in the event of pressure increase or pressure decrease at both sides of the throughflow opening 40, no additional valve closing forces or valve opening forces act upon the valve needle 41. This pressure equalization is obtained statically by equal diameter of the valve needle 41 on the valve seat 52, on the one hand, and on the sealing edge 63 which seals the valve needle 41 in the axial opening 44, on the other hand. Dynamically it is obtained by a respective geometry of the valve seat 52 and the part of the valve needle 41 which cooperates with the valve seat.
The point of time of turning on of the electromagnet 43 as well as of the turning on of the partial or full excitation of the electromagnet 43 is controlled by a control device 58 which provides, in dependence on two control signals, full or partial excitation of the electromagnet 43. The control device 58 operates so that in idle running and in lower partial load region the partial excitation is obtained, and with full load or in upper partial load region the full excitation of the electromagnet 43 is obtained at the point of time of the turning on. The control signals are produced by two sensors 59 and 60. The load sensor 59 determines the position of a drive pedal 61, while the rotary speed sensor 60 determines the rotary speed of the internal combustion engine. The point of time of the turning on of the partial or full excitation is adjusted in dependence upon the rotary position of the valve control cam 14, while the point of time of the turning off is controlled in dependence upon the required fuel mixture-filling quantity. For avoiding the fluctuations in the filling quantity because of tolerances in magnetic valve stroke and because of temperature influence, a control signal for correcting the point of time of turning-on is supplied to the control device 58. This control signal is produced from the rotary speed of the internal combustion engine determined by a known smooth running measuring device 62, and from the comparison of the nominal and actual values.
The above described valve control arrangement operates in the following manner:
During rotation of the valve control cam 14 with the cam shaft 13, the cam piston 27 moves downwardly. In the beginning of this movement, the changeover switch 54 is controlled by the control device and the exciting winding 53 is connected with the direct current source 55. If the motor is in the full load or upper partial load region, the magnetic valve 35 is excited fully and transfers by closing of the throughflow opening 40 by the valve needle 41 to its blocking position. The stroke transmitting chamber 29 is thereby blocked, so that with the introduced axial displacement of the piston part 26 of the cam piston 27 no oil can discharge from the stroke transmitting chamber 29. The stroke movement of the cam piston 27 is transmitted thereby via the oil cushion available in the stroke transmitting chamber 29 to the valve piston 25. The latter performs the same stroke path as the piston part 26. The stroke movement of the valve piston 25 causes an identical stroke movement of the valve plunger 12 and thereby the valve member 11 of the inlet valve 10. The stroke of the inlet valve 10 is shown in FIG. 2 by curves I and II. The curve I corresponds to the inlet valve stroke for the case when the stroke transmitting chamber 29 remains closed during the entire cam stroke of the valve control cam 14. With the open inlet valve, or in other words, the valve member 11 lifted from the valve seat 18, the fuel mixture flows into a not shown cylinder of the combustion motor.
The closing process of the inlet valve 10 is started by turning off of the magnet excitation of the magnetic valve 35, in correspondence with the desired fuel mixture-filling quantity in point of time φ SII , or in other words, in the point of time in which the valve control cam 14 has been rotated by the rotary angle φ SII . This is provided by a respective control signal of a control device 58 to the changeover switch 54.
With this turning off of the excitation current, the magnet valve 35 opens since the valve needle 41 is transferred by both return springs 46, 50 to its open position. The valve piston 25 can move upwardly under the action of both valve closing springs 16, 17 of the inlet valve 10, with expelling of oil from the stroke transmitting chamber 29 through the open throughflow opening 40. The valve member 11 is seated on the valve seat 18 and the inlet valve 10 is closed. The stroke of the inlet valve is shown in FIG. 2 by the curve II. When after respective rotation of the valve control cam 14 the cam piston 27 is again moved back to its base position shown in FIG. 1, the oil flows from the spring accumulator 31 via the opened magnetic valve 35 and via the bypass conduit 36 back into the stroke transmitting chamber 29.
Control signals are supplied to the control device 58 via the sensors 59, 60 and indicate the operational condition idling running or lower load region. In this case with starting of the stroke movement of the cam piston 27 produced by the valve control cam 14, the changeover switch 54 is switched so that the electromagnet 43 of the magnetic valve 35 is excited only partially. This partial excitation is selected so that the valve needle 41 covers only the displacement path s 1 and thereby provides a reduced cross-section of the throughflow opening 40. The axial length of the stroke transmitting chamber 29 effective between the piston part 26 and the cam piston 27 reduces. The finally adjusted dynamic pressure causes a displacement of the valve piston 25 and thereby a displacement of the valve plunger 12 and a displacement of the valve member 11 whose course is characterized by the curve III in FIG. 2. As can be clearly recognized, the opening movement of the inlet valve takes place much slower. In the point of time φ SIII , a fuel mixture flows into the cylinder of the motor and is determined in correspondence with the operational conditions. Moreover, the control device 58 provides in the point of time φ SIII a turning off signal to the changeover switch 54, so that the magnetic valve 35 is turned off as described hereinabove and the inlet valve 10 closes as described hereinabove. A curve III' for the stroke of the inlet valve is identified for comparison in FIG. 2 in dotted line, and during this stroke the opening cross-section of the inlet valve 10 in time is identical with the inlet cross-section in time for a stroke course in accordance with curve III. In both cases, the same quantity of fuel flows into the cylinder of the combustion motor. With the stroke course in accordance with curve III, the magnetic valve 35 is closed as in the full load operation during the stroke movement of the valve control cam 14. For obtaining the same cylinder filling, the stroke course in accordance with the curve III' of the magnetic valve 3 must open to the point of time φ SIII . As can clearly be seen from this comparison, with the inventive adjustment of an unloading cross-section for the stroke transmitting chamber 29 during the stroke of the valve control cam 14 which causes the valve opening by means of the magnetic valve 35, a considerably longer opening time of the inlet valve 10 is obtained. Thereby the evacuating phase in the cylinder which follows the closing of the inlet valve 10 and possesses the above described disadvantages is considerably shortened.
The invention is not limited to the above described example. For example, the second return spring 50 can be dispensed with when the stroke of the electromagnet 43 and thereby the displacement of the valve needle 41 is adjustable in a stepless manner via the exciting current for the exciting winding 53 of the electromagnet 43.
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 constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a valve control arrangement for controlling closing and opening time of a valve in a lifting piston-internal combustion engine, 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, readily 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.
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A valve control arrangement for controlling closing and opening time of a valve actuatable by a valve control cam of a cam shaft via an axially displaceable valve plunger, in a displacement piston-internal combustion engine, the valve control arrangement comprises a stroke transmitting chamber between the valve control cam and the valve plunger and arranged to be filled with a working medium, a controllable opening for supplying the pressure medium into the stroke transmitting chamber and withdrawing the pressure medium from the latter so as to change an axial dimension of the stroke transmitting chamber between the valve control cam and the valve plunger, device for controlling the opening so that a stroke of the valve control cam which acts with the beginning of a valve opening adjusts the opening to an unloading cross-section so that to a closing point of time of the valve, a partial quantity of the pressure medium can flow out of the stroke transmitting chamber.
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FIELD OF THE INVENTION
[1] 1. This invention relates to coated porous materials that exhibit air permeability and repellency to liquids having a surface tension at least equal to or greater than 20 dynes/cm.
BACKGROUND OF THE INVENTION
[2] 2. Films, fabrics, and fibrous substrates including textiles have been treated with fluorochemical uncrosslinked urethanes to impart water and soil repellency.
[3] 3. Microporous films prepared by thermally-induced phase separation (TIPS) methods are known. U.S. Pat. No. 4,539,256 (Shipman), U.S. Pat. Nos. 4,726,989 and 5,120,594 (Mrozinski) and U.S. Pat. No. 5,260,360 (Mrozinski et al.) describe such films containing a multiplicity of spaced, randomly dispersed, equiaxed, nonuniform shaped particles of a thermoplastic polymer, optionally coated with a liquid that is immiscible with the polymer at the crystallization temperature of the polymer. Micropores allow permeability to gases, including moisture vapor, but can be impermeable to high surface tension liquids such as water.
[4] 4. Microporous membranes have been coated with a urethane such that the pores are filled and the membrane is impervious to passage of gases. On the other hand, U.S. Pat. No. 5,286,279 describes a gas permeable membrane coated with a fluorochemical urethane wherein the urethane is prepared from either 1,4-cyclohexane diisocyanate or methane 4,4′-diphenyl diisocyanate.
SUMMARY OF THE INVENTION
[5] 5. The present invention fills a need by employing a precursor fluorocarbon urethane composition or curable coating composition to coat a porous material, e.g. a microporous polyolefin membrane. The urethane precursors are crosslinked in situ, upon drying, in such a way that the pathways through the membrane are not blocked or plugged with a coating. As a result, resistance to airflow and bubble point pore size values are retained after coating. Because the coated membrane is highly breathable, durable, and has a low surface energy, it is useful for making ileostomy vent filters, transdermal drug substrates, agricultural and medical apparel, as well as paint and chemical protective garments.
[6] 6. Accordingly, the present invention in its first aspect is a curable coating composition for a porous material containing fluorocarbon urethane precursors including:
[7] 7. (a) a polyisocyanate;
[8] 8. (b) a polyhydric alcohol; wherein at least one member of (a) or (b) has a functionality of greater than 2, and
[9] 9. (c) a perfluoroalkyl alcohol of the formula
R—(CH 2 ) x —OH, (I)
[10] 10. in which R is C n F 2n+1 or
[11] 11.
[12] 12. where x is 1-12; n is 3-20, and R 1 is H, alkyl of 1-4 carbon atoms or — 2 ) x —OH, wherein said composition is capable of crosslinking.
[13] 13. A second aspect of the present invention is a coated porous material which includes a porous material and a curable coating composition applied to said material which includes the following fluorocarbon urethane precursors:
[14] 14. (i) a polyisocyanate;
[15] 15. (ii) a polyhydric alcohol; wherein at least one member of (i) or (ii) has a functionality of greater than 2, and
[16] 16. (iii) a perfluoroalkyl alcohol of the formula
R—(CH 2 ) x —OH, (I)
[17] 17. in which R is C n F 2n+1 or
[18] 18.
[19] 19. where x is 1-12; n is 3-20, and R 1 is H, alkyl of 1-4 carbon atoms or — 2 ) x —OH.
[20] 20. Another aspect of the present invention is a process or method of making a coated porous material which includes the following steps:
[21] 21. applying a curable coating composition which includes the above defined fluorocarbon urethane precursors, in an organic solvent, on a porous material to cover the material, and
[22] 22. drying the resulting coating sufficiently to remove the solvent and promote cross-linking or curing, to produce the coated membrane which exhibits air permeability and repellency to liquid having a surface tension at least equal to or greater than 20 dynes/cm.
[23] 23. The inventive porous materials having a cured coating, which include non-woven, woven materials, perforated films and microporous membranes retain their liquid repellency and moisture vapor permeability properties for extended periods in all types of applications.
[24] 24. The microporous polyolefin materials may contain a compatible liquid or diluent such as mineral oil along with the fluorocarbon urethane coated material and are referred to as (oil-in) materials. Such a fluorocarbon urethane coating on an oil-in polyolefin membrane provides the membrane the ability to resist wetting by fluids like alcohols, toluene, mineral oil, water-surfactant solutions and ethylene glycol even though the membrane's pore walls are coated with approximately 35-40 wt-% mineral oil or another diluent. The same coating on a polyolefin membrane having no diluent (oil-out) or on other membranes or materials not prepared by thermally induced phase separation (TIPS) provides materials displaying even more repellency such that the coated materials resist wetting by all of the above-mentioned fluids as well as chlorohydrocarbons such as trichloroethane, and hydrocarbons such as decane, octane, heptane and hexane.
[25] 25. The present coated porous materials having a cured coating are repellent to a wide variety of fluids including the above organic fluids and are much more repellent than membranes containing prior fluorocarbon coatings such as the fluorocarbon oxazolidinone coatings on polyolefin membranes described in U.S. Pat. No. 5,260,360.
DETAILED DESCRIPTION
[26] 26. Coated and cured porous materials, e.g. microporous polyolefin membrane materials, of the present invention, exhibit significant air permeability properties and repel aqueous-based as well as non-aqueous based liquids including a wide variety of non-aqueous liquids having a surface tension at least equal to or greater than 20 dynes/cm.
[27] 27. Porous materials of the present invention having a cured coating exhibit durability of their fluid repellency properties when subjected to rubbing, touching, folding, flexing or abrasive contact. They also display oleophobic properties, resisting penetration by oils and greases and some (eg. those made from polyethylene (PE), polypropylene (PP) or PE/PP blends) may be heat sealable. For the oil-in version of the invention, the oleophobicity and heat sealing properties of the membrane materials are most surprising since the membrane materials contain an oily, oleophilic processing compound which, a priori, one would expect, would promote wetting by other oleophilic materials and which also would inhibit heat sealing.
[28] 28. Transport of a liquid challenge through most porous materials or fabrics occurs because the liquid is able to wet the material. A possible route through the material is for the liquid to initially wet the surface of the material and to subsequently enter pore openings at the surface of the material followed by a progressive wetting of and travel through interconnected pores until finally reaching the opposite surface of the material. If the liquid has difficulty wetting the material, liquid penetration into and through the material will, for the most part, be reduced. A similar phenomenon occurs in the pores, where reduced wetability, in turn, reduces pore invasion. Generally the greater the numerical difference between the liquid surface tension of the liquid and the surface energy of the porous material (the latter being lower), the less likely it is that the liquid will wet the porous material.
[29] 29. In the case of aqueous solutions containing surface active agents (eg. surfactants) the wetting of the porous materials is usually time-dependent, controlled by the slow diffusion and absorption of surfactants onto the surface of the porous materials.
[30] 30. In the present invention, the extent of barrier protection may be described by four levels, of which the first two describe existing levels and the last two describe levels of protection as a result of the coatings presented by this invention.
[31] 31. Level 1 TIPS membranes without diluents (polypropylene (PP), or high density polyethylene (HDPE)) TIPS membranes with diluents, particle-filled membranes, and polytetrafluoroethylene (PTFE) membranes. In terms of repellency beyond water, these materials immediately wet through with a 0.1 wt.% surfactant, Triton X-1000/water solution with a surface tension of 30 dynes/cm under a constant pressure of 69 kpa (10 psi). These microporous materials also wet easily with mineral oil and solvents like alcohol, toluene, methylethyl ketone (MEK) and the like.
[32] 32. Level 2 TIPS oil-in PP membranes containing fluorocarbon oxazolidinone (FCO) as a melt additive or a topical coating. These membranes prevent penetration of the above surfactant/water solution for 32 minutes at 69 kpa (10 psi). They, also resist wetting by methyl alcohol and water/isopropyl alcohol mixtures (IPA) (up to 80% IPA), but are wetted by pure IPA, toluene, MEK, and other solvents.
[33] 33. Level 3 TIPS oil-in PP membranes with a fluorocarbon-urethane coating presented by this invention. These materials do not allow flow of the above surfactant/water solution through the membrane in over three days of continuous testing under a constant pressure of 69 kpa (10 psi). In addition, these materials resist wetting by any alcohol, toluene, ethylene glycol, ethyl acetate, and by a number of concentrated surfactants.
[34] 34. Level 4 TIPS diluent-free (or oil-out) membranes, PTFE, particle-filled membranes, polyamides and other polymer membranes with a fluorocarbon-urethane coating of the present invention. These materials resist wetting (except under high pressure) by surfactants, alcohol, MEK, toluene, dodecane, decane, octane, heptane, and hexane.
[35] 35. The oleophobic, hydrophobic, moisture permeable, air permeable, coated porous materials of the present invention may be prepared by topically applying a fluorocarbon urethane precursor, the curable coating composition, to a porous material through spray or roll-on application, through dip coating or transfer coating techniques. Following the application, the coating is dried sufficiently to remove solvent and to promote cross-linking or curing of the fluorocarbon urethane coating membrane.
[36] 36. By porous material, it is meant that a material has a pore size less than about 250 micrometers. Preferably the pore size is from about 0.01 to about 250 micrometers. The materials include non-woven and woven materials and perforated films. Porous polymeric materials include polyurethane, polyesters, polycarbonates, polyamides, and preferably polytetrafluoroethylene (PTFE) and polyolefins. The polymeric materials may also be referred to as microporous membranes.
[37] 37. Examples of membranes which are made by thermally induced phase separation include crystalline or crystallizable polyolefin membranes described, for example, in U.S. Pat. No. 4,539,256 (Shipman), U.S. Pat. No. 4,726,989 (Mrozinski), U.S. Pat. No. 4,863,792 (Mrozinski), U.S. Pat. No. 4,824,718 (Hwang), U.S. Pat. No. 5,120,594 (Mrozinski) and U.S. Pat. No. 5,260,360 (Mrozinski) each of which is incorporated herein by reference.
[38] 38. An example of a perforated films is the plain surface, polycarbonate, Track-etch membrane filter screens available from Poretics Corporation, of Livermore, Calif.
[39] 39. Further, the curable coating compositions can be topically applied to materials such as stretched PTFE, as mentioned above, or particle loaded films which do not contain a diluent or compatible liquid (oil-out). The compatible liquid may be removed from the microporous polyolefin sheet material, either before or after orientation, to form a diluent-free microporous polymeric material. The compatible liquid can be removed by, for example, solvent extraction, volatilization, or any other convenient method.
[40] 40. Crystallizable olefin polymers suitable for use in the preparation of coated microporous membrane materials of the present invention are melt processable under conventional processing conditions. That is, on heating, they will easily soften and/or melt to permit processing in conventional equipment, such as an extruder, to form a sheet, tube, filament or hollow fiber. Upon cooling the melt under controlled conditions, suitable polymers spontaneously form geometrically regular and ordered crystalline structures. Preferred crystalizable olefin polymers for use in the present invention have a high degree of crystallinity and also possess a tensile strength of at least about 689 kpa (100 psi).
[41] 41. Examples of suitable commercially available crystallizable polyolefins include polypropylene, block copolymers or other copolymers of ethylene and propylene, or other polymers, such as polyethylene, polypropylene and polybutylene polymers which can be used singularly or in a mixture.
[42] 42. Materials suitable as processing compounds for blending with the crystallizable polymer to make the microporous membrane materials of the present invention are liquids or solids which are not solvents for the crystallizable polymer at room temperature. However, at the melt temperature of the crystallizable polymer the compounds become good solvents for the polymer and dissolve it to form a homogeneous solution. The homogeneous solution is extruded through, for example, a film die, and on cooling to or below the crystallization temperature of the crystallizable polymer, the solution phase separates to form a phase separated film.
[43] 43. Preferably, these second phase compounds have a boiling point at atmospheric pressure at least as high as the melting temperature of the polymer. However, compounds having lower boiling points may be used in those instances where superatmospheric pressure may be employed to elevate the boiling point of the compound to a temperature at least as high as the melting temperature of the polymer. Generally, suitable compounds have solubility parameter and a hydrogen bonding parameter within a few units of the values of these same parameters for the polymer.
[44] 44. Some examples of blends of olefin polymers and processing compounds which are useful in preparing microporous materials in accordance with the present invention include; polypropylene with mineral oil, dibenzylether, dibutyl phthalate, dioctylphthalate, or mineral spirits; polyethylene with xylene, decalin, decanoic acid, oleic acid, decyl alcohol, diethyl phthalate, dioctyl phthalate, mineral oil or mineral spirits, and polyethylene-polypropylene copolymers with mineral oil or mineral spirits. Typical blending ratios are 20 to 80 weight percent polymer and 20 to 80 weight percent blending compound.
[45] 45. A particular combination of polymer and processing compound may include more than one polymer, i.e., a mixture of two or more polymers, e.g. polypropylene and polybutylene, and/or more than one blending compound. Mineral oil and mineral spirits are examples of mixtures of processing compounds, since they are typically blends of hydrocarbon liquids. Similarly, blends of liquids and solids may also serve as the processing compound.
[46] 46. The curable coating composition or fluorocarbon urethane precursors include a combination of polyisocyanate, a polyhydric alcohol and a perfluoroalkyl alcohol as above defined. These components are mixed in an organic solvent and the resulting solution is applied as above described to the polyolefin membrane. The composition contains at least equimolar amounts of polyisocyanate and alcohol. Preferably, an excess of polyisocyanate may be used.
[47] 47. As the polyfunctional isocyanate component employed in the curable coating composition of the present invention, various compounds may be employed without any particular restrictions, so long as they are bifunctional or of higher functionality. Preferred polyisocyanates are di or tri-functional isocyanates. For example, di-functional isocyanate compounds may include aromatic isocyanates such as 2,4-toluenediisocyanate, 4,4′-diphenylmethanediisocyanate, tolidinediisocyanate and dianisidinediisocyanate; alicyclic diisocyanates such as 2-methyl-cyclohexane-1,4-diisocyanate, isophoronediisocyanate and hydrogenated MDI
[48] 48. and aliphatic diisocyanates such as hexamethylenediisocyanate and decamethylenediisocyanate. These compounds may be represented by the formula OCN—Y—NCO. When two OCN—Y—NCO are reacted in the presence of water, a dimer of the formula OCN—Y—NHCONH—Y—NCO will be formed. The difunctional isocyanate compounds include such dimers. Another difunctional isocyanate is
[49] 49. Desmodur N3400
[50] 50. In addition to the difunctional isocyanate compounds, polyfunctional isocyanate compounds such as trifunctional, tetrafunctional or pentafunctional isocyanate compounds may be mentioned. Specific examples of trifunctional isocyanate compounds include, in addition to the after-mentioned compounds, a trimer of the formula
[51] 51. obtained by reacting the above-mentioned dimer of the formula OCN—Y—NHCONH—Y—NCO with a monomer of the formula OCN—Y—NCO. Examples of other tri-functional isocyanate compounds include:
[52] 52. Desmodur N-100
[53] 53. Isocyanurate of toluene diisocyanate (TDI)
[54] 54. Desmodur N3300
[55] 55. The polyhydric alcohol includes any multifunctional monomer alcohol having at least two hydroxyl groups. Preferred polyhydric alcohols are those having 2 to 8 carbon atoms and preferably being a diol or triol. Particularly useful are, for example, 1,4-butane diol, neopentyl glycol or trimethylol propane.
[56] 56. Preferred perfluoroalkyl alcohols are those of formula I, defined above,
[57] 57. wherein R is
[58] 58. in which x is 1-4, and R 1 is methyl, ethyl or —CH 2 OH.
[59] 59. Most preferred is the alcohol of formula I wherein R is C n F 2n+1 SO 2 —N—R 1 in which n is 8, and x is 2 and R 1 is methyl.
[60] 60. The above components of the curable coating composition are combined in a solvent in which the solution contains from about 2 to about 40 wt-% solids, preferably from about 5-10 wt-% solids. A most preferred composition contains about 7 wt-% solids. This solution is applied as described above to the porous material.
[61] 61. An optional ingredient to enhance the crosslinking of the components of the curable coating composition is a catalyst. Such catalysts are wellknown in the art and may include
[62] 62. (a) tertiary amines;
[63] 63. (b) tertiary phosphines;
[64] 64. (c) strong bases;
[65] 65. (d) acidic metal salts of strong acids;
[66] 66. (e) chelates of various metals;
[67] 67. (f) alcoholates and phenolates of various metals;
[68] 68. (g) salts of organic acids with a variety of metals such as alkali metals, alkaline earth metals;
[69] 69. (h) organometallic derivatives of tetravalent tin, trivalent and pentavalent As, Sb, and Bi and metal carbonyls of iron and cobalt.
[70] 70. Organotin compounds deserve particular mention as catalysts for catalyzing the urethane forming reaction. These compounds include the dialkyltin salts of carboxylic acids, e.g., dibutyltin diacetate, dibutyltin dilaurate, dibutyltin maleate, dilauryltin diacetate, dioctyltin diacetate, dibutylin-bis(4-methylaminobenzoate), dibutyltin-bis(6-methylaminocaproate), and the like. Similarly, there may be used a trialkyltin hydroxide, dialkytin oxide, dialkytin dialkoxide or dialkyltin dichloride. Examples of these compounds include trimethyltin hydroxide, tributyltin hydroxide, trioctyltin hydroxide, bitutyltin oxide, dioctyltin oxide, dilauryltin oxide, dibutyltin-bis(isopropoxide), dibutyltin-bis(2-dimethylaminopentylate), dibutyltin dichloride, dioctyltin dichloride, and the like. Particularly useful for the present invention is dibutyltin dilaurate.
[71] 71. As an organic solvent used to facilitate the application of the precursors, the following may be used: an ether such as dioxane, tetrahydrofuran, ethyl propyl ether; an amide such as formamide, dimethylformamide or acetamide; ketones such as acetone, methyl ethyl ketone, methyl isopropyl ketone or methyl isobutyl ketone; and esters such as methyl acetate, ethyl acetate, propyl acetate or butyl acetate. Such an organic solvent is added usually in an amount of from about 60 to about 98 wt-%, preferably about 90-95 wt-%. The most preferred amount of solvent is about 93 wt-% of the total of coating precursors, and the preferred solvent employed is a ketone such as methyl ethyl ketone.
[72] 72. Certain conventional additive materials may also be blended in limited quantities with the curable coating composition. Additive levels should be chosen so as not to interfere with the formation of the microporous membrane material or to result in unwanted exuding of the additive. Such additives may include, for example, dyes, pigments, plasticizers, UV absorbers, antioxidants, bactericides, fungicides, ionizing radiation resistant additives, and the like. Additive levels should typically be less than about 10% of the weight of the polymer component, preferably less than about 2% by weight.
[73] 73. An additional aspect of the present invention is the use of at least one surfactant which may be applied onto the porous material as a precoat or made part of the curable coating composition.
[74] 74. The surfactant adds hydrophilic character to the porous material and decreases the interfacial tension of a liquid or liquid system against the surface of the pores within a porous material. Normally any surfactant used will be a wetting agent which will facilitate the surface of the pores within a membrane being wetted by water. If desired, a mixture of different wetting agents may be employed in any specific application.
[75] 75. Accordingly, any surfactant which, when applied to the porous material (i.e., in the absence of the coating polymer), lowers the surface tension thereof to the extent that the substrate will exhibit a contact angle with water of less than about 80°, preferably less than about 60°, will render said substrate hydrophilic and can be employed in conjunction with the coating polymer.
[76] 76. Surfactants used may be a nonionic, cationic, or anionic type, or a combination of two or more of these surfactants.
[77] 77. Examples of nonionic surfactants are: polyol fatty acid monoglyceride, polyoxyethylene fatty acid ester, polyoxyethylene sorbitan fatty acid ester, polyoxyethylene alkyl ether, polyoxyethylene alkyl allyl ether, and polyoxyethylene alkylether phosphate.
[78] 78. Examples of cationic surfactants are: quaternary ammonium salts, polyoxyethylene alkylamines, and alkylamine oxides.
[79] 79. Examples of anionic surfactants are: alkylsulphonates, alkylbenzene sulphonates, alkylnaphthalene sulphonates, alkylsulphosuccinates, alkylsulphonate ester salts, polyoxyethylene alkyl sulphonate ester salts, alkyl phosphates, and polyoxyethylene alkyl phosphates.
[80] 80. A preferred nonionic surfactant is, for example, polyethylene glycol monostearate. A preferred anionic surfactant is dioctyl sodiumsulfosuccinate.
[81] 81. In the following non-limiting examples, all parts and percentages are by weight unless otherwise indicated. In evaluating the materials of the invention and the comparative materials, the following test methods are used.
EXAMPLES
Test Methods
[82] 82. “Gurley time” is measured by means of densometer number (i.e., flow-through time) of at least 2 seconds for 50 cc of air at 124 mm (4.88 in.) H 2 O pressure to pass through a sample of the web having a circular cross-sectional area of approximately 645 mm 2 (1 square inch). A temperature of approximately 230°-24° C. (74°-76° F.) and 50 percent relative humidity are maintained for consistent measurements. The “Gurley” densometer or flow-through time may be measured on a densometer of the type sold under the trade designation “Model 4110” densometer by W. & L. E. Gurley of Troy, N.Y., which is calibrated and operated with a Gurley Teledyne sensitivity meter (Cat. No. 4134/4135). The “Gurley” densometer time is determined in a manner similar to a standard test of the Technical Association of the Pulp and Paper Industry of Atlanta, Ga., for measuring the air resistance of paper (TAPPI Official Test Method T 460 om-B3 (which is incorporated herein by reference). Gurley time is inversely related to void volume of the test specimen of web. Gurley time is also inversely related to average pore size of the test specimen.
EXAMPLE 1
[83] 83. A coating solution was prepared by mixing 38.5 g 1,6-hexane diisocyanate biuret (Desmodur™ N-75, Bayer, Philadelphia, Pa.), 56.8 g N-methyl-N-2-hydroxyethylperfluorooctylsulfonamide (available from Minnesota Mining and Manufacturing Company (3M), St. Paul, Minn.) and 4.7 g 1,4-butanediol (Aldrich Chemical Co., Milwaukee, Wis.) in 1390 g methyl ethyl ketone (MEK, Aldrich) to make a 7.0 weight percent solids solution. The solution was stirred and mixed with 0.5 g dibutyltin dilaurate (Aldrich), then applied to two different microporous membranes using a rotogravure coating process and a gravure roll having small indentations in its surface shaped like inverted pyramids. There were approximately 35 lines (of inverted pyramids) per inch (14 lines per cm) each pyramid being about 0.25 mm deep and having an internal tooth angle (angle between two edges of pyramid measured in the plane of one pyramid surface at the apex) of 90°, and the land area between inverted pyramids comprised about 50% of the gravure roll surface. The membranes were conveyed through the gravure roll apparatus at a rate of 3 m/min. Membrane 1A was a 0.04 mm thick polypropylene membrane (“oil-in” KN 9400™ porous film, 3M) and membrane 1B was a 0.05 mm thick polyethylene membrane (“oil-out” Cotran™ membrane, 3M) supported on a silicone release liner. After coating, each membrane was dried in an oven at 99° C. to remove MEK solvent and crosslink the urethane coating. Properties of the coated membranes are shown in Table 1.
TABLE 1 Gurley Coating No., Pore size Oil/ Add-On, sec/50 micro- Water/IPA Heptane Example wt % cm 3 meters resistance A resistance B 1A Comp 0 56 0.26 2 0 1A 15 60 0.25 10 2-3 1B Comp 0 12 0.34 1 0 1B 30 17 0.32 10 6
[84] 84. Table 1 shows that a fluorourethane coating of the invention increases membrane resistance to wetting by both water and oil, whether the membrane is “oil-in” (i.e., Example 1A) or “oil-out” (Example 1B) without reducing breathability (Gurley Number) too much and without filling pores of the membrane. In addition, the table shows that coatings of the invention are effective on both polypropylene and polyethylene membranes.
EXAMPLE 2
[85] 85. A coating solution was prepared as described in Example 1 by mixing 35.1 g 1,6-hexane diisocyanate biuret (Desmodur N-75, Bayer) diisocyanate, 51.3 g N-methyl-N-2-hydroxyethyl-perfluorooctylsulfonamide, 12.2 g polyethylene glycol 400 monostearate (Aldrich) and 1.4 g 1,4-butanediol in 1329 g methyl ethyl ketone to make a 7.0 weight percent solids solution. The solution was stirred and mixed with 0.5 g dibutyltin dilaurate then applied to a 0.05 mm thick polyethylene membrane (“oil-out” Cotran™ membrane, 3M Co.) supported on a silicone release liner, dried and crosslinked. Coating weight was approximately 30 wt.%. Properties of the coated membrane are shown in Table 2.
TABLE 2 Gurley No., Pore size Water/IPA Oil/Heptane Example sec/50 cm 3 micrometers resistance A resistance B 2 Comp 12 0.34 1 0 2 17 0.32 10 8
[86] 86. The data of Table 2 show that a chain-extended fluorourethane provided increased oil/heptane resistance (compared to Example 1B) over that provided by a non-chain extended fluorourethane.
EXAMPLE 3
[87] 87. A solution of 44 g polyhydroxyl polyether (Pluracol™ PEP 550, BASF Corp., Mt. Olive, N.J.), 94 g N-methyl-N-2-hydroxyethyl-perfluorooctylsulfonamide and 150 g Desmodur™ N-75 diisocyanate in 2212 g methyl ethyl ketone was stirred and mixed with 2.5 g Irganox™ 1010 antioxidant (Ciba-Geigy, Ardsley, N.Y.) and 2.5 g dibutyltindilaurate to make a 10% by weight solution of isocyanate/polyol. The solution was coated onto porous polyethylene membrane (3M, St. Paul, Minn.) from a dip pan onto a trihelical gravure cylinder (40 lines/2.54 cm) having a volume factor of 51 micrometers and a tooth angle of 135°. Coating speed was 3.65 m/min after which the saturated membrane was heated in three successive ovens at 104° C. (total residence time 4 minutes) to complete the polyurethane formation. Initial membrane weight was 4.5 g/m 2 and final, cured coated membrane weight was 6.75 g/m 2 .
[88] 88. The coated membrane had a moisture vapor transmission rate (MVTR) that was 95% of the original uncoated film. Gurley porosity of the uncoated film was 14 sec/SO cc, and that of the coated film was 142 sec/50 cc. The coated film was not wet by toluene, octane, ethyl acetate and isopropyl alcohol, and it was wet by heptane, ethylether and Freon™ 113.
EXAMPLE 4
Effect of Various Formulations on Performance
[89] 89. In order to evaluate certain polyurethane formulations, several isocyanates, aliphatic diols, and fluorocarbon alcohols were formulated into coatings for oil-in, oil-out and laminated porous membranes. The results are shown in Table 4. In Table 4:
[90] 90. D-75N was Desmodur 75N™, the trifunctional biuret of hexane diisocyanate (Bayer Corp., Pittsburgh, Pa.)
[91] 91. D-I was Desmodur I™, toluene diisocyanaate (Bayer Corp.)
[92] 92. D-W was Desmodur W™, methane bis(4,4′-isocyanatocyclohexane) (Bayer Corp.)
[93] 93. MDI was methane bis(4,4′-isocyanatobenzene)
[94] 94. D-H was Desmodur H™, 1,6-hexanediisocyanate (Bayer Corp.)
[95] 95. BDO was 1,4-butane diol
[96] 96. TMP was trimethylolpropane
[97] 97. N-MeFOSE was N-methyl-N-(2-hydroxyethyl)perfluorooctane sulfonamide (3M, St. Paul, Minn.)
[98] 98. Zonyl Ba-N™ was perfluoroalkyl ethyl alcohol (DuPont Chemical Co., Wilmington, Del.)
[99] 99. Oil-out PP film was prepared according to U.S. Pat. No. 5,120,594, Example 1, incorporated by reference; precoatiny Gurley=10-12; W=3; O=0 Oil-in PP film was KN 9400™ microporous film (3M Company); precoating Gurley=80-125; W=3; O=0 Gurley numbers were as described supra, in units of sec/50 cc
[100] 100. O and W refer to resistance to Oil and Water, respectively, as described for Table 1, supra Laminate refers to a single-ply oil-in KN 9400™ film laminated with a 1 ounce polypropylene spunbonded web (Polybond, Inc., Waynesboro, Va.) as described in U.S. Pat. No. 5,260,360, Example 17, incorporated by reference;
[101] 101. for formulation 4B Laminate, Gurley=439 for formulation 4B Laminate, coated twice,
[102] 102. W=10, O=4, Gurley=1140
[103] 103. for formulation 4I Laminate, Gurley=336
[104] 104. for formulation 4I Laminate, coated twice, W=10, Gurley=1403
[105] 105. Data in Table 4 shows that post-coating resistance was approximately the same for almost every formulation, and it was improved significantly over pre-coated values. In one example each, both N-ethyl FOSE and Zonyl™ BA-N appeared to provide slightly less post-coating resistance than precoated or uncoated films, for both oil and water on both oil-in and oil-out films.
TABLE 4 Aliphatic Lami- N-Me N-Et Zonyl ™ Sample D-75N D-I D-W MDI D-H BD0 TMP FOSE FOSE BA-N Gurley W O Gurley W O W O 4A 825 67 838 12.6 10 6 128 10 3 4B 825 68 838 12.0 10 6 84.5 10 3 10 3 4C 383 67 838 12.2 9 6 157 9 3 4D 396 67 838 12.6 9 6 156 9 3 4E 429 67 838 25.1 10 8 1048 10 3 4F 252 67 838 20.3 10 8 235 10 3 4G 504 203 838 37.3 10 8 1200 10 3 4H 825 68 860 12.9 6 6 209 5 2 4I 577.5 68 838 13.0 10 6 180 10 2 10 2 4J 825 68 771 22.0 10 6 180 5 1 4K 1650 68 838 12.3 10 6 170 10 2 4L 275 45 559 12.8 10 6 170 10 2
EXAMPLE 5
Effect of Coating on Various Substrates
[106] 106. In order to demonstrate the effectiveness of fluorourethane coatings on a number of microporous membranes, a standard mixture of 3.0 equivalents Desmodur N-75™ (Bayer Corp.), 1.5 equivalents N-methyl FOSE (3M), and 1.5 equivalents 1,4-butanediol (Aldrich Chemical Co.) in methyl ethyl ketone solvent, at the percent solids shown in Table 5, was prepared, and membranes were coated as described in Example 1. In some cases (5F, 5M-O, 5R) a surfactant was added to the coating solution, which generally increased wetting of the membrane, increasing coating effectiveness. Samples 5P and 5Q describe a membrane prepared by melt-blending a waxy surfactant with the polypropylene/mineral oil nucleating agent mixture to prepare a hydrophilic membrane prior to solution-coating the polyurethane precursor solution. Samples 5G and 5H were coated with the urethane precursor solution, dried, then re-coated (hence the designation “2X.” In Table 5:
[107] 107. Oil-in PP refers to KN 9400™ microporous film (3M Company);
[108] 108. Oil-out PP refers to microporous film prepared according to U.S. Pat. No. 5,120,594, Example 1;
[109] 109. PEGML 200 refers to poly(ethylene glycol) monolaurate surfactant of MW 200 (Aldrich);
[110] 110. Laminate refers to a single-ply oil-in KN 9400™ film laminated with a 1 ounce polypropylene spunbonded web (Polybond, Inc., Waynesboro, Va.) as described in U.S. Pat. No. 5,260,360, Example 17;
[111] 111. PEGMS 400 refers to a poly(ethylene glycol)monostearate surfactant of MW 400 (Aldrich);
[112] 112. TYVEK™ refers to a spunbonded polyethylene material (DuPont Co.);
[113] 113. EXXAIRE™ refers to a particle-filled polyethylene membrane (Exxon Chemical Co.);
[114] 114. SONTARA™ refers to a woven fabric comprising cellulose and poly(ethylene terphthalate) fibers (DuPont)
[115] 115. Porous PTFE refers to a poly(tetrafluoroethylene) membrane, Gurley=5 sec/50cc, (Tetratec Corp., Feasterville, Pa.).
[116] 116. DOS 3 refers to dioctyl sodiumsulfosuccinate (Aldrich)
[117] 117. The data in Table 5 show that, for essentially any type of surfactant, using a surfactant in the urethane-precursor coating solution or coating on an oil-out membrane prior to treating with urethane-precursor solution improves wetting, hence improves oil and water resistance of the coated membrane over membranes coated in the absence of a surfactant. For oil-in membranes, melt blending a surfactant in the extrusion formation process (rather than coating with a surfactant on an oil-in membrane prior to treating with urethane precursor solution) results in improved water and oil resistance, compare Sample 50 (melt) to 5G (topical).
TABLE 5 Min. Oil, Gurley Sam- % + Solution Before Gurley After W/IPA W/IPA Oil/Hept Oil/Hept ple Description additive % Solids, % cm/50 cc cm/50 cc Before After Before After 5A Oil-in PP (3M) 27 7 80 85 3 10 0 3 5B ″ 27 7 120 213 3 10 0 3 5C ″ 27 20 120 450 3 10 0 3 5D ″ 27 40 120 >5000 3 10 0 4 5E ″ 27 2 120 125 3 10 0 1 5F Oil-in PP (3M) 27 7 295 510 3 10 0 2 2X 5G Oil-in PP (3M) + 27 7 120 300 3 9 0 1 PEGML 200 5H Oil-out PP (3M) 0 7 12 12 3 10 0 6-7 5I ″ 0 20 12 20 3 10 0 6-7 5J ″ 0 40 12 240 3 10 0 6-7 5K ″ 0 2 12 12 3 8 0 4 5L Oil-out PP (3M) + 0 7 12 13 3 10 0 8 FC-13876 5M Oil-out PP (3M) + 0 7 12 13 3 10 0 7-8 PEGML 200 5N Oil-out PP (3M) + 0 5 12 15 3 10 0 8 PEGMS 400 5O Oil-in PP + PEGML 37 + 3 7 25 47 0 10 0 2 200 melt 5P Oil-in PP + PEGMS 27 5 125 155 3 10 0 2 400 5Q TYVEK ™ (Dupont) 0 7 5 3 1 7 0 6 5R EXXAIRE ™ (Exxon) 0 7 185 950 3 10 0 6-7 5S SONTARA ™ (DuPont) 0 7 <1 <1 8 10 5 6-7 5T Porous PTFE 0 7 5 4 4 10 0 8 (Tetratech) 5U Oil-out PP + 0 7 12 15 3 10 0 8 DOS 3 before ure thane coating 5V Oil-out PP + 0 7 12 15 3 10 0 8 DOS 3 in urethan precursor coating
[118] 118. The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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Coated porous materials that exhibit air permeability and repellency to liquids having a surface tension at least equal to or greater than 20 dynes/cm which are suitable for making ileostomy vent filters, transdermal drug substrates, agricultural and medical apparel, as well as paint and chemical protective garments. The coating for the porous material is applied as a curable composition containing fluorocarbon urethane precursors which are cross-linked in situ.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to the field of support systems for use in display devices and other elements. More particularly, this invention relates to support bracket assemblies for adjustably securing a horizontal mounting bar to an upright member for height-adjustable support of display shelves.
[0002] In the field of retail sales, items for sale or other merchandise is generally displayed on a display or support system. Many different forms of custom-built support systems are known, and these generally include partition walling and upright support posts. The upright support posts of such retail merchandise display units, a portion of which is shown in FIG. 1, often called “standards,” are generally made of roll formed steel sections mounted into weighted bases. Such standards typically have vertically-oriented slots cut into the front of the standards along the height of the standard, from top to bottom, and these slots are of varied height, width, depth (thickness of the standard), slot-to-slot spacing and slot-to-edge spacing. Wall structures, themselves also often having apertures formed therethrough, are typically held between the standards.
[0003] Other elements, such as horizontal pole brackets or bars (called “faceouts”), shelves, drawers or the like, can be adjustably secured to the standards by interaction between the slots and hooked prongs or flanges that are formed on the attachment portion of the faceouts, shelves or other attachments, also as shown in FIG. 1. These prongs or flanges are either integrally formed as part of the attachment portion of the faceout or are welded or soldered onto the attachment end of the faceout after manufacture. A typical prior art attachment flange has a gripping gap, as shown in FIG. 1, within which the bottom edge of the slot, i.e., the thickness of the standard, fits snugly when the attachment flange is inserted into the slot and forced downwards. By removing the attachment flange from one slot in the standard and setting it within another slot, faceout bars and other attachments can be vertically adjustable relative to the upright, so as to allow the retailer to raise or lower these attachments and the items displayed thereon, as desired.
[0004] Typically, however, once a display unit is constructed, adjusting the height and positions of shelves or individual faceouts can be very difficult, and adjusting the height and position of an entire shelving unit can be that much more onerous. This is especially so where the shelves or standards are placed in close relation to one another, where the shelving units project away from the wall and where the items are already loaded onto the display unit. In each of these instances, it will be very difficult to maneuver the hooked attachment prongs or flanges into the slots for height adjustment, and often the entire display must be deconstructed in order to adjust even just one portion of the display. A means to remotely adjust the faceout position without having to break apart the entire display is needed.
[0005] In retail situations, there is a need for a faceout to be quickly and easily adjustable so that a salesperson can change the retail display without using tools. In addition, because these displays are often changed and moved about by people who are not skilled technicians, the adjustability of the faceouts should be foolproof, sturdy and tight-fitting so that the displays will not be broken during adjustment and so that, once adjusted, the position of the faceout will not change. Unfortunately, many of the assemblies that use screws or other external attachment mechanisms for adjustment are not suitable, because tools are generally required for adjustment of these mechanisms, and there is often little or no room for manipulation of tools at the retail site. In addition, even if tools were not required and they can be installed by hand, there is often very little room between or among display units for manipulation of hands in installation of faceouts.
[0006] In addition, the slots that are cut into the front of the standards along the height of the standard, from top to bottom, are very often unique from manufacturer to manufacturer and from standard to standard, often varying in height, width, spacing between slots, spacing from slot to edge and particularly depth, i.e., the thickness of the material of the standard. As shown in FIG. 1, a typical prior art attachment flange has a gripping gap within which the bottom edge of the slot fits snugly when the attachment flange is inserted into the slot and forced downwards. Accordingly, the hooked attachment flanges that are used with the standards are likely to be slot-specific, meaning that each attachment flange will fit tightly and best onto the bottom edge of one sized slot and will be loosely-fit or will be too small for other slots. This often causes confusion and improperly constructed shelving units, as hooked attachment flanges that are meant to be used with one standard and its slots may be used with another standard and its slots. Even worse, a display unit constructed using attachment flanges that do not match the standard may collapse due to the improper construction of the display unit. Moreover, if a particular retailer possesses a specific standard or wall unit, any display that is built for that retailer using that standard or wall unit will necessarily have to employ only hooked attachment flanges that are specific for and fit within the slots of that standard or wall unit of the retailer. This is inconvenient for the display designer, who is now obligated to use the attachment flanges that match the standard possessed by the retailer instead of other, perhaps more appropriate, attachment flanges. Thus, there is a need for a universal faceout attachment flange that is adjustable so as to be used with all different sizes of slots.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is one object of this invention to provide an improved assembly for securely attaching a horizontal faceout display bar to an upright standard or wall unit for retail display purposes.
[0008] It is another object of this invention to provide an improved retail display apparatus that would allow a horizontal faceout display to be easily and quickly removed from and secured to an upright standard or wall unit while still providing a secure and stable attachment.
[0009] It is a further object of this invention to provide an improved display apparatus having an attachment assembly that allows a horizontal faceout display bar to be easily and securely attached to an upright standard or wall unit from a distance away.
[0010] It is still another object of this invention to provide an improved display apparatus having an attachment assembly that is universal such that it could be used with most if not all display unit attachment slots.
[0011] These and other objects and advantages of the invention are accomplished in accordance with the principles of the invention by providing a hooked attachment prong, flange or bracket that is adjustable at the end of a faceout by way of a threaded screw between the end of the faceout and the bracket prong. The hooked attachment prong or flange is shaped to fit within all slots within the various manufacturers' standards. Generally, once the attachment flange or prong is inserted within a slot, the prong end cannot turn within the standard. The faceout is attached to the standard from outside the display by remotely inserting the prongs into a slot and turning the faceout bar, thereby screwing the faceout tightly against the standard. The faceout bar could be telescoping to allow the attachment flange to be inserted within the slot from an even greater distance away.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The above and other objects and advantages of the invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which the reference characters refer to like parts throughout and in which:
[0013] [0013]FIG. 1 shows a perspective view of a prior art slotted standard and faceout having an attachment flange;
[0014] [0014]FIG. 2 shows a side view of the prior art apparatus of FIG. 1;
[0015] [0015]FIG. 3 shows an exploded perspective view of an embodiment of the invention;
[0016] [0016]FIG. 4 shows a side and partially transparent view of the embodiment of the invention shown in FIG. 3; and
[0017] [0017]FIG. 4 shows another embodiment of the attachment flange.
DETAILED DESCRIPTION OF THE INVENTION
[0018] [0018]FIG. 1 shows a typical prior art upright support post or standard 10 of a retail merchandise display unit, which is generally made of roll formed steel and is mounted into a weighted base. Standard 10 typically has vertically-oriented slots 12 cut into the front side 14 of the standard 10 along its height. Standard 10 may also have sides 11 on either side of front side 14 for support of standard 10 . Separate attachment elements, collectively called faceouts 16 , can be adjustably secured to standard 10 by interaction between slots 12 and hooked prongs or flanges 18 , one or more of which are formed on the attachment portion of faceouts 16 . Attachment flanges 18 are generally either integrally formed as part of faceout 16 or are welded or soldered onto the end of faceout 16 after manufacture. A typical prior art attachment flange 18 has a gripping gap 24 between the tip 20 and base 22 of flange 18 , within which the bottom edge 13 of slot 12 , i.e., the thickness of standard 10 , fits snugly when attachment flange 18 is inserted into slot 12 and forced downwards onto bottom edge 13 of slot 12 , as shown in FIG. 2. Faceout 16 and other attachments can be vertically adjustable relative to the standard 10 by removing attachment flange 18 from one slot 12 in standard 10 and setting it within another slot 12 .
[0019] Referring to the drawings, in particular to FIG. 3, the retrofit faceout bracket of the present invention consists preferably of an attachment flange 28 that cooperates with a faceout 26 . Attachment flange 28 is shaped preferably as the letter “T”, having two distal, free ends 30 , 31 , an elongated proximal base portion 32 for adjustable mounting to faceout 26 , and a neck 33 between free ends 30 , 31 and base portion 32 . Elongated base portion 32 is most preferably a threaded bolt. Attachment flange 28 could be formed in any of many known ways and with any of many known materials, but is preferably formed of a molded plastic or a metal, such as roll formed steel or aluminum, for strength and relative inexpensiveness, and made such that free ends 30 , 31 , neck 33 and attachment base 32 are all integrally formed.
[0020] Faceout 26 can have any shape, as it normally would, as a horizontal pole bracket or bar, shelf, drawer or the like. In the embodiment of FIG. 3, faceout 26 has a shaft 25 , at the proximal, attachment end 27 of which attachment flange 28 is adjustably mounted. A second, telescoping faceout portion 26 ′ may be used in order to provide faceout 26 with additional extension when used in a tight spot. Attachment end 27 preferably has an end cap 34 with a flat face 35 . Attachment end 27 preferably also has an annular bore 36 , which is most preferably threaded, in at least the region closest to end cap 34 . Threaded bolt 32 fits into annular bore 36 and is adjustable relative thereto due to cooperation between the respective threads on threaded bolt 32 and annular bore 36 .
[0021] As shown in FIG. 4, faceout 26 is attached to standard 10 by first threading bolt 32 part of the way into annular bore 36 . Attachment flange 28 is then inserted into slot 12 within standard 10 and moved downward so that neck 33 of attachment flange 28 rests on bottom edge 13 of slot 12 . In order to set attachment flange 28 within slot 12 , shaft 25 of faceout 26 is then twisted (screwed), preferably clockwise, so that bolt 32 proceeds farther into bore 36 and so that free ends 30 , 31 are drawn closer to cap 34 . Generally, free ends 30 , 31 do not turn within standard 10 ; this is often due either to friction between free ends 30 , 31 and the back side of standard 10 or to the fact that free ends 30 , 31 are prevented from turning because they abut against and are braced by the sides of standard 10 . In order to create friction between free ends 30 , 31 and the back side 15 of standard 10 , faceout 26 is pulled away from standard 10 at the time shaft 25 is being twisted or screwed, such that free ends 30 , 31 abut the back side 15 as bolt 32 is being screwed into bore 36 .
[0022] Faceout 26 is twisted to such an extent and bolt 32 proceeds into bore 36 until the point that free ends 30 , 31 of flange 28 and flat face 35 of end cap 34 grip and clamp standard 10 between them. In this position, once attachment is complete, flat face 35 abuts the front side 14 of standard 10 , and free end 30 of attachment flange 28 abuts the back side 15 of standard 10 . As such, faceout 26 is thereby screwed tightly against standard 10 . Because the gripping gap between flange 28 free ends 30 , 31 and flat face 35 is adjustable due to the threading action of bolt 32 in bore 36 , faceout 26 can be used with a standard of any front wall thickness.
[0023] If desired, a washer 38 having a flat face 39 may be placed between attachment flange 28 and end cap 34 of faceout 26 , as shown in FIG. 3. Washer 38 has a central aperture 40 through which threaded bolt 32 of attachment flange 28 is passed. When washer 38 is used with attachment flange 28 , as shown in FIG. 4, attachment flange 28 is set within slot 12 such that standard 10 is gripped and clamped between free ends 30 , 31 and flat face 39 of washer 38 . In this position, flat face 39 abuts the front side 14 of standard 10 , and free end 30 of attachment flange 28 abuts the back side 15 of standard 10 .
[0024] In an alternative embodiment of the invention, illustrated in FIG. 5, attachment flange 28 ′ is shaped as the letter “L” and has only one distal, free end 30 ′, which is bent downward. When this alternative embodiment is used, the attachment of faceout 26 to standard 10 is accomplished without much change from its attachment using the first embodiment of FIG. 3. Bolt 32 ′ is first threaded into annular bore 36 of faceout 26 , and attachment flange 28 ′ is then inserted into slot 12 within standard 10 and moved downward so that neck 33 ′ of attachment flange 28 ′ rests on bottom edge 13 of slot 12 and so that free end 30 ′ points downward. Faceout 26 is then twisted, preferably clockwise, so that bolt 32 ′ proceeds further into bore 36 and so that free end 30 ′ is drawn closer to cap 34 . Faceout 26 is twisted further such that standard 10 is gripped and clamped between free end 30 ′ and flat face 35 of end cap 34 . In this position, flat face 35 abuts the front side 14 of standard 10 , and free end 30 ′ of attachment flange 28 ′ abuts the back side 15 of standard 10 .
[0025] When it is desired for the vertical position of faceout 26 to be changed, shaft 25 of faceout 26 is twisted (unscrewed), preferably counterclockwise, so that attachment flange 28 is threaded out of bore 36 , and the grip of free ends 30 , 31 and end cap 34 is loosened. Again, free ends 30 , 31 turn within standard 10 due only either to friction between free ends 30 , 31 and the back side of standard 10 or to the fact that free ends 30 , 31 are prevented from turning because they abut against and are braced by the sides of standard 10 . Friction between free ends 30 , 31 and the back side 15 of standard 10 can be created by pulling faceout 26 away from standard 10 at the time shaft 25 is being twisted or screwed, such that free ends 30 , 31 abut the back side 15 as bolt 32 is being screwed out of bore 36 . Once attachment flange 28 has been loosened from slot 12 , faceout 26 is lifted slightly, in order to allow free ends 30 , 31 of attachment flange 28 to be disengaged from back side 15 of standard 10 , free ends 30 , 31 are removed from slot 12 , and attachment flange 28 is pulled away from standard 10 . The height of the faceout 26 relative to standard 10 can then be readjusted by resetting attachment flange 28 into another slot 12 .
[0026] In order to allow the faceout 26 to easily and firmly attach to slotted standard 10 , even when standard 10 is equipped with custom designed slots 12 whose widths, depths or spacing is not typical, attachment flange 28 need not necessarily match slots 12 in standard 10 in both depth and spacing, provided that the width of attachment flange 28 from the farthest edge of free end 30 to the farthest edge of free end 31 is less than the length and width of slot 12 , in order that attachment flange 28 will fit within slot 12 .
[0027] Thus, an adjustable universal faceout bracket has been provided. One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not limitation.
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An adjustable bracket assembly has a hooked attachment prong or flange that is adjustable at the end of a faceout by way of a threaded screw between the end of the faceout and the bracket flange. The hooked attachment flange is shaped to fit within all slots within the various manufacturers' standards. Generally, once the attachment flange is inserted within a slot, the flange end cannot turn within the standard. The faceout is attached to the standard from outside the display by remotely inserting the flange into a slot and turning the faceout bar, thereby screwing the faceout tightly against the standard. The faceout bar could be telescoping to allow the attachment flange to be inserted within the slot from an even greater distance away.
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FIELD OF THE INVENTION
[0001] The present invention relates to a personal emergency contact tag comprised of light-weight, Polyvinyl Chloride or PVC (the primary material used for typical plastic cards) that is secured to the waist, wrist, arm or ankle with a belt or band for the purpose of providing first responders with critical identification, contact information and blood type in the case of an accident or emergency.
BACKGROUND OF THE INVENTION
[0002] This invention was conceived after witnessing an ever-increasing number of runners, cyclists, swimmers, and other athletes training away form home without personal identification or emergency contact information on their person. Without emergency contact information available, it is almost impossible for first responders at the scene of an accident to identify the injured party or contact anyone, other than 911, for help. Further research shows a huge deficit in adequate emergency contact information to benefit the elderly, school-age children, and pre-school age children.
[0003] Because much of today's trim-line athletic gear specifically designed for runners, cyclists, swimmers, and other high-endurance sports does not include secure pockets, many athletes do not carry any form of identification with them when they train. Swim suits typically have no pocket at all to carry identification, nor do wet suits—and, if they did, most current identification is paper-based and cannot withstand water and chemicals.
[0004] For athletes who do carry identification, it is usually in the form of a driver's license slipped into a small pocket or pouch. A drivers license includes limited information for first responders since it only includes a name and address and not a phone number, blood type, or medical information. Another drawback to using a license as a form of emergency contact information is that it requires the user to consistently remove their driver's license from their wallet or purse, which increases the likelihood of misplacing the license or forgetting to replace it. Finally, many drivers licenses also include a social security number which, if lost, may lead to instances of identity theft.
[0005] Using a driver's license as a form of emergency contact information is not an option for parents concerned about their children's well-being especially when they are away form home at daycare, school, class trips, birthday parties, sports practices, and other activities—because children are no issued a driver's license until the are at least 16 years old in most states.
[0006] Similarly, many elderly do not have valid drivers licenses and of they do, this form of identification does not provide vital emergency contact information in case of emergency.
[0007] Today, there are manufacturers that produce identification tags fashioned from metal which are embossed with emergency contact information. The metal is typically heavy and requires the emergency contact information to be etched into the piece. The material heats up from exposure to the sun, which makes it quite uncomfortable against the wearer's skin. Engraving metal bracelets, as is well known in the art, is both expensive and time consuming.
[0008] Metal identification tags that are worn via a necklace or chain have several drawbacks. The constant motion of many sports makes a dangling necklace-type identification tag quite uncomfortable for the wearer. In this instance, many athletes will tuck the tag under their clothing which greatly reduces the chances of a first responder locating the critical information in case of emergency. On the other hand, men who prefer to exercise without a shirt in the warm weather will likely opt not to wear the necklace because of the heat discomfort and repetitive motion annoyance.
[0009] Furthermore, metal, necklace-type identification tags are not safe for children because they can cause a strangulation hazard in many scenarios including sports, play and sleep.
[0010] In the case of adults and the elderly, metal tags are typically considered unattractive and unsuitable for daily wear. This impression results in the tags not being worn, or being tucked beneath clothing which, again, greatly reduces the chances of a first responder locating the critical information in case of emergency.
[0011] Various personal information packets, cards, and tags have also been attempted in the prior art. Stephens, U.S. Pat. No. 5,380,046, teaches a secured personal information packet that can be carried by a child to provide personalized identification information about the child. The packet includes a paper information card that is filled out by the parents and sealed within a plastic envelope. Taft, U.S. Pat. No. 4,892,335, also teaches a card construction that is also useful for protecting an information-bearing card within a protective coating. However, these forms are not made to withstand the rigors of daily wear or use and pose the same logistical issues as carrying a driver's license. They cannot be adequately, safely, and obviously carried by a person involved in sports or other activities in which a wallet or purse is not suitable.
[0012] While there are many other forms of identification and emergency contact information available, most are not multipurpose, water/weather resistant, inexpensive, or easily worn on different parts of the body for maximum comfort and visibility.
SUMMARY OF THE INVENTION
[0013] The present invention in its various aspects addresses the above problems with current forms of identification and emergency contact tags. It presents a solution for athletes, children and the elderly in need of visible, comfortable, and convenient emergency contact information that can he worn on various parts of the body to provide first responders with identification and contact phone numbers in case emergency.
[0014] In accordance with a preferred embodiment of the invention, the described emergency contact tag is comprised of Polyvinyl Chloride, which is the primary material used for typical plastic cards. Today, PVC cards are used for hundreds of applications including credit cards, gift cards, reward programs, corporate ID badges, and more.
[0015] This wearable, emergency contact tag would be designed to be compact and unobtrusive—in a size ranging from a 1 inch high by 2 inch wide by 1 millimeter thick to 1.5 inches high by 3 inches wide by 1 millimeter thick. The size of the tag could be altered depending on the amount of information the wearer would like to have printed on the tag and depending on preferred style. The tags could be produced in any color as long as the printed information can he easily read. For example, a dark-colored card would require a light-colored text and vice versa.
[0016] In accordance with the preferred embodiment of the present invention, the wearer's emergency contact information would be thermally, digitally printed onto the PVC-based emergency contact tag directly from a computer system using a card printer specifically designed to transfer ink to a plastic card using either dye sublimation or thermal transfer printing. A process that is inexpensive and can be quickly completed by any organization or retail outfit that currently uses plastic card printing technology to produce full-size access badges, gift cards, credit cards, etc.
[0017] To ensure adequate emergency contact information, the preferred embodiments include at least the following printed information: A statement that clearly describes the usefulness of the tag with language that indicates “Emergency Contact Information;” the wearer's name; an emergency contact phone number; wearer's blood type; other special medical needs. The cards can also be customized with an organization's logo or other printable design.
[0018] Because PVC-based plastic cards can be printed on the front side only or on both sides, it is preferred that the personal identity tags be produced with information on both sides. To integrate a level of security an privacy, the printed personal information would be produced on one side only. In accordance with the preferred embodiments, the reverse side of the card would be printed with a statement that clearly identifies the tag as an emergency contact tag that includes critical information on the reverse side to assist first responders in case of emergency. This design allows wearers keep the personal information safely on the inside of the tag while ensuring that the usefulness of the tag is evident to first responders.
[0019] An alternative version of the present invention integrates a matte, write-on surface in the space that incorporates the thermally-printed name, phone number, and blood type described in the original version above. While the tag would still be thermally-printed on both sides and include a pre-printed statement that clearly indicates the usefulness of the tag with language that indicates “Emergency Contract Information,” the wearer would have the flexibility to write on the matte surface of the tag with indelible ink. This format increases the usefulness of the invention by allowing the wearer to quickly update his/her emergency contract information without third-party intervention or a digital, thermal printer.
[0020] The PVC-based emergency contract tag, in preferred embodiment, would include a slot on each opposing end spanning approximately 80 percent of the height of the tag. The slot opening would be approximately one centimeter wide to accommodate a belt-style created from flexible fabric or webbed belting material.
[0021] A key to the invention's functionality and success is visibility—ensuring that the emergency contact information is prominently visible to first responders in emergency situations. As noted above, while many current forms of identification include limited information, they are also not prominently worn or displayed usually tucked under clothing or in a concealed pocket. To address this, the preferred embodiment of the invention would be such that the emergency contact tag is attached to a waistband or armband which is then worn directly on the arm or waist, worn over clothing, or securely attached at the waist through the garment's belt loops. Preferably, added security would be gained by using a band or belt comprised of reflective material.
[0022] In accordance with this invention's preferred embodiments, the emergency contact tag, when threaded onto a waist- or arm-belt, eliminates the bouncing and shifting that occurs with necklace-type identity tags. As noted above, the discomfort caused by the repetitive motion of the dangling tag results in the wearer tucking it beneath clothing or removing it altogether.
[0023] Because the preferred embodiment of the invention is designed to be only approximately 1 inch by 2 inch by 1 millimeter made from a plastic-based material, it is intrinsically lightweight and does not absorb heat in the way metal identification tags do. Therefore, if the emergency contact tag is worn against the skin, there is no risk of discomfort from weight or excessive heat.
[0024] The present invention, being designed from thermally-printed PVC material, is both water proof and sweat proof. It will withstand regular washing, routine attaching and removing, and swimming. With this design, there is virtually no risk of loss destruction, fading, illegibility, or shrinkage.
[0025] The present invention, being designed from PVC material with a write-on matte surface, is both water proof and sweat proof. When printed with indelible ink, it will withstand washing, routine attaching and removing, and swimming. Depending on several factors, however, the emergency tag with the write-on matte surface may sustain some fading which can be addressed by reapplying the contact information with indelible ink.
[0026] A dual use for the current invention includes optional bar-coding to serve as both entry and identification into workout facilities, daycare centers, nursing homes, and pre-schools. The pre-printed emergency contact tag would allow the member to both scan into the facility and then visibly wear the emergency tag for identity and emergency purposes.
[0027] The emergency contact tag in accordance with the preferred embodiment of the present invention thus overcomes the drawbacks of current and prior identification forms noted above. The emergency contact tag can be worn comfortably and conveniently during any type of physical activity or sport without heat or motion discomfort. It can be worn by anyone—specifically those who do not or cannot carry adequate emergency contact identification including athletes, the elderly and children. The PVC-based material is lightweight, water- and sweat-proof, can be developed with a number of attractive designs, can be effortlessly printed with up-to-date contact information, or written on by the wearer. With a waistband or armband attachment, the described emergency contact tag is effortlessly attachable to the body and fully visible to first responders in the case of an emergency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The above and other objects, features and advantages of the invention will become more apparent from the following description of certain preferred embodiments thereof, when taken in conjunction with the accompanying drawings in which:
[0029] FIG. 1 is a perspective view of the emergency contact tag and waist band only depicted in accordance with the preferred embodiment of the invention.
[0030] FIG. 2 is a detailed view of only the emergency contact tag and the preferred information that would be thermally-printed on each side.
[0031] FIG. 3 is a detailed view of only the emergency contact tag with the matte, write-on surface and the preferred information that would be manually-printed on one side and thermally-printed on the other.
[0032] FIG. 4 is a detailed view of the construction of the PVC-based emergency contact tag shown in FIG. 1 .
[0033] FIG. 5 is a perspective view, from the front, showing a person wearing the emergency contact tag around the waist in accordance with the preferred embodiment of the invention.
[0034] FIG. 6 is a perspective view, from the side, showing a person wearing the emergency contact tag on the arm or ankle in accordance with the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] 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 alternative forms and should not be construed as limited to the embodiments set forth herein. The emergency contact tag is preferably worn by athletes to provide first responders with critical emergency contact information and blood type in the case of an accident, however, it is worth noting that the invention can also be worn by any adult, elderly person or child that may not regularly carry suitable identification. The emergency contact tag described herein overcomes many of the drawbacks associated with current identification cards and tags.
[0036] A wearable emergency contact tag 10 and a method for constructing the tag in accordance with the preferred embodiment of the invention are illustrated in FIGS. 1 through 6 .
[0037] In FIG. 1 , the wearable emergency contact tag 10 is constructed from Polyvinyl Chloride 11 or PVC and designed to be of a size 12 ranging from a 1 inch high by 2 inch wide by 1 millimeter thick to 1.5 inches high by 3 inches wide by 1 millimeter thick.
[0038] The wearable emergency contact tag 10 in this view includes room for logo or design at the top 13 , a statement that clearly describes the usefulness of the tag 14 and necessary contact information about the wearer including but not limited to the wearer's name; an emergency contact phone number, and wearer's blood type 15 which is digitized and thermally printed onto the PVC-based emergency contact tag via computer using a card printer specifically designed to transfer ink to a plastic card using either dye sublimation or thermal transfer printing. The PVC-based has two slots 16 punched vertically out of its opposing sides.
[0039] An adjustable band or belt 17 is threaded through the vertical slots 16 . The band or belt 17 can be produced in varying lengths depending on where the emergency contact tag is preferably attached. It is comprised of a flexible material including but not limited to nylon webbing or spandex with a hook and loop closure material 18 such as Velcro® attached at both ends.
[0040] FIG. 2 is an exploded view of the front of th wearable emergency contact tag 10 as described above and depicts the preferred embodiment of th reverse side of the emergency contact tag 10 . At the top of the tag would be space for a thermally-printed logo or design 19 , a statement that clearly describes the usefulness of the tag 20 and necessary contact information about the wearer including but not limited to the wearer's name; an emergency contact phone number; and wearer's blood type 21 .
[0041] The reverse side of the emergency contact tag 22 has space for a thermally-printed logo or design 23 and would be thermally-printed with a statement 24 that clearly identifies it as an emergency contact tag providing critical information necessary to assist first responders in case of emergency.
[0042] FIG. 3 is an exploded view of the front of the wearable emergency contact tag 10 with the matte write-on surface 25 . As described in FIG. 2 , the top of the tag would include a space for a thermally-printed logo or design 26 , a statement that clearly describes the usefulness of the tag 27 and a matte finish surface in which the wearer could write their necessary contact information including name; an emergency contact phone number; and wearer's blood type 28 .
[0043] FIG. 4 is a detailed view of the construction of the Polyvinyl Chloride-based emergency contact tag shown in FIG. 1 . The back and front layers of the PVC plastic card 29 are fused together by heat and pressure and are then covered by clear film laminate 30 . These cards are produced in sheets and then cut to size.
[0044] FIG. 5 is a perspective view, from the front, showing a person wearing the emergency contact tag around the waist 31 in accordance with the preferred embodiment of the invention. In this perspective, the emergency contact tag, attached to a waist belt, is threaded through the belt loops 32 of a specially-designed athletic short. This embodiment is not, however, critical to the usefulness of the invention since the emergency contact tag and waistband attachment can be easily worn over a short, skirt, swim suit, or bare waist.
[0045] FIG. 6 is a perspective view, from the side, shoeing a person wearing the emergency contact tag on the arm 33 and ankle 34 in accordance with the preferred embodiment of the invention.
[0046] Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, the emergency contact tag could be attached to a waistband constructed of a material that coordinates with and attaches to a specific active wear garment through belt loops at the waist. Another example of an alternative embodiment would be a differing closure material or the use of an elastic-constructed waistband, ankle band or arm band. 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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A personal emergency contact tag comprised of lightweight, Polyvinyl Chloride (PVC) that is digitally and thermally printed and secured to the waist, wrist, arm or ankle with a belt or band. It presents a solution for athletes, children and the elderly in need of visible, comfortable, water/weather resistant, inexpensive and convenient emergency contact information that can be worn to provide first responders with identification and emergency contact information and blood type in case of accident or emergency.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to landscape sprinkler systems and more particularly to landscape sprinkling systems and methods having a computer configured spray pattern.
[0003] 2. Description of the Related Art
[0004] In the past, it has been a well-known practice to provide automatic watering devices, such as sprinklers, in order to supply plants with a proper amount of moisture so that the plants will flourish. Homeowners and commercial establishments, such as golf courses, recreational parks, and farms, use automatic watering systems.
[0005] A conventional system employs a timer controller, which operates a solenoid valve incorporated into a water system so that when the time as arbitrarily set by the user arrives, power is supplied via the solenoid to the water supply valve so that water is then supplied to a system of sprinklers or other irrigation devices. However, the sprinkler system supplies water even though the ground or plant medium is saturated such as after a heavy rain or the like.
[0006] For example, an area or zone requiring irrigation may contain thin sandy soil with low water holding capacity from which water drains easily. Another zone may contain a deeper sand, clay and silt mixture, which drains slowly and holds water for a longer period. If the irrigator applies water uniformly at a rate equal to the average required over the area, the user is faced with the dilemma of having too little water in one zone and too much in the other. In practice, the user typically irrigates the entire area at the rate required for the most deficient soil, which wastes water in the zones, which do not require additional water. As the cost of water increases, this creates an unnecessary expense for the user.
SUMMARY OF THE INVENTION
[0007] In one embodiment, a sprinkler head configured to water a zone including first and second portions is disclosed, wherein the sprinkler head includes an adjustable spray pattern, and wherein the first portion of the area corresponds to a first distance, and wherein the second portion of the area corresponds to a second distance. A first moisture sensor is provided at the first distance, wherein the first moisture sensor is configured to collect a first moisture data; and a second moisture sensor provided at the second distance, and wherein the second moisture sensor is configured to collect a second moisture data. Also provided is a controller configured to obtain the moisture data and control the adjustable spray pattern based on the first moisture data and the second moisture data. The controller controls the adjustable spray pattern such that water is applied in the first portion of the zone if the first moisture data indicates that the first portion of the zone needs water. The controller controls the adjustable spray pattern such that water is applied in the second portion of the zone if the second moisture data indicates that the second portion of the zone needs water.
[0008] In one embodiment, a method includes obtaining moisture data from a first moisture sensor associated with a rotating sprinkler head; obtaining moisture data from a second moisture sensor associated with a rotating sprinkler head; and automatically configuring an adjustable spray pattern based on the moisture data. Automatically configuring the adjustable spray pattern includes watering a first portion of the zone if the moisture data indicates the first portion of the zone to be less moist, and watering a second portion of the zone if the moisture data indicates the second portion of the zone to be less moist. The first portion of the zone corresponds to a radial distance substantially apart from the second portion of the zone.
[0009] In one embodiment, a sprinkler system obtains moisture data from a first moisture sensor associated with a rotating sprinkler head; obtains moisture data from a second moisture sensor associated with a rotating sprinkler head; and automatically configures an adjustable spray pattern based on the moisture data. The adjustable spray pattern includes watering a first portion of the zone if the moisture data indicates the first portion of the zone to be less moist, and watering a second portion of the zone if the moisture data indicates the second portion of the zone to be less moist. The first portion of the zone is located at a different distance from the second portion of the zone.
[0010] In one embodiment, the sprinkler system includes a rotating sprinkler head including an adjustable spray pattern; a zone to be watered by the rotating sprinkler head, the zone at least including a first region and a second region, wherein the first area and the second area are located at a different distances from the sprinkler head; one or more moisture sensors provided in the zone, wherein the one or more moisture sensors are configured to collect moisture data; and a controller configured to obtain the moisture data and configure the adjustable spray pattern based on the moisture data. The controller adjusts the adjustable spray pattern to apply water to the first area and/or the second area of the zone as indicated by the one or more moisture sensors to need watering.
[0011] In one embodiment, the sprinkler system includes a sprinkler having a sprinkler head, a spreader plate and a nozzle; one or more moisture sensors that measure moisture in a zone to be watered by the sprinkler head, wherein the one or more moisture sensors are configured to provide moisture data related to the zone; and a controller configured to obtain the moisture data and control the distances in the zone where the sprinkler applies water. The controller adjusts one or more of the position of the sprinkler head, the position of the spreader plate, the position of the nozzle, or volume of water going through the sprinkler to control the distances in the zone where the sprinkler applies water.
[0012] For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] A general architecture that implements the various features of the invention will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate embodiments of the invention and not to limit the scope of the invention.
[0014] FIG. 1 shows a multi-zone sprinkler system.
[0015] FIG. 2 is a schematic diagram of a multi-zone sprinkler system.
[0016] FIG. 3 shows an adjustable-pattern sprinkler head with associated moisture sensors.
[0017] FIG. 4 is a block diagram of a rotating sprinkler with controllable rotation rates.
[0018] FIG. 5 shows a rotating sprinkler with an actuator to control rotation speed.
[0019] FIG. 6 is a schematic diagram of a non-rotating sprinkler head with an adjustable spray pattern.
[0020] FIG. 7 shows a schematic diagram of one embodiment of a multi-zone sprinkler system.
[0021] FIG. 8 shows an adjustable-pattern sprinkler head with associated multi-level moisture sensors.
[0022] FIG. 9 is a block diagram of a rotating sprinkler with controllable rotation speed, water elevation angle, spreader plate position and/or water flow parameters.
[0023] FIG. 10A shows a rotating sprinkler having a water elevation angle actuator and a spreader plate position actuator.
[0024] FIG. 10B shows a rotating sprinkler with a water elevation angle actuator and a water flow actuator.
[0025] FIG. 11 is a schematic diagram of one embodiment of a non-rotating sprinkler head with an adjustable spray pattern.
[0026] FIG. 12 shows a multi-zone sprinkler system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] FIG. 1 illustrates a golf course as one exemplary application for one embodiment of a multi-zone sprinkler system 100 . Other exemplary applications include, but are not limited to, recreational parks, home lawns, theme parks, cemeteries, farms, nurseries, and any other setting that provides water to vegetation through an automatic watering system. FIG. 1 illustrates one or more sprinklers 102 , each having an adjustable spray pattern 104 . In some embodiments, the adjustable spray pattern 104 is electrically controlled, such as, for example, using solenoids, step motors, and other devices capable of generating electric signals.
[0028] FIG. 2 is a schematic diagram of one embodiment of the multi-zone sprinkler system 100 . The sprinkler system 100 includes the sprinklers 102 , first level moisture sensors 200 , water supply valves 202 , a water supply 204 , and a central control system 206 .
[0029] In a typical arrangement, a series of water supply valves 202 each connect to the water supply 204 . Each water supply valve 202 connects to a series of sprinklers 102 , each sprinkler 102 having the adjustable spray pattern 104 . When a switch or solenoid in the water supply valve 202 activates, the water from the water supply 204 flows through the water supply valve 202 . Depending on the spray pattern 104 of the sprinkler 102 , the sprinkler 102 waters some, all, or none of the area surrounding the sprinkler 102 . In one embodiment, the sprinkler system 100 is arranged in watering zones.
[0030] In one embodiment, the water supply can include fertilizer, weed control solution, or any other soluble compound the user desires to apply to the area associated with the sprinkler system 100 .
[0031] In other arrangements, the multi-zone sprinkler system 100 includes at least one water control valve 202 , and at least one sprinkler 102 having an adjustable spray pattern 104 .
[0032] The first level moisture sensors 200 are provided to sense the moisture in the soil. In one embodiment, the first level moisture sensors 200 form a circular or semi-circular arrangement around each sprinkler 102 . The first level moisture sensors 200 provide data indicating the moisture content of the soil to the central control system 206 . In one embodiment, the first level moisture sensors 200 provide data to the central control system via a radio frequency (RF) link, or other wireless transmission system.
[0033] In another embodiment, the first level moisture sensors 200 electrically connect to the sprinklers 102 and the sprinklers 102 communicate with the central control system 206 via the wireless transmission system. The first level moisture sensors 200 collect the moisture data and provide the moisture data through the electrical connection to the sprinklers 102 . The sprinklers 102 provide the moisture data via the wireless transmission system, such as the RF link, to the central control system 206 .
[0034] In another embodiment, the first level moisture sensors 200 electrically connect to the sprinklers 102 and the sprinklers 102 electrically connect to the central control system 206 . The first level moisture sensors 200 collect the moisture data and provide the moisture data through the electrical connection to the sprinklers 102 . The sprinklers 102 provide the moisture data through the electrical connection to the central control system 206 .
[0035] In another embodiment, the multi-zone sprinkler system 100 further includes a zone controller 210 . The first level moisture sensors 200 located in the zone controlled by the zone controller 210 provide the moisture data to the zone controller 210 . The zone controller 210 provides the moisture data to the central control system 206 .
[0036] In one embodiment, the moisture sensors 102 provide the moisture data via a wireless transmission system, such as, for example, the RF link, to the zone controller 210 . In another embodiment, the first level moisture sensors 200 electrically connect to the zone controller 210 . Each moisture sensor 200 can be individually wired to the zone controller 210 , or groups of first level moisture sensors 200 can be wired in a consecutive pattern, i.e., daisy chained, and the last moisture sensor 200 in the chain electrically connects to the zone controller 210 . The first level moisture sensors 200 provide the moisture data to the zone controller 210 through the electrical connection.
[0037] In one embodiment, the zone controller 210 communicates with the central control system via the wireless transmission system, such as, for example, the RF link, and provides the moisture data via the wireless transmission system to the central control system 206 . In another embodiment, the zone controller 210 electrically connects to the central control system 206 , and provides the moisture data to the central control system 206 through the electrical connection.
[0038] Based on the moisture data, the central control system 206 decides how much water to put down in each zone. The central control system 206 activates the water control valves 202 , which permits water from the water supply 204 to flow through the water control valves 202 . Further, based on the moisture data, the central control system 206 configures the electrically adjustable spray pattern 104 of the sprinklers 102 .
[0039] The central control system 206 includes one or more computers. The computers include, by way of example, processors, program logic, or other substrate configurations representing data and instructions, which operate as described herein. In other embodiments, the processors can include controller circuitry, processor circuitry, processors, general-purpose single-chip or multi-chip microprocessors, digital signal processors, embedded microprocessors, microcontrollers and the like.
[0040] The central control system 206 includes information relating to the locations of the sprinklers 102 , the area watered or the maximum spray pattern of each sprinkler 200 , watering zones controlled by each zone controller 210 , and the like.
[0041] The central control system 206 processes the moisture data to determine which areas require moisture. The central control system 206 provides instructions to configure the spray pattern 104 of the sprinklers 102 , such that the areas requiring moisture are watered, and the areas not requiring moisture are not watered.
[0042] In one embodiment, the central control system 206 provides instructions to the zone controller 210 through the wireless transmission system or the electrical connection, as described above. The zone controller 210 then provides the instructions to the sprinkler 200 through the wireless transmission system or the electrical connection, as described above.
[0043] In another embodiment, the central control system 206 provides instructions directly to the sprinkler 102 through the wireless transmission system or the electrical connection, as described above.
[0044] In another embodiment, the multi-zone sprinkler system 100 further includes fire sensors 208 . The fire sensors 208 are, for example, smoke detectors, infrared detectors, ultraviolet (UV) detectors, infrared cameras, temperature sensors, or the like. The fire sensors 208 provide fire data to the central control system 206 directly or through the zone controller 210 through the wireless transmission system or an electrical connection, as described above. Based on the fire data, the central control system 206 provides instructions to configure the spray pattern 104 of the sprinklers 102 , as described above, such that the areas requiring moisture are watered.
[0045] FIG. 3 is a schematic diagram of a sprinkler system 300 . The sprinkler system 300 includes the sprinkler 102 having the adjustable spray pattern 104 , and the first level moisture sensors 200 . The sprinkler 102 includes a sprinkler head 302 , which includes at least one computer 304 .
[0046] The computer 304 includes, by way of example, processors, program logic, or other substrate configurations representing data and instructions, which operate as described herein. In other embodiments, the processors can include controller circuitry, processor circuitry, processors, general-purpose single-chip or multi-chip microprocessors, digital signal processors, embedded microprocessors, microcontrollers and the like.
[0047] The sprinkler head 302 receives water when the water control valve 202 activates. The computer 304 receives control data and power from a central location, such as the central control system 206 . In another embodiment, the computer 304 receives only power from the central location.
[0048] At least one moisture sensor 200 is associated with and electrically connects to the sprinkler head 302 . In one embodiment, two or more first level moisture sensors 200 form a circular pattern around the sprinkler head 300 .
[0049] The first level moisture sensors 200 provide the moisture data to the computer 304 . In one embodiment, the computer 304 provides the moisture data to the central control system 206 and receives instructions to configure the spray pattern 104 from the central control system 206 . In another embodiment, the computer 304 receives the moisture data, processes the moisture data to determine the correct spray pattern 104 , and configures the spray pattern 104 based on the moisture data.
[0050] FIG. 3 illustrates the adjustable spray patterns 104 partially overlapping. In another embodiment, the adjustable spray patterns 104 do not overlap. In a further embodiment, the adjustable spray patterns 104 overlap, such that the area of the sprinkler system 300 is watered by at least one sprinkler 102 .
[0051] FIG. 4 is a schematic diagram of one embodiment of a rotating sprinkler 400 . The rotating sprinkler 400 rotates in a 360 degree arc, or portions of the 360 degree arc, when water flows through the sprinkler 400 . In one embodiment, the rate of rotation through various portions of the arc determines the quantity of water applied to the area surrounding the sprinkler 400 . As the sprinkler slowly rotates, the sprinkler 400 applies more water. When the sprinkler 400 rotates relatively quickly, relatively less water is applied.
[0052] The sprinkler 400 includes a sprinkler head 402 . The sprinkler head 402 includes an actuator 404 , positional information 406 , and a data interface 408 . The positional information 406 received through the data interface 408 controls the activation of the actuator 404 . The actuator 404 controls the rate of rotation of the sprinkler head 402 . Typically, the sprinkler 400 would be used in a golf course or other industrial application with rotating sprinklers.
[0053] In one embodiment, when the actuator 404 is open or active, the sprinkler head 402 rotates quickly. In another embodiment, when the actuator 404 is closed or inactive, the sprinkler head 402 rotates slowly.
[0054] The water supply 204 , through the activated water supply valve 202 , supplies water to the sprinkler 400 . The moisture sensor 200 sends moisture data 410 to the central control system 206 directly or through the sprinkler 400 via the wireless transmission system or electrical connections, or a combination of the wireless transmission system or the electrical connections.
[0055] Based on the moisture data 410 , the central control system 206 sends positional information 406 through the data interface 408 to the sprinkler 400 via the wireless transmission system or electrical connections, or a combination of the wireless transmission system or the electrical connections. Using the positional information, the sprinkler 400 opens or closes the actuator 404 to control the speed at which the sprinkler head 402 rotates.
[0056] In another embodiment, the sprinkler 400 , using the computer 304 , determines the positional information 406 based on the moisture data 410 . Using the positional information from the computer 304 , the sprinkler 400 opens or closes the actuator 404 to control the rate of rotation of the sprinkler head 402 .
[0057] Although FIG. 4 shows the rotating sprinkler 400 having an actuator, other suitable devices such as solenoids, stepper motors, switches, relays, valves or the like can be used to control the rate of rotation of the sprinkler 400 .
[0058] FIG. 5 is a schematic diagram of one embodiment of the sprinkler 400 having the actuator 404 . The actuator 404 can be, for example, a solenoid, a stepper motor, a switch, a relay, a valve, or the like.
[0059] FIG. 6 is a schematic diagram of one embodiment of a non-rotating sprinkler 600 . The sprinkler 600 includes a sprinkler head 602 . The sprinkler head 602 includes at least one port actuator 604 having an active state and an inactive state. Each port actuator 604 controls a port 606 associated with the port actuator 604 . In one embodiment, the actuators 604 and their associated ports 606 form a ring around the perimeter of the sprinkler head 602 . For example, eight solenoids could be used to control eight zones of a circular patterns around the sprinkler 600 . Typically, the sprinkler 600 would be used in a residential application or other application with non-rotating sprinklers.
[0060] The water supply 204 through the activated water supply valve 202 supplies water to the sprinkler 600 . When the port 606 is open, water flows through the port 606 .
[0061] In one embodiment, when the port actuator 604 is active, the port 606 is open. In another embodiment, when the port actuator 604 is active, the port 606 is closed. In another embodiment, when the port actuator 604 is inactive, the port 606 is closed. In a yet further embodiment, when the port actuator 604 is inactive, the port 606 is open.
[0062] Based on the moisture data 410 , the central control system 206 sends state information to the sprinkler 600 to control the state of the actuators 604 . The actuators 604 open the ports 606 as determined by the state information. The sprinkler 600 waters the area associated with the open ports 606 .
[0063] In another embodiment, the sprinkler 600 , using the computer 304 , controls the state of the actuators 604 based on the moisture data 410 . The sprinkler 600 activates the actuators 604 to open the ports 606 , which waters the areas associated with the open ports 606 .
[0064] FIG. 7 is a schematic diagram of another embodiment of a multi-zone sprinkler system 700 configured to water areas of a zone. The sprinkler system 700 includes the sprinklers 102 , first level moisture sensors 200 , second level moisture sensors 720 , the water supply valves 202 , the water supply 204 , and the central control system 206 .
[0065] In a typical arrangement, a series of water supply valves 202 each connect to the water supply 204 . Each water supply valve 202 connects to one or more sprinklers 102 , each sprinkler 102 having the adjustable spray pattern 104 . When a switch or solenoid in the water supply valve 202 activates, the water from the water supply flows through the water supply valve 202 . In some embodiments, the water supply 204 supplies water through the water supply valve 202 at differing flow parameters, such as, for example, volume, velocity, rate, pressure, etc. In other embodiments, the water supply valve 202 provides water at varying flow parameters such as volume, velocity, rate, pressure, etc. Depending on the spray pattern 104 of the sprinkler 102 , the sprinkler 102 waters some, all, or none of the area surrounding the sprinkler 102 . In one embodiment, the sprinkler system 700 is arranged in watering zones. In some embodiments, the sprinkler 102 is configured to water areas at varying distances away from the sprinkler 102 . For example, in one embodiment, the sprinkler 102 waters areas in a zone corresponding to a first distance away from the sprinkler 102 . In other embodiments, the sprinkler 102 waters areas in a zone corresponding to a second distance away from the sprinkler 102 .
[0066] In one arrangement, the multi-zone sprinkler system 700 includes at least one water control valve 202 , and at least one sprinkler 102 having an adjustable spray pattern 104 . As described herein, the adjustable spray pattern 104 can be configured to water areas of the zone that correspond to varying distances from the sprinkler 102 .
[0067] The first level moisture sensors 200 and the second level moisture sensors 720 are provided to sense the moisture in the soil. The first level moisture sensors 200 and the second level moisture sensors 720 can be provided in any suitable location, such as, for example, near the facility where the central control system 206 is located. In some embodiments, the first level moisture sensors 200 and the second level moisture sensors 720 are remote sensors located above ground on structures such as, for example, antennas, poles, trees, buildings, houses, etc. In some embodiments, the first level moisture sensors 200 and the second level moisture sensors 720 are in the soil surrounding the sprinkler 901 . In other embodiments, the first level moisture sensors 200 and the second level moisture sensors 720 are remote sensors located in regions different from the area to be watered, such as, for example, a weather station.
[0068] As shown in FIG. 7 , the first level moisture sensors 200 and the second level moisture sensors 720 form a relatively circular or semi-circular arrangement around each sprinkler 102 . In other embodiments, the first level moisture sensors 200 and the second level moisture sensors 720 are arranged in other geometric configurations, such as, for example, rectangles, squares, ovals, or the like. The first level moisture sensors 200 and the second level moisture sensors 720 provide data indicating the moisture content of the soil to the central control system 206 . In other embodiments, the first level moisture sensors 200 and the second level moisture sensors 720 send the moisture data to the sprinkler 102 . In still other embodiments, the first level moisture sensors 200 and the second level moisture sensors 720 send the moisture data to any other system configured to analyze the moisture data including, without limitation, personal computers, mobile devices, other types of stand-alone computing devices, or the like.
[0069] As shown in FIG. 7 , the first level moisture sensors 200 are located at approximately a radial distance R 1 from the sprinkler 102 and the second level moisture sensors 720 are located at approximately a radial distance R 2 from the sprinkler 102 . The adjustable spray pattern 104 can be configured to water areas located at varying distances. For example, the adjustable spray pattern 104 can water areas of the zone corresponding to the radial distance R 1 . In other embodiments, the adjustable spray pattern 104 can water areas corresponding to the radial distance R 2 . In still other embodiments, the adjustable spray pattern 104 can be configured to water regions corresponding to both the radial distance R 1 and the radial distance R 2 . In a further embodiment, the adjustable spray pattern 104 can be configured to water areas located near other radial distances from the sprinkler 102 , as described herein.
[0070] In one embodiment, the first level moisture sensors 200 and the second level moisture sensors 720 provide data to the central control system 206 via a radio frequency (RF) link, or other wireless transmission system. The sprinklers 102 provide the moisture data to the central control system 206 . In some embodiments, the first level moisture sensors 200 and the second level moisture sensors 720 collect moisture data and provide the moisture data to the sprinkler 102 using a wireless system.
[0071] In another embodiment, the first level moisture sensors 200 and the second level moisture sensors 720 electrically connect to the sprinklers 102 and the sprinklers 102 communicate with the central control system 206 via the wireless transmission system. The first level moisture sensors 200 and the second level moisture sensors 720 collect the moisture data and provide the moisture data through the electrical connection to the sprinklers 102 . The sprinklers 102 provide the moisture data via the wireless transmission system, such as the RF link, to the central control system 206 .
[0072] In another embodiment, the first level moisture sensors 200 and the second level moisture sensors 720 electrically connect to the sprinklers 102 and the sprinklers 102 electrically connect to the central control system 206 . The first level moisture sensors 200 and the second level moisture sensors 720 collect the moisture data and provide the moisture data through the electrical connection to the sprinklers 102 . The sprinklers 102 provide the moisture data through the electrical connection to the central control system 206 .
[0073] In another arrangement still with reference to FIG. 7 , the first level moisture sensors 200 and the second level moisture sensors 720 can be configured to provide the moisture data using different methods. For example, the first level moisture sensors 200 electrically connect to the sprinklers 102 and the sprinklers 102 electrically connect to the central control system 206 . The first level moisture sensors 200 collect the moisture data and provide the moisture data through the electrical connection to the sprinklers 102 . The second level moisture sensors 720 provide the moisture data to the central control system 206 via a radio frequency (RF) link, or another wireless transmission system. In other embodiments, the first level moisture sensors 200 provide the moisture data to the central control system 206 via a wireless transmission system whereas the second level moisture sensors 720 provide the moisture data using an electrical connection, for example, through the sprinklers 102 . In still further embodiments, one of the first level moisture sensors 200 or the second level moisture sensors 720 provides moisture data to the sprinkler 102 using an electrical connection whereas the other level of moisture sensor provides moisture data to the sprinkler 102 using a wireless transmission system. The sprinkler 102 then provides the moisture data to the central control system 206 using an electrical connection or a wireless transmission system or a combination of an electrical connection and a wireless transmission system.
[0074] Based on the moisture data, the central control system 206 decides how much water to put down in each zone. The central control system 206 activates the water control valves 202 , which permits water from the water supply 204 to flow through the water control valves 202 . As previously mentioned, various flow parameters of water (such as, without limitation, volume, pressure, velocity, rate, or the like) that is supplied through the water control valves 202 can be adjustable. As discussed herein, the central control system 206 can be configured to control the flow parameters of water flowing through the water control valves 202 . Further, based on the moisture data, the central control system 206 can be configured to control the electrically adjustable spray pattern 104 of the sprinklers 102 . In some embodiments, the central control system 206 configures the flow parameters of water to adjust the electrically adjustable spray pattern 104 . The central control system 206 can control the flow parameters such that water is projected to portions of the zone corresponding to other distances.
[0075] The central control system 206 can include one or more computers. The computers include, by way of example, processors, program logic, or other substrate configurations representing data and instructions, which operate as described herein. In other embodiments, the processors can include controller circuitry, processor circuitry, processors, general-purpose single-chip or multi-chip microprocessors, digital signal processors, embedded microprocessors, microcontrollers and the like.
[0076] The central control system 206 includes various types of information relating to the sprinkler system 700 . In some embodiments, the central control system 206 uses information including one or more of locations of the sprinklers 102 , the area watered or the range of distances watered by the spray pattern of each sprinkler 102 (minimum and maximum distances), the locations of the first level moisture sensors 200 , the locations of the second level moisture sensors 720 , or the watering zones controlled by each zone controller 210 , and the like. In other embodiments, the central controls system 206 uses information relating to the maximum radial distance reach of the spray pattern 104 of each sprinkler 102 .
[0077] The central control system 206 processes the moisture data to determine which areas require moisture. The central control system 206 provides instructions to the sprinklers 102 such that the spray pattern 104 of the sprinklers 102 provides relatively more water to the areas needing more moisture, and provides relatively less water to the areas needing less moisture. In one embodiment, the central control system 206 provides instruction to the sprinkler such that the spray pattern 104 applies water to regions needing moisture, and does not apply water to regions that do not need moisture. In some embodiments, the central control system 206 provides instructions such that the adjustable spray pattern 104 applies water to regions corresponding to a first radial distance away from the sprinkler 102 , such as, for example, regions located near the first level moisture sensors 200 . In other embodiments, the central control 206 provides instructions such that the adjustable spray pattern 104 provides water to areas corresponding to a second radial distance away from the sprinkler 102 , such as, for example, areas of the zone in which the second level moisture sensors 720 are located. In other embodiments, the central control 206 provides instructions such that the adjustable spray pattern 104 applies water to portions of the zone to be watered corresponding to both the first radial distance and the second radial distance away from the sprinkler 102 , such as, for example, portions of the zone in which both the first level moisture sensors 200 and the second level moisture sensors 720 are located. In still other embodiments, the central control 206 provides instructions to the adjustable spray pattern 104 of the sprinklers 102 such that the adjustable spray pattern 104 provides water to regions located at other distances. The spray pattern 104 can be configured to apply water to regions corresponding to varying distances away from the sprinkler 102 .
[0078] In one embodiment, the central control system 206 provides instructions to the zone controller 210 through the wireless transmission system or the electrical connection, as described above. The zone controller 210 then provides the instructions to the sprinkler 102 through the wireless transmission system or the electrical connection, as described above.
[0079] In another embodiment, the central control system 206 provides instructions directly to the sprinkler 102 through the wireless transmission system or the electrical connection, as described above.
[0080] Although FIG. 7 illustrates all of the first level moisture sensors 200 relatively located at the radial distance R 1 and all of the second level moisture sensors 720 relatively located at the radial distance R 2 , skilled artisans appreciate that each one of the first level moisture sensors 200 and/or the second level moisture sensors 720 can be located at varying radial distances.
[0081] FIG. 8 is a schematic diagram of a sprinkler system 800 . The sprinkler system 800 includes the sprinkler 102 having the adjustable spray pattern 104 , and the first level moisture sensors 200 and the second level moisture sensors 720 . The sprinkler 102 includes a sprinkler head 302 , which includes at least one computer 304 .
[0082] At least one of the first level moisture sensor 200 or the second level moisture sensor 720 is associated with the sprinkler head 302 and is able to provide moisture data to the sprinkler head 302 , for example, using an electrical connection. In one embodiment, two or more of the first level moisture sensors 200 and the second level moisture sensors 720 forms a circular pattern around the sprinkler head 302 .
[0083] The first level moisture sensors 200 and the second level moisture sensors 720 provide the moisture data to the computer 304 . In one embodiment, the computer 304 provides the moisture data to the central control system 206 and receives instructions to configure the spray pattern 104 from the central control system 206 . In another embodiment, the computer 304 receives the moisture data, processes the moisture data, and configures the spray pattern 104 based on the moisture data 104 .
[0084] The sprinkler 102 can be configured to project water to various distances away from the sprinkler 102 . In one embodiment, the spray pattern 104 is configured to water areas corresponding to a first radial distance away from the sprinkler 102 . In other embodiments, the sprinkler 102 waters regions in which the first level moisture sensors 200 are located. In one embodiment, the spray pattern 104 is configured to water areas corresponding to a second radial distance, such as, for example, areas of the zone in which the second level moisture sensors 720 are located. In other embodiments, the spray pattern 104 is configured to water areas located at different radial distances from the first radial distance and the second radial distance. In other embodiments, the spray pattern 104 is configured to water areas corresponding to other levels of moisture sensors, such as, for example, third or fourth level moisture sensors (not shown). In still some embodiments, the adjustable spray pattern 104 is configured to water areas corresponding to varying distances such as regions between the first radial distance and the second radial distance, areas between the sprinkler 102 and the first radial distance, areas located at farther distances than the second radial distance, etc.
[0085] FIG. 8 illustrates one embodiment of the sprinkler system 800 where the adjustable spray patterns 104 are partially overlapping. In another embodiment, the adjustable spray patterns 104 do not overlap. In a further embodiment, the adjustable spray patterns 104 overlap such that the area of the sprinkler system 800 is watered by at least one sprinkler 102 .
[0086] FIG. 9 is a schematic diagram of one embodiment of a multi-zone sprinkler system 900 . The sprinkler system 900 includes a rotating sprinkler 901 , the central control station 206 , the sensor data 410 , and a remote moisture sensor 980 . The rotating sprinkler 901 includes the sprinkler head 402 .
[0087] The rotating sprinkler 901 can be configured to rotate in a 360 degree arc, or portions of the 360 degree arc. In one embodiment, water power is used to activate the rotation of the rotating sprinkler 901 . The rotating sprinkler 901 is activated when water flows through the rotating sprinkler 901 . The rotating sprinkler 901 does not rotate when there is no water flowing through the rotating sprinkler 901 .
[0088] In one embodiment, the rotating sprinkler 901 is electrically configured to rotate in a 360 arc, or portions of the 360 degree arc. In one embodiment, the rotational rate actuator 404 is used to activate the rotating sprinkler 901 . When the rotational rate actuator 404 is in a first state, the rotating sprinkler 901 does not rotate and there is no water flowing through the rotating sprinkler 901 . When the rotational rate actuator 404 is in a second state, the rotating sprinkler 901 is activated and rotates at a first rate, such as, for example, a relatively slow rate. In one embodiment, when the rotating sprinkler 901 is rotating at the first rate, the rotating sprinkler 901 applies relatively more water to the areas of the zone through which the rotating sprinkler 901 is rotating. When the rotating rate actuator 404 is in a third state, the rotating sprinkler 901 rotates at a second rate that is, for example, relatively quicker than the first rate. In one embodiment, when the rotating sprinkler 901 is rotating at the second rate, the rotating sprinkler 901 applies relatively less or no water to the areas of the zone through which the rotating sprinkler 901 is rotating.
[0089] In another embodiment, the rotating sprinkler 901 is electrically configured to rotate in a 360 arc, or portions of the 360 degree arc, for example, using a rotation activation actuator. Using a rotation activation actuator to activate the rotation of the rotating sprinkler 901 enables the rotation rate actuator 404 to provide more states to control the rates at which the rotation sprinkler 901 rotates. When the rotational activation actuator is in a first state, the rotating sprinkler 901 does not rotate and there is no water flowing through the rotating sprinkler 901 . When the rotation activation actuator is in a second state, the rotating sprinkler 901 is activated and rotates at a first rate, such as, for example, a relatively slow rate. In one embodiment, when the rotating sprinkler 901 is rotating at the first rate, the rotating sprinkler 901 applies relatively more water to the areas of the zone through which the rotating sprinkler 901 is rotating. When the rotation activation actuator is in a third state, the rotating sprinkler 901 is activated and rotates at a second rate, such as, for example, a relatively quicker rate. In one embodiment, when the rotating sprinkler 901 is rotating at the second rate, the rotating sprinkler 901 applies relatively less or no water to the areas of the zone through which the rotating sprinkler 901 is rotating. The rotating sprinkler 901 can then use the rotational rate actuator 404 to further adjust the rates at which the rotating sprinkler 901 rotates. For example, in one embodiment, the rotational rate actuator 404 has three states and can be used to adjust the rotating sprinkler 901 to rotate at a different third rate, a fourth rate, and/or a fifth rate.
[0090] In FIG. 9 , the rotating sprinkler 901 can be manually configured to control the rate of rotation of the rotating sprinkler 901 . For example, users of the rotating sprinkler 901 can manually adjust a setting on the rotating sprinkler 901 such that when the rotating sprinkler 901 is going through portions of the arc that correspond to a first area, the rotating sprinkler 901 rotates relatively slowly, thereby applying relatively more water to the first area. Users can also manually adjust the setting on the rotating sprinkler 901 such that when the rotating sprinkler 901 is going through portions of the arc that correspond to a second area, the rotating sprinkler 901 rotates relatively quickly, thereby applying relatively less or no water to the second area.
[0091] As mentioned in connection to FIG. 4 , the rate of rotation of the rotating sprinkler 901 can also be electrically configured to control the quantity of water applied to the area surrounding the rotating sprinkler 901 . For example, in one embodiment, the rotating sprinkler 901 applies relatively more water when the rotating sprinkler 901 rotates relatively slowly. In another embodiment, the rotating sprinkler 901 applies relatively less or no water when the rotating sprinkler 901 rotates relatively quickly. In some embodiments, the rotating sprinkler 901 rotates relatively slowly and applies relatively more water in areas that are indicated as needing water by the remote moisture sensor 980 . In another embodiment, the rotating sprinkler 901 rotates relatively quickly and applies relatively less or no water to areas of the zone that are indicated by the remote moisture sensor 980 as not needing water. In other embodiments, the rotating sprinkler 901 rotates relatively slowly to apply water to areas that need moisture and rotates relatively quickly not to apply water to areas that do not need water.
[0092] Further, the rotating sprinkler 901 of FIG. 9 is configured to water areas of the zone located at varying distances away from the rotating sprinkler 901 . The rotating sprinkler 901 includes adjustable parameters to control the distances at which a region is watered, such as, for example, position of the sprinkler head 402 , position of the sprinkler nozzle controlled by the elevation angle actuator 920 , position of the spreader plate controlled by the spreader plate actuator 910 , flow parameters of water flowing through the sprinkler head 402 , etc.
[0093] With reference to FIG. 9 , several embodiments disclosed herein describe the various methods of adjusting the parameters of the rotating sprinkler 901 such that the adjustable spray pattern 104 waters areas of the zone corresponding to various distances away from the rotating sprinkler 901 . In one embodiment, the elevation angle of the adjustable spray pattern 104 is controllable. In one embodiment, the elevation angle is controlled by adjusting the angle of the sprinkler head 402 , as shown in connection with FIG. 10A . When the sprinkler head 402 is in a first position, the sprinkler head 402 projects the adjustable spray pattern 104 in a first direction at a first elevation angle. When the adjustable spray pattern 104 is projected in the first direction, the adjustable spray pattern 104 applies water to regions of the zone that correspond to a first radial distance away from the rotating sprinkler 901 . When the sprinkler head 402 is in a second position, the sprinkler head 402 projects the adjustable spray pattern 104 in a second direction at a second elevation angle. When the adjustable spray pattern 104 is projected in the second direction, the adjustable spray pattern 104 applies water to portions of the zone corresponding to a second radial distance away from the rotating sprinkler 901 .
[0094] In another embodiment, the position of a sprinkler nozzle is adjusted to control the elevation angle of the adjustable spray pattern 104 , thereby controlling where the adjustable spray pattern 104 applies water. In one embodiment, the elevation angle of the adjustable spray pattern 104 is controlled by adjusting the angular position of a sprinkler nozzle, as shown in connection with FIG. 10B . When the sprinkler nozzle is in a first position, the rotating sprinkler 901 projects the adjustable spray pattern 104 in a first direction (for example, at a first elevation angle). When the adjustable spray pattern 104 is projected in the first direction, the adjustable spray pattern 104 waters areas of the zone corresponding to a first radial distance away from the rotating sprinkler 901 . When the sprinkler nozzle is in a second position, the rotating sprinkler 901 projects the adjustable spray pattern 104 in a second direction (for example, at a second elevation angle). When the adjustable spray pattern 104 is projected in the second direction, the adjustable spray pattern 104 waters areas of the zone corresponding to a second radial distance away from the rotating sprinkler 901 .
[0095] In another embodiment, the spreader plate of the rotating sprinkler 901 is adjusted to control the distances at which the rotating sprinkler 901 applies water to portions of the zone to be watered. When the spreader plate of the rotating sprinkler 901 is in a first position, the adjustable spray pattern 104 waters areas corresponding to a first location. When the spreader plate of the rotating sprinkler 901 is in a second position, the adjustable spray pattern 104 applies water to regions corresponding to a second location. In one embodiment the first location is at a first radial distance away from the rotating sprinkler 901 and the second location is at a second radial distance away from the rotating sprinkler 901 .
[0096] In another embodiment, the flow parameter (for example, volume, velocity, rate, pressure, or the like) of water going through the sprinkler head 402 is adjusted to control the distances at which the adjustable spray pattern 104 waters areas. When the flow of water going through the sprinkler head 402 is at a first setting, the adjustable spray pattern 104 waters areas of the zone corresponding to a first radial distance away from the rotating sprinkler 901 . When the flow of water going through the sprinkler head 402 is at a second setting, the adjustable spray pattern 104 waters areas of the zone corresponding to a second radial distance away from the rotating sprinkler 901 . In some embodiments, the flow parameter adjusted is the volume of the water flowing through the rotating sprinkler 901 . When the water flowing through the rotating sprinkler 901 is at a first volume, the adjustable spray pattern 104 waters areas located a first radial distance away from the rotating sprinkler 901 . When the water flowing through the rotating sprinkler 901 is at a second volume, the adjustable spray pattern 104 waters areas corresponding to a second radial distance away from the rotating sprinkler 901 . In other embodiments, the flow parameter adjusted is the rate of the water flowing through the rotating sprinkler 901 . In still other embodiments, the flow parameter adjusted is the velocity of the water flowing through the rotating sprinkler 901 .
[0097] In another embodiment, two or more of the adjustable parameters of the rotating sprinkler 901 such as the rate of rotation of the sprinkler head 402 , the elevation angle of the adjustable spray pattern 104 , the position of the spreader plate, or the flow parameter of water going through the sprinkler head 402 can be adjusted to control the adjustable spray pattern 104 .
[0098] The sprinkler head 402 includes the rotation rate actuator 404 , an elevation angle actuator 920 , a spreader plate actuator 940 , a water flow actuator 960 , rotation rate positional information 406 , elevation angle positional information 930 , spreader plate positional information 950 , water flow positional information 970 , and the data interface 408 . The rotation rate positional information 406 received through the data interface 408 controls the activation of the rotation rate actuator 404 . The rotation rate actuator 404 controls the rate of rotation of the sprinkler head 402 . The elevation angle positional information 930 received through the data interface 408 controls the activation of the elevation angle actuator 920 . The elevation angle actuator 920 controls the elevation angle of spray pattern 104 . The spreader plate positional information 930 received through the data interface 408 controls the activation of the spreader plate actuator 940 . The spreader plate actuator 940 controls the position of the spreader plate. The water flow positional information 970 received through the data interface 408 controls the activation of the water flow actuator 960 . The water flow actuator 960 controls various parameters of the flow of water going through the sprinkler head 402 , such as, for example, volume, rate, velocity, pressure, etc.
[0099] As already mentioned, the rotation rate actuator 404 controls the rate of rotation of the sprinkler head 402 . In one embodiment, when the rotation rate actuator 404 is in a first state (for example, open or active), the sprinkler head 402 rotates at a first rate, for example, relatively quickly. In another embodiment, when the rotation rate actuator 404 is in a second state (for example, closed or inactive), the sprinkler head 402 rotates at a second rate, such as, for example, relatively slowly. In some embodiments, when the rotation rate actuator 404 is in a third state (for example, neutral or default state where the actuator is neither active nor inactive), the sprinkler head 402 rotates at a third rate (for example, even slower than the second rate, quicker than the first rate, or quicker than the second rate but slower than the first rate).
[0100] The elevation angle positional information 930 received through the data interface 408 controls the activation of the elevation angle actuator 920 . In one embodiment, the elevation angle actuator 920 controls the elevation angle of spray pattern 104 by controlling the position of the sprinkler head 402 . In one embodiment, when the elevation angle actuator 920 is in a first state, the sprinkler head 402 is in a first position. In another embodiment, when the elevation angle actuator 920 is in a second state, the sprinkler head 402 is in a second position. In some embodiments, when the elevation angle actuator 920 is in a third state, the sprinkler head 402 is in a third position. In some embodiments, the elevation angle actuator 920 controls the position of the sprinkler head 402 by adjusting the angular position of the sprinkler head 402 relative to a sprinkler shaft (not shown).
[0101] The elevation angle positional information 930 received through the data interface 408 also can be configured to control the activation of the elevation angle actuator 920 by separately controlling the position of the sprinkler nozzle. In one embodiment, when the elevation angle actuator 920 is in a first state, the sprinkler nozzle is in a first position. In another embodiment, when the elevation angle actuator 920 is in a second state, the sprinkler nozzle is in a second position. In some embodiments, when the elevation angle actuator 920 is in a third state (for example, a neutral state where the elevation angle actuator 920 is neither active nor inactive), the sprinkler nozzle is in a third position. In other embodiments, the elevation angle actuator 920 controls the position of the sprinkler nozzle by adjusting the angular position of the nozzle (either together with the sprinkler head 402 or separately) relative to a sprinkler shaft (for example, the sprinkler shaft 1070 shown in connection with FIG. 10A ).
[0102] Still with reference to FIG. 9 , in certain arrangements, the spreader plate positional information 930 received through the data interface 408 controls the activation of the spreader plate actuator 940 . The spreader plate actuator 940 controls the position of the spreader plate. For example, when the spreader plate actuator 940 is in a first state, the spreader plate is in a first position. In another embodiment, when the spreader plate actuator 940 is in a second state, the spreader plate is in a second position. In yet another embodiment, when the spreader plate actuator 940 is in a third state, the spreader plate is in a third position.
[0103] In another embodiment, the water flow positional information 970 received through the data interface 408 controls the activation of the water flow actuator 960 . The water flow actuator 960 controls various parameters of the flow of water going through the sprinkler head 402 , such as, for example, volume, rate, velocity, pressure, etc. In one embodiment, when the water flow actuator 960 is in a first state, water goes through the sprinkler head 402 at a first setting. In another embodiment, when the water flow actuator 960 is in a second state, water goes through the sprinkler head 402 at a second setting. In yet a further embodiment, when the water flow actuator 960 is in a third state, water goes through the sprinkler head 402 at a third setting.
[0104] The water supply 204 , through the activated water supply valve 202 , supplies water to the rotating sprinkler 901 . In some embodiments, the water flow actuator 960 is located elsewhere from the rotating sprinkler 901 , such as, for example, the water supply 204 . In other embodiments, the water flow positional information 970 is located elsewhere from the rotating sprinkler 901 , such as, for example, the water supply 204 . In one embodiment, the water flow actuator 960 remains on the sprinkler 901 and the water supply 204 includes a water supply actuator (not shown) to control the flow parameters of the water supplied to the rotating sprinkler 901 . In another embodiment, the water flow positional information 970 remains on the rotating sprinkler 901 and the water supply 204 includes a water supply positional information (not shown) to control the water supply actuator of the water supply 204 .
[0105] Still with reference to FIG. 9 , in one embodiment, when the water supply actuator of the water supply 204 is in a first state, water flows through the sprinkler head 402 at a first setting. In another embodiment, when the water supply actuator of the water supply 204 is in a second state, water flows through the sprinkler head 402 at a second setting. In a further embodiment, when the water supply actuator of the water supply 204 is in a third state, water flows through the sprinkler head 402 at a third setting.
[0106] In some arrangements, the water flow actuator 960 is located elsewhere from the rotating sprinkler 901 , such as, for example, the water supply valve 202 . In other embodiments, the water flow positional information 970 is located elsewhere from the rotating sprinkler 901 , such as, for example, the water supply valve 202 . In one embodiment, the water flow actuator 960 remains on the sprinkler 901 and the water supply valve 202 includes a water supply valve actuator (not shown) to control the flow parameters of the water supplied to the rotating sprinkler 901 . In another embodiment, the water flow positional information 970 remains on the rotating sprinkler 901 and the water supply valve 202 includes a water supply valve positional information (not shown) to control the water supply valve actuator.
[0107] In one embodiment, when the water supply valve actuator of the supply valve 202 is in a first state, water flows through the sprinkler head 402 at a first setting. In another embodiment, when the water supply valve actuator of the supply valve 202 is in a second state, water flows through the sprinkler head 402 at a second setting. In a further embodiment, when the water supply valve actuator of the supply valve 202 is in a third state, water flows through the sprinkler head 402 at a third setting.
[0108] As illustrated in FIG. 9 , the remote moisture sensor 980 is configured to collect moisture data of areas to be watered by the rotating sprinkler 901 . The remote moisture sensor 980 can collect moisture data using various techniques, including, without limitation, geophysical methods (time-domain reflectometry, frequency domain moisture sensing, capacitance probing, electrical resistivity tomography, etc.). In other embodiments, the remote moisture sensor 980 remotely senses the moisture content of soil using electromagnetic waves, such as, for example, microwave, ultra-violet, infrared or other types of radiation.
[0109] The remote moisture sensor 980 is configured to provide the moisture data 410 to the central control system 206 , the rotating sprinkler 901 , or any other system capable of receiving the moisture data 410 , such as the water supply 204 and/or the water supply valve 202 . In some embodiments, the remote sensor 980 senses the moisture data 410 and provides the moisture data 410 to either the central control system 206 or the rotating sprinkler 901 via a wireless transmission system or via electrical connections. In other embodiments, the remote sensor 980 provides the moisture data 410 to the central control system 206 or the rotating sprinkler 901 using a combination of the wireless transmission system and the electrical connections. In one embodiment, the remote moisture sensor 980 provides the moisture data 410 to the rotating sprinkler 901 and the rotating sprinkler 901 provides the moisture data, either wirelessly or using an electrical connection, to the central control system 206 .
[0110] The remote moisture sensor 980 of FIG. 9 can be located in any suitable location, such as, for example, near the facility where the central control system 206 is located. In other embodiments, the remote moisture sensor 980 is located above ground on structures such as, for example, antennas, poles, trees, buildings, houses, etc. In some embodiments, the remote moisture sensor 980 is buried under ground, such as, for example, in the soil surrounding the sprinkler 901 . In still other embodiments, the remote moisture sensor 980 may be located on extraterrestrial objects such as satellites, including weather satellites.
[0111] Based on the moisture data 410 , the central control system 206 sends one or more of the rotation rate positional information 406 , the elevation angle positional information 930 , the spreader plate positional information 950 , and/or the water flow positional information 970 through the data interface 408 to the rotating sprinkler 901 via the wireless transmission system or electrical connections, or a combination of the wireless transmission system and the electrical connections. Using the received information, the rotating sprinkler 901 adjusts the states of one or more of the rotation rate actuator 404 , the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 to control one or more of the rate of rotation, the elevation of projection of the spray pattern 104 , the position of the spreader plate, or the parameters of water flowing through the sprinkler head 402 .
[0112] As shown in FIG. 9 , the sprinkler system 900 controls the areas watered by the sprinkler 901 by sending positional information to the rotating sprinkler 901 , the water supply 204 and the water supply valve 202 to coordinate actuators located on the rotating sprinkler 901 , the water supply 204 and the water supply valve 202 . For example, the central control system 206 sends the water flow positional information 970 to the water supply 204 . Using the received information, the water supply 204 adjusts the state of the water flow positional actuator 960 located on the sprinkler 901 to control the parameter of water flowing through the sprinkler head 402 . The water flow positional actuator 960 can be positioned on the water supply 204 . Using the received information, the water supply 204 also can be configured to adjust the state of the water flow positional actuator 960 located on the water supply 204 to control the parameters of water flowing through the sprinkler head 402 . In other embodiments, the central control system 206 sends information to the water supply positional information. Using the received information, the water supply 204 adjusts the state of the water supply positional actuator (not shown) to control the parameter of water flowing through the sprinkler head 402 .
[0113] In some embodiments, the central control system 206 sends the water flow positional information 970 to the water supply valve 202 . Using the received information, the water supply valve 202 adjusts the state of the water flow positional actuator 960 located on the sprinkler 901 to control the parameter of water flowing through the sprinkler head 402 . The water flow positional actuator 960 can be positioned on the water supply valve 202 . Using the received information, the water supply valve 202 also can be configured to adjust the state of the water flow positional actuator 960 located on the water supply valve 202 to control the parameters of water flowing through the sprinkler head 402 . In other embodiments, the central control system 206 sends information to the water supply valve positional information. Using the received information, the water supply valve 202 adjusts the state of the water supply valve positional actuator (not shown) to control the parameters of water flowing through the sprinkler head 402 .
[0114] In another embodiment, the rotating sprinkler 901 , using the computer 304 , controls one or more of the rotation rate positional information 406 , the elevation angle positional information 930 , the spreader plate positional information 950 , or the water flow positional information 970 based on the moisture data 410 . Using the information from the computer 304 , the rotating sprinkler 901 changes the states of one or more of the rotation rate actuator 404 , the elevation angle actuator 920 , the spreader plate actuator 940 , or the water flow actuator 960 to control one or more of the rate of rotation, the elevation of projection of the spray pattern 104 , the position of the spreader plate, or the parameters of water flowing through the sprinkler head 402 .
[0115] In other embodiments, the rotating sprinkler 901 , using the computer 304 , controls one or more of the water supply actuator or the water supply valve actuator based on the moisture data 410 . Using the information from the computer 304 , the rotating sprinkler 901 changes the states of one or more of the water supply actuator or the waters supply valve actuator to control the parameters of water flowing through the sprinkler head 402 .
[0116] The rotation rate actuator 404 , the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 can include suitable devices such as solenoids, stepper motors, switches, relays, valves or the like. In an embodiment, the rotation rate actuator 404 , the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 include devices having at least 3 states, such as, for example, an active state, an inactive state, and a neutral or default state. A solenoid for use with the sprinkler 901 can include a coil attached to a current source. Another solenoid for use with the sprinkler 901 includes conductive wires coiled around a magnetic bar. In some embodiments, the rotating sprinkler 901 includes two or more actuators to control each of the rate of rotation, the elevation of projection, the position of the spreader plate or the flow of water. In further embodiments, the rotating sprinkler 901 includes two or more actuators configured in series to control each of the rate of rotation, the elevation of projection, the position of the spreader plate or the flow of water.
[0117] With continued reference to FIG. 9 , one embodiment of an operation of the sprinkler 901 is described herein. The sprinkler system 900 of FIG. 9 further includes relatively dry areas indicated by a first portion 990 , a second portion 991 , and a third portion 992 . As shown in FIG. 9 , the first portion 990 and the third portion 992 approximately correspond to areas located a first radial distance 995 away from the rotating sprinkler 901 . The second portion 991 approximately corresponds to areas located a second radial distance 997 away from the rotating sprinkler 901 . The first portion 990 and the second portion 991 correspond to areas similarly located along a first direction 975 and the third portion 992 corresponds to areas located along a different second direction 977 .
[0118] Because the first portion 990 and the third portion 992 correspond to the same first radial distance 995 , the rotating sprinkler 901 can substantially water the first portion 990 and the third portion 992 without having to adjust the radial distances at which the rotating sprinkler 901 applies water. In one embodiment, the central control system 206 adjusts the rate of rotation of the rotating sprinkler 901 to water both the first portion 990 and the third portion 992 . In other embodiments, although the first portion 990 and the second portion 991 correspond to the same first direction 975 , the second radial distance 997 is located substantially apart from the first radial distance 996 such that the rotating sprinkler 901 adjusts the radial distances at which it projects water to sufficiently apply water to the second portion 991 .
[0119] The remote moisture 980 senses the moisture content of the area around the rotating sprinkler 901 indicating that the first portion 990 , the second portion 991 , and the third portion 992 are relatively dry and areas that do not correspond to the first portion 990 , the second portion 991 , and the third portion 992 are relatively moist. The remote moisture 980 provides the moisture data 410 to a processor configured to control the adjustable parameters of the rotating sprinkler 901 such as, for example, the central control station 206 . In some embodiments, the central control system 206 processes the moisture data 410 to determine which areas require moisture. The central control system 206 provides instructions to configure the spray pattern 104 such that the areas needing moisture, including the first portion 990 , the second portion 991 , and the third portion 992 , are watered.
[0120] Because the first portion 990 , the second portion 991 and the third portion 992 include areas corresponding to different radial distances and different directions, the central control system 206 can use a combination of features to effectively apply water to the first portion 990 , the second portion 991 and/or the third portion 992 . In one embodiment, the central control system 206 adjusts one or more of the elevation angle actuator 920 , the spreader plate actuator 940 , or the water flow actuator 960 such that the rotating sprinkler 901 applies water to areas corresponding to the first radial distance 995 , such as, for example, the first portion 990 or the third portion 992 . The central control station 206 adjusts the rotation rate of the rotating sprinkler 901 such that when the rotating sprinkler 901 is rotating through areas corresponding to the first portion 990 and/or the third portion 992 , the rotating sprinkler 901 rotates at a relatively slow rate, therefore applying water to the first portion 990 and/or the third portion 992 . When the rotating sprinkler 901 is rotating through areas not corresponding to the first portion 990 and/or the third portion 992 , the central control system 206 adjusts the rotation rate of the rotating sprinkler 901 such that the rotating sprinkler 901 rotates at a relatively quicker rate, therefore applying less or no water to the areas that do not correspond to the first portion 990 and/or the third portion 992 . In this manner, the rotating sprinkler 901 effectively waters the first portion 990 and the third portion 992 .
[0121] In another embodiment, the central control system 206 waters the second portion 991 by adjusting one or more of the elevation angle actuator 920 , the spreader plate actuator 940 , or the water flow actuator 960 such that the rotating sprinkler 901 projects water to areas corresponding to the second radial distance 997 , such as, for example, the second portion 991 . When the rotating sprinkler 901 is rotating through areas corresponding to the second portion 991 , the rotating sprinkler 901 rotates at a relatively slow rate, therefore applying water to the second portion 991 . When the rotating sprinkler 901 is rotating through areas not corresponding to the second portion 991 , the central control system 206 adjusts the rotation rate of the rotating sprinkler 901 such that the rotating sprinkler 901 rotates at a relatively quicker rate, therefore applying less or no water to the areas that do not correspond to the second portion 991 . In this manner, the rotating sprinkler 901 effectively waters the second portion 992 .
[0122] FIG. 10A is a diagram of one embodiment of the sprinkler 1000 having a sprinkler head 1002 , the elevation angle actuator 920 , the spreader plate actuator 940 , and a spreader plate 1010 . The elevation angle actuator 920 and the spreader plate actuator 940 can be, for example, solenoids, stepper motors, switches, relays, valves, or the like. As shown in FIG. 10A , the sprinkler 1000 is configured to project water in a first direction 1005 at a first elevation angle and in a second direction 1015 at a second elevation angle. In one embodiment, water projected in the first direction 1005 waters areas corresponding to a first distance away from the sprinkler 1000 . In another embodiment, water projected in the second direction 1015 waters areas corresponding to a second distance away from the sprinkler 1000 . In other embodiments, water projected in a third direction (not shown) waters areas corresponding to a third distance away from the sprinkler 1000 .
[0123] In FIG. 10A , when the elevation angle actuator 920 is at a first state (for example, active or inactive), water is projected from the sprinkler 1000 in the first direction 1005 . In one embodiment, when the elevation angle actuator 920 is in a second state, water is projected from the sprinkler 1000 in the second direction 1015 . In still another embodiment, when the elevation angle actuator 920 is in a third state, water is projected from the sprinkler 1000 in the third direction. As shown in FIG. 10A , the elevation angle actuator 920 controls the elevation angle by controlling the position of the sprinkler head 1002 . When the sprinkler head 1002 is in a first position, the sprinkler head 1002 waters areas corresponding to a first distance away from the sprinkler 1000 . In one embodiment, when the sprinkler head 1002 is in a first position, water is projected from the sprinkler 1000 in the first direction 1005 . When the sprinkler head 1002 is in a second position, the sprinkler 1000 waters areas located a second distance away from the sprinkler 1000 . In one embodiment, the when the sprinkler head 1002 is in the second position, water is projected from the sprinkler 1000 in the second direction 1015 . In some embodiments, the sprinkler 1000 adjusts the position of the sprinkler head 1002 by adjusting the angle of the sprinkler head 1002 relative to sprinkler shaft 1070 .
[0124] Still with reference to FIG. 10A , when the spreader plate actuator 940 is in a first state, the spreader plate 1010 is in a first position. When the spreader plate 1010 is in a first position, the sprinkler 1000 waters areas corresponding to a first distance away from the sprinkler 1000 . In one embodiment, when the spreader plate 1010 is in a first position, the sprinkler 1000 projects water in the first direction 1005 . When the spreader plate actuator 940 is in a second state, the spreader plate 1010 is in a second position and the sprinkler 1000 waters areas that correspond to a second distance away from the sprinkler 1000 . In one embodiment, when the spreader plate 1010 is in the second position, water is projected from the sprinkler 1000 in the second direction 1015 . In a further embodiment, the spreader plate actuator is in a third state, the spreader plate 1010 is in a second position, water is projected from the sprinkler 1000 is the third direction and the sprinkler 1000 waters areas that correspond to a third distance away from the sprinkler 1000 .
[0125] FIG. 10B is a diagram of one embodiment of the sprinkler 1000 having a nozzle 1020 , the elevation angle actuator 920 and the water flow actuator 960 . The elevation angle actuator 920 and the water flow actuator 960 can be, for example, solenoids, stepper motors, switches, relays, valves, or the like. As shown in FIG. 10B , the sprinkler 1000 is configured to project water in a first direction 1025 at a first elevation angle and in a second direction 1035 at a second elevation angle. In one embodiment, water projected in the first direction 1025 waters areas located a first distance away from the sprinkler 1000 . In another embodiment, water projected in the second direction 1035 waters areas corresponding to a second distance away from the sprinkler 1000 . In yet another embodiment, water projected in the third direction waters areas corresponding to a third distance away from the sprinkler 1000 .
[0126] In one embodiment, when the elevation angle actuator 920 is at a first state, the nozzle 1020 of the sprinkler 1000 is in a first position and water is projected from the sprinkler 1000 in the first direction 1025 . In another embodiment, when the elevation angle actuator 920 is in a second state, the nozzle 1020 is in a second position and the sprinkler 1000 sprays water in the second direction 1035 . When the elevation angle actuator 920 is in a third state, the nozzle 1020 is in a third position and the sprinkler 1000 sprays water in the third direction.
[0127] In other embodiments, when the water flow actuator 960 is in a first state, water flows out of the nozzle 1020 at a first setting and the sprinkler 1000 waters areas corresponding to a first distance away from the sprinkler 1000 . In one embodiment, when the water flow actuator 960 is in the first state, water is projected from the sprinkler 1000 in the first direction 1025 . In another embodiment, when the water flow actuator 960 is in a second state, water flows out of the nozzle 1020 at a second setting, and the sprinkler 1000 waters regions corresponding to a second distance away from the sprinkler 1000 . In one embodiment, when the water flow actuator 960 is in the second setting, water is projected from the sprinkler 1000 in the second direction 1035 . In an embodiment, when the water flow actuator 960 is in a third setting, water is projected from the sprinkler 1000 in the third direction and the sprinkler 1000 waters areas corresponding to a third distance away from the sprinkler 1000 . The water flow actuator 960 can control various parameters of water flowing through the sprinkler 1000 such as, without limitation, volume, rate, velocity, pressure, etc.
[0128] Although the sprinkler 1000 in FIGS. 10A and 10B includes the elevation angle actuator 920 , the spreader plate actuator 940 , and the water flow actuator 960 , the sprinkler 1000 can include two or more actuators to control each of the rate of rotation, the elevation angle of projected water, the position of the spreader plate or the parameters of flow of water. For example, the sprinkler 1000 can be configured to include two or more elevation angle actuators 920 to enable the sprinkler 1000 project water in more than two directions and/or elevation angles. In some embodiments, using two or more actuators to control each of the rate of rotation, the elevation of projection, the position of the spreader plate or the parameters of flow of water provides the sprinkler 1000 more than three states (for example, active, inactive, default or neutral) to control each of the rate of rotation, the elevation of projection, the position of the spreader plate or the parameters of flow of water, thereby enabling the sprinkler 1000 to water areas of the zone corresponding to a wide array of distances. In some embodiments, the sprinkler 1000 includes two or more actuators arranged in series.
[0129] In other embodiments, the sprinkler 1000 in FIGS. 10A and 10b includes manual settings to control each of the rate of rotation, the elevation angle of projection, the position of the spreader plate or the parameters of flow of water. For example, when users set the rate of rotation at a first setting, the sprinkler 1000 waters areas corresponding to a first radial distance. When users set the rate of rotation at a second setting, the sprinkler 1000 waters areas corresponding to a second radial distance. In another embodiment, when users adjust the position of the spreader plate 1010 to a first position, the sprinkler 1000 waters areas corresponding to a first radial distance and when users adjust the position of the spreader plate 1010 to a second position, the sprinkler 1000 waters areas corresponding to a second radial distance. In one arrangement, when users set the flow of water going through the sprinkler 1000 to a first setting (for example, a first volume), the sprinkler 1000 waters areas corresponding to a first radial distance. When users set the flow of water going through the sprinkler 1000 to a second setting (for example, a first volume), the sprinkler 1000 waters areas corresponding to a second radial distance.
[0130] FIG. 11 illustrates an embodiment of a non-rotating sprinkler 1100 . The sprinkler 1100 includes the sprinkler head 602 , and at least one port actuator 1150 . In some embodiments, the port actuator 1150 includes two states, such as, for example, active and inactive states. In other embodiments, the port actuator 1150 includes three states, such as, for example, active, inactive, and neutral states. In still other embodiments, the port actuator 1150 includes more than three states, such as, for example, when the port actuator 1150 includes two or more solenoids. In one embodiment, each port actuator 1150 controls a port 606 associated with the port actuator 1150 . In another embodiment, the actuators 604 and their associated ports 606 form a ring around the perimeter of the sprinkler head 602 .
[0131] The water supply 204 through the activated water supply valve 202 supplies water to the sprinkler 1100 . When the port 606 is open, water flows through the port 606 . In one embodiment, when the port actuator 1150 is active, the port 606 is open. In another embodiment, when the port actuator 1150 is active, the port 606 is closed. In another embodiment, when the port actuator 1150 is inactive, the port 606 is closed. In a yet further embodiment, when the port actuator 1150 is inactive, the port 606 is open.
[0132] The sprinkler 1100 of FIG. 11 further includes one or more moisture sensors associated with the sprinkler 1100 , including the first level moisture sensors 200 , the second level moisture sensors 720 , third level moisture sensors 1120 and fourth level moisture sensors 1140 . As previously mentioned, the first level moisture sensors 200 , the second level moisture sensors 720 , the third level moisture sensors 1120 and the fourth level moisture sensors 1140 collect moisture data and provide the moisture data to the sprinkler 1100 or to the central control system 206 using either electrical connections or wireless transmission systems, or a combination of electrical connections and wireless transmission systems, as described above.
[0133] The non-rotating sprinkler 1100 further includes the elevation angle actuator 920 , the spreader plate actuator 940 , and the water flow actuator 960 . The sprinkler 1100 can be configured to use the elevation angle actuator 920 , the spreader plate actuator 940 , or the water flow actuator 960 to change the distances where the sprinkler 1100 applies water to areas associated with the ports 606 . In some embodiments, the sprinkler 1100 is configured to use the port actuator 1150 to adjust the areas where the sprinkler 1100 applies water.
[0134] Based on the moisture data, the central control system 206 sends state information to the sprinkler 1100 to control the actuators 604 . The actuators 604 open the ports 606 as determined by the state information. The sprinkler 1100 waters the area associated with the open ports 606 . In some embodiments, the sprinkler 1100 is configured to adjust the distances at which the sprinkler 1100 projects water by adjusting the size of the port 606 that is opened by the port actuator 1150 . In one embodiment, when the port actuator 1150 is in a first state, the port 606 is open to a first position and the sprinkler 1100 waters areas corresponding to a first portion. In another embodiment, when the port actuator 1150 is in a second state, the port 606 is open to a second position and the sprinkler 1100 waters areas corresponding to a second portion. In some embodiments, when the port actuator 1150 is in a third state, the port 606 is open to a third position and the sprinkler 1100 waters areas corresponding to a third portion. In still another embodiment, when the port actuator 1150 is in a third state, the port 606 is closed.
[0135] Also based on the moisture data, the central control system 206 sends state information to the sprinkler 1100 to control the elevation angle actuator 920 , the spreader plate actuator 940 , and the water flow actuator 960 , thereby controlling the distance at which the sprinkler 1100 waters the area associated with the open ports 606 . In one embodiment, the central control system 206 sends information to the sprinkler 1100 to control the elevation angle actuator 920 . The sprinkler 1100 uses the elevation angle actuator 920 to control the distances at which the sprinkler 1100 waters the area associated with the open ports 606 . In one embodiment, the elevation angle actuator 920 controls the distance at which the sprinkler 1100 projects water by adjusting the angle of the sprinkler head 602 . In another embodiment, the elevation angle actuator 920 changes the distance at which the sprinkler 1100 projects water by changing the angle of the nozzle (not shown).
[0136] In one embodiment, when the elevation angle actuator 920 is active, the sprinkler 1100 waters areas at a first location. In another embodiment, when the elevation angle actuator 920 is active, the sprinkler 1100 waters the area at a second location. In one embodiment, when the elevation angle actuator 920 is inactive, the sprinkler 1100 waters areas in the first location. In another embodiment, when the elevation angle actuator 920 is inactive, the sprinkler 1100 waters areas in the second location. In some embodiments, the first location is located at a radial distance different from the second location.
[0137] The central control system 206 , based on the moisture data, also sends state information to the sprinkler 1100 to control the spreader plate actuator 940 . The sprinkler 1100 uses the spreader plate actuator 940 to determine at which distance the sprinkler 1100 waters the area associated with the open ports 606 . In one embodiment, when the spreader plate actuator 940 is in a first state, the sprinkler 1100 waters areas corresponding to a first radial distance away from the sprinkler 1100 . In another embodiment, when the spreader plate actuator 600 is in a second state, the sprinkler 1100 waters the areas corresponding to a second radial distance away from the sprinkler 1100 .
[0138] The spreader plate actuator 940 can control the position of the spreader plate in several manners. In one embodiment, the spreader plate actuator 940 changes the distance at which the sprinkler 1100 projects water by moving the spreader plate in the vertical direction. In another embodiment, the spreader plate actuator 940 changes the distance at which the sprinkler 1100 projects water by moving the spreader plate in the horizontal direction. In still other embodiments, the spreader plate actuator 940 changes the distance at which the sprinkler 1100 projects water by moving the spreader plate in both the vertical and the horizontal directions. In still further embodiments, the spreader plate actuator 940 changes the distance at which the sprinkler 1100 projects water by changing the angle of the spreader plate, such as, for example, relative to the sprinkler head 602 .
[0139] In one embodiment, when the spreader plate actuator 940 is active, the sprinkler 1100 waters the area a first location. In another embodiment, when the spreader plate actuator 940 is active, the sprinkler 1100 waters the area a second location. In one embodiment, when the spreader plate actuator 940 is inactive, the sprinkler 1100 waters the area at a first location. In another embodiment, when the spreader plate actuator 940 is inactive, the sprinkler 1100 waters the area at a second location. In some embodiments, the first location and the second location are substantially apart from each other such that the sprinkler 1100 has to adjust the distances at which the sprinkler 1100 applier water to effectively water the first location and the second location.
[0140] Still based on the moisture data, the central control system 206 sends state information to the sprinkler 1100 to control the water flow actuator 960 . The sprinkler 1100 uses the water flow actuator 960 to determine at which distance the sprinkler 1100 waters the area associated with the open ports 606 . In one embodiment, when the water flow actuator 960 is in a first state, the sprinkler 100 waters areas corresponding to a first radial distance away from the sprinkler 1100 . In another embodiment, when the water flow actuator 960 is in a second state, the sprinkler 1100 waters the areas corresponding to a second radial distance away from the sprinkler 1100 . In some embodiments, the first radial distance and the second radial distance are substantially apart from each other such that the sprinkler 100 has to adjust the distances at which the sprinkler 1100 applier water to effectively water areas corresponding to the first radial distance and the second radial distance.
[0141] The water flow actuator 960 can also be configured to change the distance at which the sprinkler 1100 projects water by changing flow parameters associated with the water flowing through the sprinkler 1100 . In one embodiment, the water flow actuator 960 changes the volume of water flowing through the sprinkler 1100 . In another embodiment, the water flow actuator 960 controls the distance at which the sprinkler 100 projects water by adjusting the rate at which water flows through the sprinkler 1100 . In a further embodiment, the water flow actuator 960 controls the velocity of water flowing through the sprinkler 1100 to adjust where the sprinkler 100 applies water.
[0142] In one embodiment, when the water flow actuator 960 is active, the sprinkler 1100 waters areas located corresponding to a first position. In another embodiment, when the water flow actuator 960 is active, the sprinkler 100 waters areas located surrounding a second position. In one embodiment, when the water flow actuator 960 is inactive, the sprinkler 100 waters areas associated to the first position. In another embodiment, when the water flow actuator 960 is inactive, the sprinkler 1100 waters areas associated with the second position. In some embodiments, the first position is located at a radial distance different from the second position. In other embodiments, the first position and the second position are located substantially apart from each other such that the sprinkler 1100 adjusts the distances the sprinkler 1100 projects water to effectively water the first and the second positions.
[0143] Still with reference to FIG. 11 , the sprinkler 1100 can be configured to use a combination of two or more of the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 to control the areas watered by the sprinkler 1100 . For example, in one embodiment, the sprinkler 1100 uses two of the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 to adjust where the sprinkler 1100 applies water, including the distance at which the sprinkler 1100 projects water. In other embodiments, the sprinkler 1100 uses all of the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 to control where the sprinkler 1100 applies water, including controlling the distances at which the sprinkler 1100 projects water.
[0144] With continued reference to FIG. 11 , the sprinkler 1100 in some embodiments can use a combination of the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 to compound the distance at which the sprinkler 1100 applies water to the area associated with the sprinkler 1100 . For example, in one embodiment, when all of the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 are at a first state (for example, inactive) the sprinkler 1100 waters areas applies at or near a first radial distance R 1 . In another embodiment, when one of the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 is at a second state (for example, active) and the other remaining actuators remain at the first state, the sprinkler 100 waters areas near a second radial distance R 2 . In other embodiments, when two of the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 are at the first state, the sprinkler 1100 waters areas at or near a third radial distance R 3 . In still other embodiments, when all of the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 are at the first state, the sprinkler 1100 waters areas corresponding to a fourth radial distance R 4 .
[0145] In another embodiment, the sprinkler 1100 , using the computer 304 , controls the state of the actuators 604 based on the moisture data. The sprinkler 1100 activates the actuators 604 to open the ports 606 , which waters the areas associated with the open ports 606 . Using the computer 304 , the sprinkler 1100 also activates one or more of the elevation angle actuator 920 , the spreader plate actuator 940 , and/or the water flow actuator 960 to change the distance at which the sprinkler 1100 waters the areas associated with the ports 606 .
[0146] FIG. 12 illustrates one embodiment of a sprinkler system 1200 wherein the sprinklers 1202 apply water to a watering zone, including relatively large watering zones, such as, for example, golf courses, recreational parks, and farms. The watering zone in FIG. 12 shows subsections of the watering zone to be watered, including first regions 1210 , second regions 1220 , and third regions 1230 .
[0147] In one embodiment, the first regions 1210 , the second regions 1220 , and the third regions 1230 correspond to areas that are substantially apart. The area corresponding to the center of the third regions 1230 can be located tens or hundreds of meters away from the area corresponding to the center of the second regions 1220 . Similarly, the area corresponding to the center of the second regions 1220 can be located tens or hundreds of meters away from the area corresponding to the center of the first regions 1210 . To effectively water the first regions 1210 , the second regions 1220 , and the third regions 1230 , a relatively large number of sprinklers normally would have to be placed throughout the watering zone, sometimes including in the first regions 1210 , the second regions 1220 , and the third regions 1230 .
[0148] As shown in FIG. 12 , the sprinklers 1202 can be configured to project water to relatively large distances and, therefore, are able to water relatively large watering zones. The sprinklers 1202 are configured to apply water to different subsections of the watering zone, including first regions 1210 , second regions 1220 , and third regions 1230 of the watering zone. As mentioned herein, adjusting the distances at which the sprinklers 1202 apply water enables the sprinkler 1202 to effectively water the first regions 1210 , the second regions 1220 , and/or the third regions 1230 . Because the sprinklers 1202 can project water to larger distances, and because the sprinklers 1202 can adjust the distances at which the sprinklers 1202 apply water, the sprinkler system 1200 can use a relatively small number of sprinklers 1202 to effectively water the watering zone, including the first regions 1210 , the second regions 1220 , and/or the third regions 1230 .
[0149] Still with reference to FIG. 12 , the sprinklers 1202 can be positioned strategically at alternating ends of the watering zone, thereby providing a relatively low number of the sprinklers 1202 to effectively water relatively large portions of the watering zone, including the first regions 1210 , the second regions 1220 , and/or the third regions 1230 .
[0150] The ability of a relatively small number of the sprinklers 1202 to apply water to the different regions of the watering zone covering large areas reduces the overall number of sprinklers 1202 used in the sprinkler system 1200 . Reducing the number of sprinklers 1202 used in the sprinkler system 1200 can reduce the installation, as well as maintenance, cost of the sprinkler system 1202 .
[0151] In some embodiments, the sprinkler 1202 is a rotating sprinkler, such as, for example, the rotating sprinkler 901 of FIG. 9 . A rotating sprinkler 1202 rotates in an arc or in portions of an arc to apply water to, for example, each of the three sections of the first regions 1210 . In other embodiments, the sprinkler 1202 is a non-rotating sprinkler, such as, for example, the non-rotating sprinkler 1100 of FIG. 11 . The non-rotating sprinkler 1202 can be configured to include multiple ports associated with, for example, each of the three sections of the first regions 1210 . As described in connection with FIG. 11 , the non-rotating sprinkler 1202 opens the port associated with a particular section of the first region 1210 to water the section.
[0152] As described herein, the sprinklers 1202 , whether rotating or non-rotating, can adjust the distances at which they apply water by adjusting one or more of the water elevation angle of water that is projected from the sprinklers 1202 , the position of a spreader plate, and/or the flow parameters of the water that is projected from the sprinklers 1202 (for example, volume, velocity, rate, pressure, etc.) to water areas of the watering zone, such as, for example, the third regions 1230 .
[0153] While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions, and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
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An irrigation system comprises sprinkler heads with an electrically adjustable spray pattern, moisture sensors, and a controller. Based upon input signals from the moisture sensors, the controller dynamically configures the spray pattern of the sprinkler head to allow more water to fall on areas that need to be watered and less water to fall on areas that do not require additional water.
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FIELD OF THE INVENTION
[0001] This invention relates to a ball drying implement for use by an official to dry such game balls as footballs or soccer balls and more particularly to a wearable pouch with an interior of water absorbing material.
BACKGROUND OF THE INVENTION
[0002] A football player or fan will be familiar with an official's use of a towel to dry the game ball when a game is being played in rain or snow.
[0003] The use of a pouch for the purpose of drying footballs has been suggested known in the art. One such pouch is shown in a Stephenson U.S. Pat. No. 5,615,769. That pouch has an outer waterproof covering and an interior, removable moisture-absorbent liner. The pouch has at its top an opening closable by a flap and held closed by hook and loop fasteners. In use the pouch's sides are tied closed by laces. Insertion and retrieval of the football is through the upper opening so that it appears one hand would be needed to pull back the closure flap and the remaining hand of the wearer would be needed to insert or retrieve the football. The pouch is supported by a strap hung from the official's neck and shoulders.
[0004] In another U.S. patent, U.S. Pat. No. 5,730,287 to Martin, a pair of stretchable bag-like ball carriers are attached by a long cord to be draped over the wearer's shoulders. The ball carriers stretch about the exterior of a pair of footballs to hold extra footballs for a game, and they protect those footballs from the weather. There is no, mention of drying the football once it has been in use. Other patents such as those to Hendren U.S. Pat. No. 5,813,080 and Lamonakis et al. U.S. Pat. No. 5,372,414 relate to towels that can be worn for the purpose of drying a ball and include multiple layers. In the Hendren patent, an outer layer of toweling is separated from an inner chamois layer by a water impervious layer. The Hendren arrangement is not a pouch for holding a ball, but rather a multilayer towel. The Lamonakis et al. patent shows a bell-shaped “skirt” of water repellent material that is placed over a towel to keep dry the towel. Lamonakis et al. contemplate inverting the entire arrangement to expose the towel so that a ball can be wiped. The arrangement is not a pouch that can carry a ball or enclose a ball as it is being dried.
[0005] There remains a need, therefore, for a ball drying pouch for use, e.g., with footballs or soccer balls in wet conditions wherein the ball can be inserted easily and one handedly and similarly easily retrieved once the ball has been rubbed dry by an interior water-absorbent liner.
BRIEF SUMMARY OF THE INVENTION
[0006] In accordance with the present invention a ball drying pouch has an exterior layer of substantially water impervious flexible sheet material and an inner lining layer of water absorbent material. The exterior and interior layers are formed, as by sewing or folding, into a pouch capable of containing a ball to be dried. The top and bottom of the pouch so fashioned is closed. One or both side edges of the pouch form openings into which the ball can be inserted. Because the bottom of the pouch is permanently closed, there is little likelihood that an official using the pouch will drop the ball, but only one hand is needed to insert the ball from the side into the pouch to be briefly rubbed, and then retracted, again by a single hand. A busy on-field official can thus readily accomplish drying the ball without diverting his or her attention from other activities on the field.
[0007] In a preferred exemplary embodiment the interior layer of the pouch is chamois. Also in the exemplary preferred embodiment the pouch has attachment provisions for securing the pouch to the official's person or clothing. Typically in the preferred embodiment the pouch is secured to the wearer's belt at two locations along the top of the pouch. One preferred attachment arrangement includes strap loops that receive a wearer's belt to hold the pouch in place. The strap loops can have fasteners that open and close to open and close the loops about the wearer's belt. The strap loops are in one exemplary embodiment sewn to the pouch body. Similarly in one exemplary embodiment the interior water absorbent layer is sewn to the exterior water repellent or impervious layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a fragmentary front view of an official wearing a ball drying pouch in accordance with the present invention;
[0009] FIG. 2 is an enlarged front view of the pouch of FIG. 1 and shows its side openings and loop fasteners;
[0010] FIG. 3 is an enlarged fragmentary perspective view showing the manner of assembly of the pouch and the loop fasteners; and
[0011] FIG. 4 is a further fragmentary front view of the official inserting a football into the ball drying pouch of FIG. 1 .
DETAILED DESCRIPTION
[0012] As seen in FIG. 1 , a football official 10 wears a pouch 12 secured to his belt 14 by a pair of strap loops 16 and 18 .
[0013] As shown in FIG. 2 the pouch has a closed top edge 20 , a closed bottom edge 22 , and a pair of side edges 24 and 26 at which are formed openings 28 and 30 . Fixed to the pouch at or near the top edge 20 are a pair of strap loops 32 and 34 for securing the pouch to an official's belt. A pair of quick fasteners 36 and 38 of a known commercially available kind permit opening and closing of the loops 32 and 34 . Other fasteners than those shown can be used as desired. For example Velcro loop and hook fastening patches, snaps, ties or any other known, convenient fastener suitable to bring together the two strap pieces into a loop will suffice. Likewise fastening devices other than the strap loops can hold the pouch 12 in place. For example, hook and loop fastening patches secured to the pouch and the official's uniform could be used to secure the pouch. Clips positioned to clip onto the official's belt loops and attached at or near the top edge 20 of the pouch 12 is a further example alternative.
[0014] The construction of the pouch is better illustrated from FIG. 3 . In the illustrated exemplary embodiment shown, the pouch is formed by an exterior layer 40 of substantially waterproof or water repellent material such as vinyl or other plastic. An interior layer 42 is of chamois or other water absorbent material. In this exemplary embodiment the chamois layer 42 is sewn to the external water resistant material 40 as indicated at 44 , 46 and 48 . At the top edge of the pouch 12 , several strips of binding material 50 , 52 and 54 (seen in FIG. 2 ) are sewn along the edge. The strips straddle the top edge of the brought-together layers and have down-turned edges. Stitching 48 shown in FIG. 3 stitches together the edges of the strips 50 , 52 and 54 and the top four edges of the layers 40 and 42 . The straps that form the strap loops 32 and 34 have strap ends sewn into the interior of the pouch as indicated at 56 . In this particular exemplary embodiment the bottom of the pouch is formed by a seam 58 where the four layers of material are brought together, turned inward and sewn at 46 . It will also be appreciated that, alternatively, a single piece of the multilayer material could be folded at the bottom to form the bottom edge 22 .
[0015] As illustrated in FIG. 4 , because the pouch 12 is open at its sides it is easy for an official to insert a ball, dry the ball and extract the ball with little attention to those operations and without even looking at the pouch and ball. As previously stated this has the advantage of permitting the official to pay more attention to the activities on the field. While stitching has been shown to join the inner and outer layers of the exemplary pouch, it will be appreciated that other means such as hook and loop fastening patches, snaps, laces or other connection means may be used to secure the chamois or other water absorbent layer within the exterior. Also while the joiner of the two layers has been shown in the preferred embodiment as being permanent, the interior lining could be removable if, for example, hook and loop fastening or other easily separable fastening means are used. Also, while both sides of the pouch of the exemplary embodiment have been shown as open, it will be appreciated that just one side could be open without unduly increasing the difficulty of inserting the ball, drying the ball and retrieving the ball for play.
[0016] While a particular exemplary and preferred embodiment has been shown, it will be appreciated that many changes, modifications or revisions in the described ball drying pouch may be made as will be appreciated by those skilled in the art and without departure from the spirit and scope of the invention as set forth in the appended claims.
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A ball drying pouch for, e.g., a football or soccer ball has an absorbent interior liner and a water repellent exterior layer. Fasteners permit the pouch to be worn by an official. The top and bottom edges of the pouch are permanently closed. One or both side edges afford an opening for insertion of a ball for drying.
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BACKGROUND
[0001] The present invention described herein relates to structures formed from corrugated paper. The corrugated paper structures may be used for packaging items for storage or transportation. The corrugated paper structures are relatively inexpensive to produce, and provide superior protection from damage for items stored using the corrugated paper structure.
[0002] Corrugated paper has been used to create a wide variety of structures for storing and transporting items. The strength and protective capability of a corrugated paper structure varies depending on the specific design of the structure. For example, simple corrugated paper boxes are well known but, without additional packing structures inside the box, they provide little protection to their contents from damage from dropping or other impact or crushing forces.
[0003] Often corrugated paper structures that are designed to provide higher levels of damage protection for their contents are complex in design or require components designed to protect a specific item. The corrugated paper structure described has a structure that may be utilized to encase and protect a variety of items.
SUMMARY OF THE INVENTION
[0004] The corrugated paper structure comprises a first and second base pad of corrugated paper; at least one structural member comprising a corrugated paper tube with a rectangular cross-section and a corrugated paper truss member disposed diagonally within the corrugated paper tube; wherein each of the structural members is disposed between and attached to the first and second base pads.
[0005] In an embodiment of the corrugated paper structure, the structural members are disposed adjacent to the edges of the first and second base pads defining an interior volume for containing an item. In a preferred embodiment of the corrugated paper structure the structural members are attached to the first and second base pads by a cohesive composition applied to the members and the pads.
[0006] The invention also includes a method for packing an item comprising the steps of providing a first and second base pad of corrugated paper; providing a plurality of structural members of corrugated paper; attaching each of the plurality of structural members to the first base pad; placing the item on the first base pad between the plurality of structural members; and attaching the second base bad to the plurality of structural members.
[0007] In a preferred embodiment, the step of providing a plurality of structural members of corrugated paper further comprises the steps of providing a tube of corrugated paper with a rectangular cross-section; and providing a truss member of corrugated paper; and disposing the truss member diagonally within the tube and attaching the truss member to the interior surface of the tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an exploded perspective view of an embodiment of the corrugated paper structure.
[0009] FIG. 2 is a perspective cross-sectional view of an embodiment of the corrugated paper structure.
[0010] FIG. 3 is a top plan view of a component of an embodiment of the corrugated paper structure.
[0011] FIG. 4 is a top plan view of a component of an embodiment of the corrugated paper structure.
[0012] FIG. 5 is a perspective cross-sectional view of an alternative embodiment of the corrugated paper structure.
[0013] FIG. 6 is a top plan view of an alternative embodiment of the corrugated paper structure.
DETAILED DESCRIPTION
[0014] The corrugated paper structure as described in reference to the embodiment depicted in the figures provides an improved structural design for use in corrugated paper packs, boxes, pallets and other corrugated paper structures. The corrugated paper structure has improved resistance to failure resulting from crushing, bending, breaking or other external forces.
[0015] Referring now to FIG. 1 , an exploded perspective view of an embodiment of the corrugated paper structure is depicted in use in a corrugated paper pack. The corrugated paper pack depicted in the figure comprises four structural members 100 . Two pads 102 are provided for joining to the members 100 to form a pack for protecting and shipping an item. The bases 102 are attached to opposing sides of the members 100 defining an interior volume of the pack for containing the item to be protected.
[0016] The members 100 and pads 102 are formed from corrugated paper. The internal structure of members 100 is described in relation to later figures. Pads 102 are sheets of corrugated paper of appropriate size and thickness for the application.
[0017] The top and bottom surfaces 104 of members 100 are coated with a material to attach the members 100 to the pads 102 . Similarly, areas 106 adjacent to the edges of pads 102 are coated with a material to attach to members 100 . The materials may be glues, adhesives or other materials suitable for attaching two corrugated paper components together.
[0018] In a preferred embodiment of the corrugated paper structure, a cohesive material is utilized to coat the top and bottom surfaces 104 and areas 106 . The cohesive materials may be applied to the areas, and once dried will cohere to each other when placed in contact, forming a permanent connection between the components. Cohesive materials used in a preferred embodiment do not adhere to other materials when dried, but instantly adhere to other coatings of the same material.
[0019] The cohesive materials are typically applied by rolling them onto a surface of a component and allowing them to cure or dry if necessary, though different materials may be sprayed on or applied as appropriate for a specific cohesive material. Once the cohesive materials have properly cured, become tacky or dried they are placed in contact with a coating of the same material on the surface of the other component, at which time the two coatings cohere and securely attach the two components together.
[0020] The corrugated paper structure members 100 may alternatively be attached to each other near the ends of each member, though in a preferred embodiment they are not attached to each other directly. In a preferred embodiment, the attachment to pads 102 described above is sufficient to secure the members 100 together in the desired configuration.
[0021] The specific size, shape and number of components shown in FIG. 1 is not limiting of the present invention. Other sizes and shapes of pad 102 may be utilized, such as triangular, hexagonal or other polygonal shapes. Similarly embodiments of the invention may utilize more or fewer members 100 than shown in FIG. 1 , and the members 100 may be arranged in different configurations. Structures may be formed by attaching members 100 to other members to form taller sides to a structure, or structures may include multiple layers of members 100 and pads 102 to form structures as desired.
[0022] In some embodiments pads 102 may have holes, openings, or other perforations. Similarly, structures created according to the present invention may have multiple separate interior volumes defined by the pads 102 and the members 100 . In other embodiments of the present invention, not all the edges, or portions of edges, of the pads 102 are attached to a member 100 .
[0023] Referring now to FIG. 2 , a perspective cross-sectional view of an embodiment of the corrugated paper member 100 is depicted. The corrugated paper structure comprises a tube member 200 and a truss member 202 . The tube member 200 is a tube with a rectangular cross-section formed from corrugated paper. In various embodiments of the corrugated paper structure the dimensions and cross-section of the tube member 200 vary as necessary for specific applications.
[0024] The tube member 200 is formed from a single sheet of corrugated paper. A top plan view of the corrugated paper sheet for an embodiment of the tube member 200 is depicted in FIG. 3 . The flat sheet of corrugated paper may be of any size necessary to form a member 100 of the size necessary for a given application. In one embodiment of the present invention, the sheet of corrugated paper is 16 ½ inches by 96 ⅜ inches. In other embodiments the sheet may be of varying length and width. The sheet may be formed from varying weights and thicknesses of corrugated paper as necessary for a given application.
[0025] The flat sheet is scored or otherwise prepared for folding along its length to create sides 300 , 302 , 304 , 306 and a glue tab 308 , each running the length of the flat sheet. The sides are folded into a tube and secured by gluing the glue tab 308 to side 300 using standard techniques for processing corrugated paper. In a preferred embodiment of the present invention, the corrugation will be oriented across the width of the sheet from which the tube 200 is formed, perpendicular to the scoring for the sides and glue tab.
[0026] In an embodiment of the tube member 200 , side 300 is 2 ⅞ inches wide, side 302 is 4 ⅜ inches wide, side 304 is 2 15/16 inches wide, side 306 is 4 5/16 inches wide and glue tab 308 is 2 inches wide. A tube formed from the described sheet has inside dimensions of 4 3/16 by 2 ¾ by 96 ⅜. In other embodiments, the sheet and resulting tube may have other dimensions as necessary for a given application.
[0027] The truss member 202 is formed from a second sheet of corrugated paper. A top plan view of the corrugated paper sheet for an embodiment of the truss member 202 is depicted in FIG. 4 . The sheet of corrugated paper may be of varying size so long as it is appropriately sized to be folded into a configuration that will fit inside the tube member 200 . In one embodiment of the present invention the truss member 202 , sized to fit the preferred embodiment of tube member 200 described in relation to FIG. 3 , the sheet of corrugated paper for the truss member 202 is 10 ¼ inches by 96 ⅜. The sheet may be formed from varying weights and thicknesses of corrugated paper as necessary for a given application.
[0028] The truss member comprises a panel 400 that extends diagonally across the interior of truss member 200 , from one corner thereof to the opposing corner. In the embodiment of the truss member 202 designed to be inserted into the embodiment of the tube member 200 described above, the truss member panel 400 is 4 ¾ inches wide. At each end of panel 400 , a glue tab 402 is provided for attaching the truss member 402 to the tube member 200 . In the depicted embodiment, glue tabs 402 are 2 ¾ inches wide. In other embodiments, the sheet and resulting truss may have other dimensions as necessary for a given application.
[0029] The truss member 202 is prepared by folding the flat sheet along the depicted lines into a Z shape. The folding of truss member 202 may be accomplished using typical methods known for processing corrugated paper. As part of the folding process or as a subsequent process, glue or adhesive is applied to the outer surfaces of glue tabs 402 . The truss member 202 is then inserted into tube member 200 and the glue tabs 402 contact and bond with the inner surfaces of tube member 200 .
[0030] In a preferred embodiment of the process, after applying the glue to the glue tabs 402 , the glue tabs 402 are folded against or nearly against panel 400 of the truss member 202 . The truss member 202 is inserted into the tube member 200 . Once the truss member 202 is fully inserted into tube member 200 , glue tabs 402 are released and expand to contact the interior of tube member 200 . After curing the adhesive attachment between glue tabs 402 and the interior surfaces of tube member 200 , the structural members 100 may be attached to pads 102 to form a corrugated paper structure.
[0031] Referring now to FIG. 5 , a perspective cross-sectional view of an alternative embodiment of the corrugated paper member 100 is depicted. The corrugated paper structure comprises a scored tube member 500 formed from a single sheet of corrugated paper. The tube member 500 is a tube with a rectangular cross-section and an internal truss 502 formed when folding the tube. In various embodiments of the corrugated paper structure the dimensions and cross-section of the tube member 500 vary as necessary for specific applications.
[0032] In the alternative embodiment depicted in FIG. 5 , the tube member 500 and the truss member 502 are formed from a single sheet of corrugated paper. A top plan view of the corrugated paper sheet for an embodiment of the tube member 500 is depicted in FIG. 6 . The flat sheet of corrugated paper may be of any size necessary to form a member 100 of the size necessary for a given application. In one embodiment of the present invention, the sheet of corrugated paper is 24 ⅝ inches by 96 ⅜ inches. In other embodiments the sheet may be of varying length and width. The sheet may be formed from varying weights and thicknesses of corrugated paper as necessary for a given application.
[0033] The flat sheet is scored or otherwise prepared for folding along its length and formed with side 600 , and truss area 602 and sides 604 , 606 , 608 , and 610 and a glue tab 312 , each running the length of the flat sheet. The side 600 is folded back and truss area 602 and sides 604 , 606 , 608 and 610 are folded into a tube and secured by gluing the glue tab 612 to side 604 using standard techniques for processing corrugated paper. In a preferred embodiment of the present invention, the corrugation will be oriented across the width of the sheet from which the tube 500 and cross support 502 is formed, perpendicular to the scoring for the sides and glue tab.
[0034] In an embodiment of the tube member 500 , side 600 is 2 ⅞ inches wide, side 602 is 4 ⅜ inches wide, side 604 is 2 15/16 inches wide, side 606 is 4 ¼ inches wide, 608 is 2 ¾ inches wide, 610 is 4 ¾ wide and glue tab 612 is 2 11/16 inches wide. In other embodiments, the sheet and resulting tube may have other dimensions as necessary for a given application.
[0035] Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present invention. Embodiments of the present invention have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present invention.
[0036] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described.
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A corrugated paper structure is described for providing improved impact resistant packaging products. The corrugated paper structure comprises a plurality of structural members attached to base pads for forming a packaging product. The structural members are formed from a tube of corrugated paper with a rectangular cross-section and a truss member disposed therein.
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FIELD AND BACKGROUND OF THE INVENTION
This invention relates to modular refractory blocks or tiles. The invention is for a modular refractory block individually, and when used with other modular refractory blocks, to create a frame or support structure for holding ceramic tiles in a kiln during the firing process of the tile.
U.S. Pat. No. 6,644,966 (Chiang) discloses a carriage for supporting objects to be heated in a kiln comprising a pair of beams 2 with orifices 21 . Rods are engaged between orifices of a pair of beams. Objects 8 or 9 to be heated are placed on the rods 4 . A stack comprising the beams and rods may be formed. U.S. Pat. No. 1,885,691 (Dressler) teaches means for supporting ceramic ware while being fired in kilns. U.S. Pat. No. 2,923,997 (Emmerling) teaches a device for exposing ceramic ware to the heat of a kiln in the heat treatment of the ware, and particularly relates to a device for supporting ceramic tile during a glazing operation.
U.S. Patent Application No. 2004/0040245 (Sinclair) teaches a building block system and is more for use in constructing buildings than for use in a kiln. U.S. Pat. No. 2,745,276 (Kuhlman) discloses precast building units, not particularly for use in a kiln, the building blocks having channels disposed therein to accommodate pipes, cables etc. U.S. Pat. No. 2,462,289 (Rochow) teaches a furnace refractory construction including refractory bricks having at least one face provided with recessed portions.
U.S. Pat. No. 4,716,847 (Moreau) teaches a furnace wall comprising feed nozzles molded in two complementary paths, which may include a bundle of cylindrical and parallel pipes 24 which pass between elements in the openings. U.S. Pat. No. 3,471,136 (Hodl) teaches a rotary cement kiln lining block which includes channels 2 .
SUMMARY OF THE INVENTION
According to one aspect of the invention, there is provided a variable modular support system for use in a kiln comprising: a plurality of refractory blocks each having an upper surface and a lower surface and at least one transverse recess in either the upper or lower surface, the plurality of refractory blocks comprising a first base refractory block and a second base refractory block spaced from the first refractory block by a variable and selectable distance; and connecting rods extending from the recess of the first base refractory block or a refractory block stacked thereon to the recess of the second base refractory block or a refractory block stacked thereon, the connecting rods forming a rack or shelf located between the first base refractory block and the second base refractory block.
Preferably, both the upper and lower surfaces have at least three equispaced recesses thereon, the recesses of the upper surface being in substantial alignment with the recesses on the lower surface.
The recesses may be of generally of semicircular shape, or have a generally semicircular base portion and substantially vertical side walls.
In one embodiment, the variable modular support system comprises a plurality of refractory blocks vertically stacked on the first base refractory block and a plurality of refractory blocks vertically stacked on the second base refractory block, preferably substantially parallel to one another, and wherein connecting rods forming a plurality of vertically arranged shelves extend in a generally horizontal plane between and perpendicular to the refractory blocks vertically stacked on the first base refractory block and the refractory blocks vertically stacked on the second base refractory block, the connecting rods being supported in the recesses of the refractory blocks.
Preferably, the refractory blocks and connecting rods are variably configured so as to optimize the use of space in the kiln and structured to support objects being fired or cured in a kiln based on the dimensions of the objects. The invention may include secondary support pieces which can be utilized to provide additional support to a vertical stack of refractory blocks.
According to another aspect of the invention, there is provided a method of stacking objects to be fired in a kiln by placing the objects on a variable modular support system formed in the kiln, the method comprising: arranging on the floor or base of the kiln a plurality of refractory blocks each having an upper surface and a lower surface and at least one transverse recess in either the upper or lower surface, the plurality of refractory blocks including a first base refractory block and a second base refractory block spaced from the first refractory block by a variable and selectable distance; and placing connecting rods which extend from the recess of the first base refractory block or a refractory block stacked thereon to the recess of the second base refractory block or a refractory block stacked thereon, so that the connecting rods form a rack or shelf located between the first base refractory block and the second base refractory block.
In one form, the plurality of refractory blocks are vertically stacked on the first base refractory block and a plurality of refractory blocks are vertically stacked on the second base refractory block, and wherein connecting rods are placed to form a plurality of vertically arranged shelves which extend in a generally horizontal plane between the refractory blocks vertically stacked on the first base refractory block and the refractory blocks vertically stacked on the second base refractory block, the connecting rods being placed for support in the recesses of the refractory blocks.
The refractory blocks and connecting rods may be variably configured so as to optimize the use of space in the kiln and structured to support objects being fired or cured in a kiln based on the dimensions of the objects. Further, secondary support pieces may be used to provide additional support to a vertical stack of refractory blocks.
Preferably, the refractory blocks are comprised of a material which is selected for its ability to withstand multiple firings in the kiln at high temperatures.
In one aspect, there is provided a modular refractory block in accordance with the invention which can be used with other refractory blocks to create a customized frame or support structure for supporting ceramic tiles during the firing process in a kiln.
In the field of ceramics, and related areas, it is common practice to mold or configure objects such as tiles or containers, using various types of materials, such as clay, and thereafter place the molded object in a kiln to be fired. In the kiln, there is a process whereby a clay tile is heated to the appropriate temperature over a period of time until the internal chemistry of the clay achieves a vitreous or semi-vitreous state rendering it resistant to water and chemicals. An secondary step before placing it in the kiln is the painting or glazing or other treatment of the object. The kiln is generally a large oven, having walls and a sealable opening or door, and structures of different shapes, sizes and configurations are placed therein. Therefore, in order to maximize used of the space within the kiln, the frame or support mechanism comprising the invention may be inserted into the kiln so that a plurality of differently shaped and sized objects can be placed in the kiln to optimally utilize the space available therein.
In one aspect, the modular refractory block of the present invention is directed towards a series of specially configured blocks which may be assembled or located with a number of other similarly configured blocks in order to create a frame, rack or other form of support, in order to create spaces and distances within the kiln, for optimal placement of objects to be set within the kiln. Preferably, and in accordance with one aspect of the invention, the modular refractory block is used in association with rods made of a similar refractory material, and the modular refractory blocks, in combination with the rods, may be configured in any desired manner, so as to create a rack or framework suitable for a particular job.
Preferably, each modular refractory block, in accordance with the invention, has an upper surface and a lower surface, the upper surface having one or more transverse grooves spaced therealong. Furthermore, the bottom surface of the modular refractory tile may also have a series of transverse spaced grooves running therealong, and these grooves in the upper and lower surfaces may, in accordance with the invention, be substantially opposed to each other and thereby register with each other. The grooves are preferably but not necessarily semi-circular in shape, and are designed to receive at least the end of cylindrical-shaped (or other shaped) rods, so that a cylindrical-shaped rod can extend from the groove of one refractory block to the groove of another one, arranged in a spaced relationship therewith. Support shelves or racks are thereby created and dimensioned according to specific need based on the objects they will support.
The modular refractory block of the invention is thus designed to support ceramic tiles during the firing process of the tiles. The modular refractory block may be made from a high-fired refractory material, meaning that it is typically fired at between 2,300 and 2,500 degrees F. The refractory material may be ram, or dry-pressed, either of which process will create an equally durable product.
The material and the technique for pressing the modular refractory block is of some importance in creating a block that is not only durable, but also strong enough to withstand literally thousands of heating and cooling firings in the kiln. As will be appreciated, kilns are fired up and cooled down on an ongoing basis in order to cure many products, and the refractory block of the invention is preferably constructed so as to be able to withstand these extremes in multiple firings and uses.
The temperature of a firing in a kiln is sometimes measured by “cone” levels. For tile firings up to cone 1 , which is approximately 2,100 to 2,150° F., the refractory block of the invention will be extremely durable through thousands of firings. The refractory block of the invention is indeed capable of being fired in kilns fired up to cone 8 , which is approximately 2,300 to 2,375° F., with a potentiality for only a slightly diminished life.
In typical practice, in one aspect of the invention, two refractory blocks are necessary for the proper function of the system. These refractory blocks may be placed in the kiln (or oven) generally parallel to one another, and spaced with enough distance between them to allow for one or more tiles or other objects to be supported thereby when placed in the kiln, depending upon the size of the tile and the size of the kiln.
In one refractory block of the invention, three grooves are designed therein to accommodate three rods. The rods may be approximately a half inch in diameter, although the size, shape and dimensions of the rod will of course vary, depending upon the nature of the task at hand. The rods are also made of a refractory material and are generally available commercially. The rods are placed to rest in the grooves, between the two parallel refractory blocks, thereby creating a bridge and forming a support surface or rack between the modular refractory blocks of the invention. The tiles to be placed in the kiln are then located on top of the rods to be supported thereby, and it may then be possible to place one further refractory block on top of each one of those already placed and spaced apart from each other. Adding blocks in a stacked configuration may have at least two benefits. One benefit is that the rods resting in the groove of the lower refractory block are then sandwiched between the upper and lower refractory blocks, thus making them more stable and less likely to move or shift by casual knocking or heat effects. As such, they will not slide or be knocked out of position when in use.
In addition, the stacked upper refractory block on each side may also have grooves in its upper surface, and may form the location or cradle for further refractory rods to be placed, creating an additional shelf. Depending upon the size, configuration and requirements of the user, a series of substantially vertical shelves may be established between two spaced towers of stacked refractory blocks, thereby creating more usable space within the kiln. The structure of stacked refractory blocks and rods may be customized depending upon the nature of the tiles etc. being fired. Not only will this expedite processing of tiles, but it will also potentially save energy by using the space available in a kiln in an optimal manner.
It should be noted that this arrangement is just one of many configurations which can be constructed in accordance with the modular refractory blocks of the invention when used in combination with the refractory rods.
The refractory block in combination with the refractory rods in accordance with the invention is particularly suitable for use in top-loading kilns, but would work very well in front-loading kilns as well. Furthermore, the refractory blocks may be stacked to significant heights, and the extent of stacking will of course depend upon their size, particularly their base dimensions, in order to ensure stability of the structure. Indeed, up to fifteen or more refractory blocks may be stacked one above the other if they are free-floating inside the kiln without using at least one wall of the kiln as a form of support. If the refractory blocks are free-floating inside the kiln without being supported by the kiln walls, specially configured refractory tower pieces may be used to give additional stability to the structure, and therefore support the stacked refractory blocks and prevent any unintended toppling.
Whether the refractory blocks are stacked in an unsupported manner, i.e. one above the other without any additional structure added for stability, or whether they are supported by the kiln walls or other forms of stabilizing structure, it is always wise to ensure that each refractory block is centered exactly on top of the refractory block immediately below it, since this will provide the greatest area of contact and support between the refractory blocks as they are stacked higher, and therefore impart greater stability to the growing structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a refractory block in accordance with one aspect of the invention;
FIG. 2 is a side view of the refractory block shown in FIG. 1 of the drawings;
FIG. 3 is a top view of the refractory block shown in FIG. 1 of the drawings;
FIG. 4 is an end view of the refractory block shown in FIG. 1 of the drawings;
FIG. 5 is a perspective view of a refractory block in accordance with another embodiment of the invention;
FIG. 6 is a side view of the refractory block shown in FIG. 5 of the drawings;
FIG. 7 is a top view of the refractory block shown in FIG. 5 of the drawings;
FIG. 8 is an end view of the refractory block shown in FIG. 5 of the drawings;
FIG. 9 is a perspective view of a refractory block in accordance with yet a further embodiment of the invention;
FIG. 10 is a perspective view of a refractory block in accordance with yet a further embodiment of the invention;
FIG. 11 is a perspective view of a refractory block in accordance with yet a further embodiment of the invention;
FIG. 12 is a perspective view showing the refractory blocks in combination with refractory rods illustrating how racks and frames of different size and form may be temporarily constructed for a given purpose;
FIG. 13 is a perspective view of a support structure for use with stacked refractory blocks in accordance with yet a further embodiment of the invention;
FIG. 14 is a perspective view of a support structure for use with stacked refractory blocks in accordance with still a further embodiment of the invention;
FIG. 15 shows a support structure as shown in FIG. 13 when used with a stack of refractory blocks; and
FIG. 16 shows a support structure as shown in FIG. 14 when used with a stack of refractory blocks.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to the drawings which show various embodiments of the modular refractory block of the invention, as well as the rack system, and it should be appreciated that these are exemplary illustrations and the blocks may take a wide range of different forms and structures in accordance with the principles of this invention.
As will be seen in FIG. 1 of the drawings, there is shown a refractory block 10 of generally rectangular shape, having a front face 12 , a top face 14 , and side edges 16 and 18 . The refractory block has an upper surface 20 , as well as a lower surface 22 . The upper surface has three equi-spaced, transversely oriented grooves 24 , while the lower surface 22 has three corresponding transversely oriented grooves 26 . The grooves 24 and 26 respectively are intended to receive and hold a portion of a refractory bar or rod, as will be described in further detail below.
It will be seen from FIG. 2 of the drawings, which shows a side view of the refractory block 10 shown in FIG. 1 of the drawings, that the side edges 16 and 18 taper slightly between the upper surface 20 and lower surface 22 so that the upper surface 20 is slightly longer than the lower surface 22 . It will also be clearly seen, from FIG. 2 , that the grooves 24 and 26 are in substantial vertical alignment so that, for example, the groove 24 a in the upper surface 20 , is vertically aligned with the groove 26 b in the lower surface 22 of the refractory block 10 . While the grooves 24 and 26 may be of many different shapes and dimensions, those shown in FIGS. 1 to 5 of the drawings are generally semi-circular, a more convenient shape for receiving a cylindrical-shaped refractory rod or bar, as will be described.
In one preferred embodiment of the invention, the refractory block shown in FIGS. 1 to 4 of the drawings has a height of about 1.25 inches, the length of the upper surface 20 is approximately 4.5 inches, and the length of the lower surface 22 is about 4.25 inches. The width of the refractory block is approximately 1.375 inches and, preferably, each of the grooves has a diameter of about a 0.5 inch. It will be appreciated that these dimensions are purely examples of the wide range of size that can be used, and the dimensions provided may be suitable for supporting tiles of substantially regular shape and size within a kiln. However, for larger objects being placed in the kiln for firing, the size and dimensions of the refractory block 10 , as well as the rods for use therewith, can be increased for additional strength as desired.
With reference to FIGS. 5 to 8 of the drawings, there is shown a refractory block 40 of slightly different configuration. In these FIGS. 5 to 8 , the same reference numerals have been used to designate like elements, as were used with reference to FIGS. 1 to 4 of the drawings. It will be seen that the refractory block shown in FIGS. 5 to 8 has a slightly different shape, and does not taper from the upper surface 20 to the lower surface 22 , as shown in FIG. 1 . In FIG. 5 , the refractory block has somewhat rounded side edges 16 and 18 , and the block 40 itself, as will be apparent from the end view in FIG. 8 , bulges just slightly from between the upper and lower surfaces. Otherwise, the refractory block 40 is in many respects similar to that shown in FIGS. 1 to 4 , with similar but not identical dimensions.
With reference to FIG. 9 of the drawings, there is shown a refractory block 50 in accordance with another aspect of the invention. The refractory block 50 has a front face 52 , a rear face 54 , side edges 56 and 58 , as well as an upper surface 60 , and a lower surface 62 . The side edges 56 and 58 are somewhat rounded, and the refractory block 50 is substantially rectangular in shape.
On the upper surface 60 , there are formed three grooves which are of slightly greater depth than the semi-circular grooves shown in the preceding drawings. In one form of the invention, each of the grooves 64 has sufficient depth so as to completely or substantially accommodate a refractory rod or bar, so that the refractory rod or bar will not significantly project above the upper surface 60 of the refractory block 50 .
It will also be noted that the lower surface 62 is generally a flat surface, with no grooves therein. It will thus be seen that when one refractory block 50 is stacked on top of another, the refractory bars will be fully accommodated within the groove 64 , so that the lower surface 62 of the top refractory block can rest with significant stability on the upper surface 60 of the refractory block 50 below it. In this embodiment, therefore, it is only necessary to have grooves on either the upper or lower surface, in this case the upper surface, since the refractory block 50 will be fully accommodated therein.
With reference to FIG. 10 of the drawings, there is shown a further embodiment of the invention. In this embodiment, a refractory block 70 has the basic style and configuration of the refractory blocks shown in the previous embodiments, but the refractory block 70 is longer and has more grooves 72 . In the embodiment of FIG. 10 , the refractory block has eight grooves 72 across the upper surface and eight corresponding grooves along the lower surface thereof, and is obviously capable of creating a larger support and rack and supporting more tiles or other objects which are being fired in the kiln.
In FIG. 11 of the drawings, yet another embodiment of a refractory block 80 is shown. This refractory block 80 is somewhat similar to that shown in FIG. 6 of the drawings but the center portion is expanded or increased in dimension and two apertures 82 and 84 therein. A refractory block 80 as shown in FIG. 11 may be used in the situation where greater vertical clearance is required between racks of rods, typically where the tile or other object being fired in the kiln is higher than would normally be the case.
In FIG. 12 of the drawings, an assembled or partially assembled system is shown to illustrate the capability of the invention and its capacity to be customized as may be needed. Based refractory blocks 90 and 92 are placed on a surface, typically the floor of the kiln (not shown) and are spaced apart by a distance a little less than the length of the rods 94 which will bridge the space between the refractory blocks 90 and 92 . Rod 94 a is placed in groove 96 of refractory block 92 and groove 98 of refractory block 90 . Likewise, rod 94 b is placed in grooves 100 and 102 , and rod 94 c is placed in grooves 104 and 106 . The three rods 94 a , 94 b and 94 c form a base or rack upon which a tile 110 may be placed for support during firing in the kiln.
Additional layers may be created as needed. This refractory block 112 is placed above refractory block 92 in a stacked fashion with the three grooves on the lower surface of the refractory block 112 covering the ends of rods 94 a , 94 b and 94 c . The refractory block 112 therefore has two important functions: first, it secures the rods 94 so that they are less likely to move out of grooves 96 , 100 and 104 , and, second, it provides a surface and grooves 114 , 116 and 118 for accommodating another row of rods to create another rack vertical disposed above the rack formed by rods 94 . Additionally refractory blocks like the ones shown in this figure can be utilized to create a storied set of racks which are stable and sized so as to make optimal use of the space within a kiln providing increased energy economy and faster processing of tiles within a given kiln.
FIG. 13 show another embodiment of the invention. A support block 130 comprises a vertical component 132 , and a horizontal component or leg 134 which functions as a base and is placed on a substrate or surface in the kiln. The vertical component 132 has three apertures 136 , 138 and 140 . A pair of support blocks 130 are located spaced from each other in the kiln so that the stacked refractory blocks with rods can extend therebetween providing the shelf as described above with respect to other embodiments. FIG. 15 show a view of the opposing support blocks 130 with the refractory blocks therebetween.
FIG. 14 shows a similar support block 144 to that illustrated in FIG. 13 except that the horizontal component or leg 146 extends to both sides of the vertical component 132 . Figure show a view of the opposing support blocks 144 with the refractory blocks therebetween.
The support block 130 in FIG. 13 is designed as a support structure to be used in conjunction with the refractory blocks. Once the refractory blocks have been stacked in the kiln according to their intended use as has already been discussed detail, the support blocks 132 can be placed, if needed, alongside the stacked refractory blocks in contact with these blocks, as shown in FIG. 15 . The vertical component 132 as shown is placed in contact with the stack of refractory blocks to give the stack extra support.
The support block 144 in FIG. 14 is yet another version of a support structure also to be used in conjunction with the modular refractory blocks. Once the refractory blocks have been stacked in the kiln according to their intended use, extra support for the stacked refractory blocks may be desirable. FIG. 16 shows a depiction of how the support block 144 with the leg 146 on both sides of the vertical component may be used in a kiln with stacked refractory blocks and rods.
The apertures 136 , 138 and 140 within the vertical component 132 in FIG. 13 and FIG. 14 generally have specific function in terms of how the pieces are used as support structures. The cuts or holes are placed in the surface mainly for the purpose of making these pieces lighter and less dense for the ease of manufacturing and use. They also facilitate holding the support structures when placing them and removing them in the kiln.
The invention is not limited to the precise details as described and illustrated herein. The blocks and rods may be of different dimensions and the blocks can be arranged in any suitable orientation and position so as to fit the desired objective. Shorter an longer rods can be used to form shorter and longer racks within a configured structure, and there may, in such an embodiment, be three or more stacks of blocks arranged along a line with connecting rods creating longer or shorter racks.
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A variable modular support system for use in a kiln, as well as a method of constructing such a support system in a kiln, comprises plurality of refractory blocks each having an upper surface and a lower surface and at least one transverse recess in either the upper or lower surface, the plurality of refractory blocks comprising a first base refractory block and a second base refractory block spaced from the first refractory block by a variable and selectable distance. Connecting rods extend from the recess of the first base refractory block or a refractory block stacked thereon to the recess of the second base refractory block or a refractory block stacked thereon, the connecting rods forming a rack or shelf located between the first base refractory block and the second base refractory block.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of and an apparatus for producing methanol.
Methods and apparatuses for conversion of methane into methanol are known. It is known to carry out a vapor-phase conversion of methane into a synthesis gas (mixture of CO and H2) with its subsequent catalytic conversion into methanol as disclosed, for example, in Karavaev M. M., Leonov B. E., et al “Technology of Synthetic Methanol”, Moscow, “Chemistry” 1 1984, pages 72-125. However, in order to realize this process it is necessary to provide a complicated equipment, to satisfy high requirements to purity of gas, to spend high quantities of energy for obtaining the synthesis gas and for its purification, to have a significant number of intermittent stages from the process. Also, for medium and small enterprises with the capacity less than 2000 t/day it is not efficient.
A method for, producing methanol is also known which includes a separate supply of a hydrocarbon-containing gas heated to 200-500° C. under pressure 2.15 MPa and an oxygen-containing gas in a mixing chamber, subsequent stages of incomplete oxidation of methane with a concentration of oxygen 1-4 volume percent with an additional introduction of reagents (metal oxide catalyst, higher gaseous hydrocarbons or oxygen containing compositions, a cold oxidizer) into the reaction zone of a reactor, cooling of the reaction mixture in a heat exchanger, separation of methanol from liquid reaction products in a partial condenser, supply of gaseous waste products to an input of the reactor as disclosed in the Russian patent no. 2,049,086. However, this method requires the use of a catalyst or additional reagents and an intense heating of the reacting gasses, which leads to a decrease of methanol yield and to an increased possibility of soot formation.
A further method of producing methanol is known, which includes a separate supply into a mixer of a hydrocarbon-containing gas (natural gas typically) and an oxygen-containing gas (air or oxygen). This mixture a subsequently supplied into a non-catalytic reactor for gas phase incomplete oxidation at pressures of 1-10 MPa during up to 1000 seconds at a temperature 300-500° C. without catalyst, return of waste reaction gasses which contain non-reacted methane for mixing with the initial hydrocarbon containing gas into the first reactor or into the second reactor (which is connected in series with the first reactor), as disclosed in the British patent document GB 2,196,335A. This method provides a high yield of methanol. However, due to significant time of reaction and relatively low per pass conversion (5-15% of methane can reacts during each passage through the reactor) this method has a low efficiency.
A further method of producing methanol by a separate supply and oxidation of hydrocarbon-containing gas and oxygen-containing gas at temperature 370-450° C. and pressure 5-10 MPa and time of contact in the reactor 0.2-0.22 sec is also known, and includes cooling of the heated reaction mixture to 330-340° C., introduction of methanol into the reactor, as disclosed in the patent document of the Soviet Union SU 1,469,788. Cooling of the reaction mixture without intermediate condensation and separation to 380-400° C. in multi-stage heat exchangers arranged in the reactor with subsequent supply of the mixture to 2-3 successive stages of oxidation is disclosed in the patent document of the Soviet Union 1,336,471. In the first case it is necessary to have an additional consumption and a secondary separation of methanol that leads to unavoidable losses, and in the second case it is necessary to provide additional cooling loops with circulation of additional cooling agent in them.
An apparatus for producing methanol is known, which includes a plurality of units arranged after one another and connected by pipes, in particular a mixing chamber connected to separate sources of hydrocarbon containing gas and air or oxygen, a reactor composed of an inert material with a heating element for incomplete oxidation of methane in a mixture supplied into the reactor under an excessive pressure, a condenser and a partial condenser for separation of methanol from the products of reaction, a vessel for re-circulated gaseous reaction products with a pipe for their supply into the initial hydrocarbon-containing gas or mixing chamber as disclosed in the British patent no. 2,1 96,335A. However, a significant time of presence of the reagents in the reactor reduces efficiency of the apparatus, and makes the process practically unacceptable in industrial conditions.
An apparatus which is close to the present invention is disclosed in Russian patent no. 2,162,460. It includes a source of hydrocarbon-containing gas, a compressor and a heater for compression and heating of gas, a source of oxygen-containing gas with a compressor. It further includes successively arranged reactors with alternating mixing and reaction zones and means to supply the hydrocarbon-containing gas into a first mixing zone of the reactor and the oxygen-containing zone into each mixing zone, a recuperative heat exchanger for cooling of the reaction, mixture through a wall by a stream of cold hydrocarbon-containing gas of the heated hydrocarbon-containing gas into a heater, a cooler-condenser, a partial condenser for separation of waste gasses and liquid products with a subsequent separation of methanol, a pipeline for supply of the waste gas into the initial hydrocarbon-containing gas, and a pipeline for supply of waste oxygen-containing products into the first mixing zone of the reactor.
In this apparatus however it is not possible to provide a fast withdrawal of heat of the highly exothermic reaction of oxidation of the hydrocarbon-containing gas, because of inherent limitations of the heat exchanger. This leads to the necessity to reduce the quantity of supplied hydrocarbon-containing gas and, further it reduces-the degree of conversion of the hydrocarbon-containing gas. Moreover, even with the use of oxygen as an oxidizer, it is not possible to provide an efficient re-circulation of the hydrocarbon-containing gas due to fast increase of concentration of carbon oxides in it. A significant part of the supplied oxygen is wasted for oxidation of CO into C02, which additionally reduces the degree of conversion of the initial hydrocarbon-containing gas and provides a further overheating of the reaction mixture. The apparatus also requires burning of an additional quantity of the initial hydrocarbon-containing gas in order to provide a stage of rectification of liquid products with vapor. Since it is necessary to cool the gas-liquid mixture after each reactor for separation of liquid products and subsequent heating before a next reactor, the apparatus is substantially complicated, the number of units is increased, and an additional energy is wasted.
A further method and apparatus for producing methanol is disclosed in the patent document RU 2,200,731, in which compressed heated hydrocarbon-containing gas and compressed oxygen-containing gas are introduced into mixing zones of successively arranged reactors, and the reaction is performed with a controlled heat pick-up by cooling of the reaction mixture with water condensate so that steam is obtained, and a degree of cooling of the reaction mixture is regulated by parameters of escaping steam, which is used in liquid product rectification stage.
Other patent documents such as U.S. Pat. Nos. 2,196,188; 2,722,553; 4,152,407; 4,243,613; 4,530,826; 5,177,279; 5.959,168 and International Publication WO 96/06901 discloses further solutions for transformation of hydrocarbons.
It is believed that the existing methods and apparatus for producing methanol can he further improved.
SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide a method of and an apparatus for producing methanol, which is a further improvement of the existing methods and apparatuses.
It is another feature of the present invention to provide a method of and an apparatus for producing methanol which can be used directly on gas and gas-condensate deposits, and also at any gas consumer, such as power plants, gas distributing and gas reducing stations, chemical production facilities, etc.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a method of producing methanol, which includes the steps of supplying into a reactor a hydrocarbon-containing gas, supplying into the reactor an oxygen containing gas; carrying out in the reactor an oxidation of said heated hydrocarbon-containing gas by oxygen of said oxygen-containing gas; and supplying into the reactor a cold hydrocarbon-containing gas to be mixed directly with a mixture of said heated hydrocarbon containing gas and said oxygen containing gas at a later stage of the reaction to produce methanol and also formaldehyde.
Another feature of the present invention is an apparatus for producing methanol, which has a reactor for receiving and reacting a hydrocarbon-containing gas with an oxygen-containing gas, to carry out in the reactor oxidation of said heated hydrocarbon containing gas by oxygen of said oxygen-containing gas; and means for supplying into the reactor a cold hydrocarbon-containing gas to be mixed directly with a mixture of said heated hydrocarbon containing gas and said oxygen containing gas at a later stage or the reaction to produce methanol and also formaldehyde.
As can be seen, in accordance with the present invention, heated hydrocarbon containing gas and air are supplied into a reaction zone or into a reactor, where a gas phase oxidation of the hydrocarbon containing gas is performed at elevated temperature and pressure in the reaction zone. The reaction mixture is cooled before extraction and the cooled reaction mixture is separated into waste gas and liquid product, the liquid products are rectified with separation of methanol, the waste gas is withdrawn, and a liquid is rectified with production of formaldehyde, wherein cold hydrocarbon containing gas is supplied into a regulation zone of the reactor to reduce the reaction temperature for example by 70-90° C. and thereby to provide a production and a redistribution of the ratio of products to produce corresponding quantities of methanol and formaldehyde.
The reaction is performed in a homogenous phase by a partial combustion without presence of a hydrogenous catalyst.
The regulating zone is provided with a device for introduction of unheated hydrocarbon containing gas for cooling of the reaction mixture by means of its turbulent mixing with the main stream.
The device for final cooling of the reaction mixture before separation can include a gas-liquid heat exchanger connected with the reactor, a partial condenser, and formaldehyde and methanol rectification units, and a device for cooling, located one after the other.
The inner wall of the reaction zone can be coated with a material which is inert to the reaction mixture. The reactor can be provided with thermal pockets for introducing devices for control of temperature in the reaction zone and for control and regulation in the regulating zone, such as for example thermocouples.
In accordance with a preferred embodiment of the present invention, the required temperature at the inlet of the reactor is provided by heating of the hydrocarbon containing gas to a needed temperature, for example in a tubular oven.
In accordance with a Preferred embodiment of the Present invention, the introduction of the cold hydrocarbon containing gas for reduction of temperature in the regulating zone can be performed by an introducing device and a temperature regulating valve arranged in the introduction line.
In accordance with a preferred embodiment of the present invention, during cooling of the reaction mixture in the gas-liquid heat exchanger, heat is transmitted to the raw liquid stream supplied into a formaldehyde rectification column, up to a desired temperature for performing rectification the input of the rectification coolant. The final cooling of the product gas stream is carried out in the cooling device. Then, the cooled gas is supplied into a partial condenser, in which dry gas is separated from raw liquids, including methanol, formaldehyde, ethanol, and water. The raw liquids, through the heat exchanger with temperature 100-120° C., are supplied into a rectification column. The temperature of the top of the column is 70-75° C., the pressure in the column is up to 0.2 MPa. Formaldehyde with a concentration up to 96% is supplied to storage or further processing, while the residue which contains methanol, ethanol, and water is supplied to the methanol rectification column with temperature at its top up to 80°. The final product is supplied to storage or further processing.
Alternatively, formaldehyde can be separated in the partial condenser from the liquid methanol product stream which would then comprise methanol, ethanol, and water by allowing formaldehyde to remain in the gaseous stream. In this case, the liquid stream exiting the partial condenser can bypass the formaldehyde rectification portion of the process and enter the methanol rectification column after having optionally passed through the gas liquid heat exchanger.
The time of presence of the reaction mixture in the reactor is 1.2 sec. The period of induction takes approximately 70% of this time, and thereafter a significant temperature increase of the mixture takes place. The content of methanol in the exiting gas, due to its high stability is 40%, while the content of the formaldehyde is 4%. In order to increase the portion of formaldehyde to 8-13% in the final product, the temperature of the reaction is reduced by 70-80° in the moment of jump after the period of induction at 0.7-1.4 sec of reaction due to the injection of the cold hydrocarbon-containing gas into the regulating zone.
When the temperature of reaction is changed from 370° C. to 450° C., the content of aldehydes is increased from 5% to 13% the content of organic acids is increased from 0.5% to 0.7%. The selectivity which is close to a maximum with respect to liquid organic products, including methanol and formaldehyde, is maintained at a concentration of oxygen in the initial gas mixture 2-2.8%.
In accordance with the present invention, the waste gasses are returned back into the process in the apparatus for gas preparation, with negligible distortion of its operation and quality of gas. Also, when the apparatus is arranged at gas power plants, the returned gas does not substantially change its caloric content.
The apparatus is ecologically clean and does not produce hazardous wastes. In contrast, in known apparatuses, it is necessary to burn up to 3 million tons per year of formaldehyde mixture when the capacity of the apparatus is 6 million tons per year.
The novel features which are considered as characteristic for the present 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 drawings
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view schematically showing a reactor of an apparatus for producing methanol in accordance with the present invention;
FIG. 2A is a view showing the apparatus for producing methanol, including the reactor and other devices, in accordance with the present invention;
FIG. 2B is a view showing the apparatus for producing methanol, including the reactor and other devices, in accordance with an alternative embodiment of the present invention;
FIG. 2C is a view showing the apparatus for producing methanol, including the reactor and other devices, in accordance with a further alternative embodiment of the present invention; and
FIGS. 3 and 4 are views illustrating concentrations of oxygen, formaldehyde and methanol during reactions in accordance with the prior art and in accordance with the present invention correspondingly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An apparatus for producing methanol in accordance with the present invention has a reactor which is shown in FIG. 1 and identified as a whole with reference numeral 1 . In the reactor a gas phase oxidation of a hydrocarbon-containing gas is carried out. The reactor 1 has a reaction zone 2 which is provided with a device 3 for introducing a heated hydrocarbon containing gas and a device 4 for introducing an oxygen-containing gas, for example air.
The reactor further has a regulation zone 5 provided with a device 6 for introducing a cold hydrocarbon-containing gas, for reducing the temperature of reaction during operation of the apparatus. In addition, the reactor 1 is provided with thermal pockets 7 for control and regulation of temperatures in corresponding zones, provided for example with thermocouples.
As can be seen from FIG. 2A , the apparatus has a device for cooling the reaction mixture before separation, which includes a gas-liquid heat exchanger 8 and an cooling device 9 , as well as a regulator of cold gas supply 10 . The gas-liquid heat exchanger 8 is connected with a rectification unit, in particular with a rectification column 11 and a partial condenser 12 . The rectification column 11 is connected with a cooling device 13 , which is connected with a vessel 14 . Formaldehyde is supplied from the vessel 14 by a pump 21 to storage or further processing.
The reactor 1 is connected with a compressor 15 for supply of compressed air, and with an oven 16 for heating of hydrocarbon-containing gas. The apparatus further has a unit for rectification of methanol which includes a rectification column 17 , a cooling device 18 and a vessel 19 , from which methanol is supplied to storage or further processing.
In operation, a hydrocarbon-containing gas with a methane content for example up to 98% is supplied from an installation for preparation of gas or any other source 20 to the oven 16 , in which it is heated to temperature 430-470° C. Then the heated hydrocarbon-containing gas is supplied into the reaction zone 2 of the reactor 1 . Compressed air with pressure for example 8 MPa and with a ratio 1-2.5% of oxygen is supplied by the compressor 15 also into the reaction zone 2 of the reactor 1 . Oxidation reaction takes place in the reaction zone of the reactor 1 . A second stream of cold or in other words not heated hydrocarbon-containing gas from the same source is supplied through the introducing device 6 into the regulation zone 5 of the reactor 1 . This stream is regulated by the regulating device 10 , which can be formed as a known gas supply regulating device, regulating valve or the like.
Depending on an intended mode of operation of the apparatus, in particular the intended production of methanol or formaldehyde, the reaction mixture is subjected to the reaction in the reactor without the introduction of the cold hydrocarbon-containing gas if it is desired to produce exclusively methanol, and with the introduction of the cold hydrocarbon containing gas when it is desired to produce also formaldehyde. By introduction of the cold hydrocarbon-containing gas, the temperature of the reaction is reduced for example by 70-90° so as to increase the content of formaldehyde into the separated mixture.
The reaction mixture is supplied into the heat exchanger 8 for transfer of heat to the raw liquids from the partial condenser 12 , and after further cooling in the cooling device 9 is supplied with temperature 20-30° C. to the partial condenser 12 . Separation of the mixture into highly volatility gases and low volatility liquids is performed in the partial condenser 12 which may condense at least some of the formaldehyde into the raw liquid stream as desired. The dry gas is returned to the gas source 20 , while the raw liquids through the gas-liquid heat exchanger 8 is supplied to the rectification column 11 . From the rectification column 11 vapors of formaldehyde through the cooling device 13 are supplied into the vessel 14 . Formaldehyde is supplied by a pump 21 to storage or further processing. A part of formaldehyde is supplied from the vessel 14 for spraying of the rectification column 11 .
An alternative embodiment with the present invention would be to use the incoming hydrocarbon stream for cooling of the product gases exiting the reactor. Gas from the hydrocarbon source enters heat exchanger 23 , where it cools the hot gases exiting the reactor, as seen in FIG. 2B . This process configuration lowers the duty of the cooling device 9 while simultaneously pre-heating the hydrocarbon stream before entering the furnace for heating up to the necessary temperature of the reactor. The heat exchanger may either be internal or external to the reactor.
Alternatively, at least some of the formaldehyde can be allowed to remain in the gas phase by operation of the partial condenser. The liquid methanol product stream which would then comprise methanol, ethanol, and water by allowing formaldehyde to remain in the gaseous stream. In this case, the liquid stream exiting the partial condenser can bypass the formaldehyde rectification portion of the process and enter the methanol rectification column after having optionally passed through the gas liquid heat exchanger as seen in FIG. 2C .
The method in accordance with the present invention and the operation of the apparatus in accordance with the present invention are illustrated by an example of operation of the apparatus with the capacity of 6,000 t/year, with cooling of the reaction mixture by 30° C.
TABLE I
Example 1 without
Example 2 with
Parameters
cooling
cooling by 30° C.
Natural gas supply,
56800 (40570)
60208 (43004)
m 3 /hour (kg/hour)
Gas consumption in
1700 (1215)
1700 (1215)
reaction, m 3 /hour
(kg/hour)
Conversion degree,
Oxygen concentration in
reaction entry zones,
Pressure in reactor, MPa
7
7
Cooling in regulation zone
no cooling
direct mixing
with cold gas
Methanol yield, kg/hour
800
800
Formaldehyde yield, kg/hour
115
230
Total organic products
920
1040
yield, kg/hour,
Initial temperature, ° C.
Reaction temperature, ° C.
Temperature in regulation
530
500
zone, ° C.
FIGS. 3 and 4 show diagrams of concentration of oxygen, formaldehyde and methanol in reactions without cooling and with cooling.
As can be seen from FIG. 3 , approximately after 2 sec, oxygen is burnt completely. At this moment the reaction temperature reaches its maximum; and in the reaction mixture methanol and formaldehyde are produced with their proportions. Methanol as a more stable product at the end of the reaction reaches its maximum concentration and maintains it practically stable. Formaldehyde is less stable, and therefore with a temperature increase (the temperature increases until oxygen is burnt completely) its concentration somewhat reduces.
In the reaction with the cooling shown in FIG. 4 , with introduction of the cold gas when the formation of methanol and formaldehyde is completed, the temperature of a final period of the reaction is reduced, so that formaldehyde can not decompose and reduce its concentration. Since methanol remains stable, its concentration remains constant (see Table I), while content of formaldehyde increases (on the account of other reaction products).
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 methods and constructions differing from the types described above.
While the invention has been illustrated and described as embodied in method of and apparatus for producing methanol, 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, readily 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.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims.
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An apparatus and method of producing methanol includes reacting a heated hydrocarbon-containing gas and an oxygen-containing gas in a reactor; and adding a relatively cold hydrocarbon-containing gas, to be mixed directly with a mixture of the heated hydrocarbon-containing gas and the oxygen-containing gas, after formaldehyde is formed to inhibit decomposition of formaldehyde in the reactor, to provide a product stream comprising methanol and formaldehyde; and transferring heat from the product stream to the hydrocarbon-containing gas to heat the hydrocarbon containing gas.
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This is a continuation of application Ser. No. 08/670,767 filed on Jun. 24, 1996, now abandoned.
The present invention relates to a rotating spray system which provides an apparatus and a method to coat the inside surfaces of a part with an arc spray when it is difficult or not possible to rotate the part. In particular, the present invention describes an arc spray gun containing an air knife, or lines of deflecting air jets, wherein the only part of the gun head that rotates is the atomizing air jet which is focused upon the metal droplets of an arc ball, or molten particles, in a manner which assures good atomization and projection of a well defined and uniform spray stream. In addition, the present invention describes the use of a compensator means (a lower rear airjet) which is placed on the air knife which forms the arc ball so as to maintain and prevent the arc ball from contacting the knife.
BACKGROUND OF THE INVENTION
Numerous types of thermal spray coating methods and systems are known in the prior art. In general, such methods comprise the deposition of a wire or powdered material onto a surface to be coated. In one particular process, known as electric-arc (two wire) spray coating, two consumable wires form electrodes of an electric arc or "arc ball". The two wires are electrically energized and converge at a point in which the electric arc is formed. A stream of compressed atomizing gas is passed through the converging point to atomize the molten material and drive a molten metal particle stream formed by the electric arc along an axis forward of the converging zone.
Various prior patents discuss electric-arc spray systems, noteworthy of which include U.S. Pat. Nos. 1,968,992 (apparatus for coating surfaces), 2,610,092 (spray discharge nozzle), 4,464,414 (method for spraying metallic coatings), 4,992,337 (electric arc spraying of reactive metals); 5,066,513 (method of producing titanium nitride coatings by electric arc thermal spray); 4,937,417 (metal spraying apparatus); 4,98,557 (method of arc spraying); 4,986,477 (spray gun with adjustment of the shape of the jet); 4,992,337 (electric arc spraying of reactive metals); 5,017,757 (pulsed arc welding machine); 5,109,150 (open-arc plasma wire spray method and apparatus); 5,143,139 (spray deposition method and apparatus); 5,145,710 (method and apparatus for applying a metallic coating to threaded end sections or plastic pipes and resulting pipe); 5,148,990 (adjustable arc spray and rotary stream sprinkler); 5,191,186 (narrow beam arc spray device), 5,194,304 (method of thermally spraying solid lubricant onto a metal target), 5,442,153 (high velocity electric-arc spray apparatus and method of forming materials); 5,466,906 (process for coating automotive engine blocks) and 5,468,295 (apparatus and method for thermal spray coating of interior surfaces).
More specifically, of the above listed patents, U.S. Pat. No. 5,468,295 to Marantz describes a thermal spray coating apparatus, such as a two wire arc apparatus. The nozzle contains a plurality of pores facing generally inwardly towards a coating material particle stream, such as an atomized molten metal stream of a two-wire arc thermal spray apparatus. The ports sequentially receive a deflecting gas flow, such that the direction moves circumferentially about the axis of the particle stream. The deflecting gas entrains the coating materials and carries it radially to the surface of the part to be coated or the nozzle assembly. When such nozzle is inserted into an engine bore, it is described as radially coating the bore, on its surface.
However, a number of problems exist with the prior art device of Marantz that have been overcome by the present invention First, as a pneumatic device it is less responsive than the electro-mechanical device herein described, and more cumbersome and bulky with-multiple air passages. In addition, by sequencing or strobing the air stream, the Marantz device will tend to overlap the coating layers, whereas the apparatus herein describe provides a true continuous stream coating which can vary over a wide range of rotation rates. Moreover, valving, i.e. switching from one tube to an adjacent tube, is non-linear. Accordingly, it is very difficult by such process to provide a smooth transition from full flow on one set tube to the next. In addition, the lift of the arc ball in the Marantz device must be substantial. This translates into some instability in the radial flow which is further complicated by the comparative size of the orifices which would have a tendency to cause chatter (i.e., intermittent extinguishing of the arc and reignition thereof), and a focused spray (or narrowed pattern) is impossible.
In addition, one pervasive problem with all thermal-arc spraying devices of the prior art, rotatable or otherwise, is that air flow from the air knife has been found to create a negative pressure between the wicket (the area immediately behind the consumable electrodes), and the knife base, as the air flows away from the knife. This negative pressure is believed to be responsible for drawing material from the arc ball and depositing such material onto the knife.
Accordingly, it is a first object of this invention to overcome the aforesaid problems of prior art thermal spray devices and provide a rotating arc spray gun wherein the only part of the gun head that rotates is the atomizing air jet.
More specifically, it is an object of the present invention to overcome the aforesaid problems of the prior art thermal spray devices and provide a rotating arc spray gun wherein a continuous stream coating can be applied over a wide range of rotation rates, and which avoids a sequencing, strobing or pulsed air stream.
In addition, the present invention has as a more specific object the preparation of a rotating arc spray gun wherein a deflecting valve assembly (or air knife) rotates about an arc ball formed by two consumable electrodes and wherein the deflecting valve assembly contains a plurality of ports providing a semi-circular pattern thereby providing a hooped shaped air flow around the arc and a focused radial delivery of an atomized metal coating.
Finally, the present invention has as its object the installation of what can be described as a negative pressure compensator means, in an arc gun containing a deflecting valve assembly (rotatable or stationary). The negative pressure compensator eliminates any negative pressure formed by the effect of the air flow from the deflecting valve assembly as the air flows away from said assembly, thereby maintaining the arc ball in the proper alignment position for efficient coating.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of the electric-arc coating apparatus incorporating the present invention, without detail of the deflecting gas valve assembly.
FIG. 2, is a further schematic view of the electric-arc coating apparatus of the present invention, illustrating a radial spray pattern generated, without detail of the deflecting gas valve assembly.
FIG. 3 is a more detailed schematic view of the present invention illustrating the wire path, and the preferred semi-circular pattern on the deflecting valve assembly, in a non-rotating version.
FIG. 4 is yet another detailed schematic view of the present invention, illustrating gas flow, but in a non-rotating version.
FIG. 5 is another detailed schematic view of the present invention, in a non-rotating version, illustrating the preferred additional gas nozzle port or negative pressure compensator disposed on the deflecting valve assembly which directs air flow to specifically support the arc and maintain it in line with the atomizing gas supply pathway.
FIGS. 6 and 7 are yet another detailed schematic view of the present invention in rotating version thereof.
FIG. 8A is a detailed schematic face view of the deflecting valve gas assembly, illustrating the preferred plurality of ports disposed on said gas assembly in a substantially semi-circular pattern. FIG. 8B is an ever further detailed view of the port configuration, and FIG. 8C is a cross-section illustration of FIG. 8B indicating the preferred air flow through the valve assembly in operation.
SUMMARY OF THE INVENTION
An apparatus for coating a part with a metallic coating comprising at least two consumable electrically conductive metallic wire electrodes converging to converging point at their ends, an electric current into said wires creating an arc and melting said wire ends forming an arc ball, an atomizing gas supply supplying gas to said converging point of said wires to convert said arc ball into a molten particle stream, and a deflecting gas valve assembly disposed outwardly of said consumable wires, said deflecting gas valve assembly deflecting gas from a direction which is rotatable relative to said two wires, said deflecting gas valve assembly containing a plurality of ports relative to and behind said molten particle stream supplying a steady flow of deflecting gas thereby deflecting said molten metal particle stream radially outward towards a surface to be coated.
In a further embodiment, an apparatus for coating a part with a metallic coating is disclosed comprising at least two consumable electrically conductive metallic wire electrodes converging to a converging point at their ends, an electric current into said wires creating an arc and melting said wire ends forming an arc ball, an atomizing gas supply supplying gas to said converging point of said wires to convert said arc ball into a particle stream, a deflecting gas valve assembly disposed outwardly of said consumable wires, said deflecting gas valve assembly deflecting gas from a direction which is rotatable relative to said two wires, said deflecting gas valve assembly containing a plurality of ports arranged in a substantially semi-circular line pattern relative to and behind said molten particle stream therein deflecting said molten metal particle stream radially outward towards a surface to be coated.
In a still further embodiment of the present invention, an improvement is disclosed for a thermal spray coating apparatus containing at least two consumable wire electrodes converging at a converging zone to produce a molten metal particle arc ball, including a stream of compressed gas passing through a deflecting gas valve and through said converging zone to atomize said molten metal particle arc ball and drive a particle stream forward of said converging zone, wherein the flow of gas from the deflecting gas valve produces a negative pressure between the arc ball and the deflecting gas valve causing the arc ball to deposit on said deflecting gas valve, the improvement comprising the incorporation of a second flow of gas in the deflecting gas valve not directed at the arc ball and positioned to compensate for said negative pressure between the arc ball and said deflecting gas valve thereby substantially maintaining the arc ball in alignment position in the converging zone for atomization.
In method embodiment, the present invention comprises a method of thermally spraying a metal matrix coating comprising first creating an electrical arc ball into which a consumable strand is fed to produce a melt, the strand being comprised of a consumable electrode, applying a steady flow of deflecting gas from a deflecting gas valve directed at said electrical arc ball and rotating the deflecting gas around said arc ball to project said melt radially outward towards a surface to be coated.
In the method of coating a part according to the present invention, the coating apparatus described above is disposed within a part to be coated. The coating apparatus is moved axially along the surface of the part and while the coating apparatus is moved axially, compressed air is steadily delivered to the plurality of ports positioned relative to and behind the particle stream, and the stream is deflected radially outward towards said part surface to provide a complete and even coating.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As noted above, the present invention provides both an apparatus and a method for thermal spray coating a part when it is not possible to rotate the part. The apparatus includes a single radial atomizing nozzle which rotates about an arc ball. The deflecting nozzle is fed from a single circumferenced plenum (i.e., the deflecting gas valve assembly) without interruption of flow. The deflector preferably employs an array and plurality of staggered ports, in a substantially semi-circular pattern, that direct a hooped shaped air flow around the arc. The ports are preferably relatively small in nature affording a diff-used flow of controlled turbulence to capture and effectively atomize the molten consumable in a radially focused manner. The shaped turbulence so provided avoids direct contact with the arc which would tend to destabilize the arc, and instead vacuums material away using a peripheral contact.
Preferably, the deflecting gas valve assembly contains an additional gas nozzle port disposed on said assembly which directs gas flow axially to the arc and maintains it in line with the atomizing gas supply pathway. Such additional gas nozzle port also prevents blow down of the arc as well as directing air flow to lift the arc and maintain it in a column of gas which symmetrically equalizes the arc ball for radial focused dispersal.
It is important to note that the above additional gas valve nozzle port, while described as a preferred aspect of the present invention, is not limited in its application or placement on the rotating and deflecting gas valve assembly as herein described. That is, as noted earlier, in all thermal-arc spraying devices containing two consumable wire electrodes converging at a converging zone to produce a molten metal particle arc ball, the air flow from the deflecting gas assembly (or "air knife") tends to create a negative pressure at that area immediately behind the consumable electrodes (the "wicket"). This negative pressure then draws material from the arc ball and deposits it onto the knife. Accordingly, the present invention provides an improvement to such problem, by incorporation of a second flow of gas in the deflecting gas assembly not directed at the arc but positioned to compensate for said negative pressure and thereby substantially maintaining the arc ball in position in the converging zone for atomization.
Preferably, this second flow of gas emerges from an opening that can be described as having an orphic configuration and which originates at the base of the air knife. This provides a spray of a limited amount of gas up and out between the wicket and the air knife. This flow is not directed at the arc ball, and instead serves to eliminate negative pressure and maintains the arc ball in the correct direction away from the knife.
With reference to FIG. 1, illustrated at 10 is a basic schematic view of the present invention. Illustrated therein at 12 is the wire drive which serves to advance the consumable electrodes for subsequent atomization, and at 13 is the drive motor for axial positioning of the device. At 14 is the means for rotating the deflecting gas assembly 16 and said means for rotating is illustrated as attaching to a pulley which rotates the deflecting gas assembly around the consumable electrodes. Rotation of between 100-400 rpm can be conveniently and preferably achieved by such construction.
Specifically, and again with reference to FIG. 1, shown at 18 is the general location for the preferred plurality of ports positioned relative to and behind the resulting and radially projected molten particle stream (not shown). This is all better illustrated in FIG. 2, wherein the deflecting gas assembly which provides a steady flow of deflecting gas deflects the molten particle stream 20 radially outwardly towards a surface to be coated. Also shown in FIG. 2 is slide table 22 which allows for axial movement of the deflecting gas assembly so that a complete and even coating can be applied to, e.g., a cylinder bore of an automobile engine. Of course, it can be appreciated that as described, the present invention is not limited to cylinder bores, and has specific utility for any type of substrate surface wherein it is difficult or impossible to rotate and provide access by a conventional thermal spray coating apparatus.
With reference to FIG. 3, greater detail is provided regarding the invention disclosed herein. Specifically, the consumable electrodes are positioned at and along position 24 so that in use, said consumable electrodes serve to provide the material for formation of the arc ball. Preferred material for the consumable electrode include steel, stainless steel, bronze, nickel, chrome, and mixtures thereof
In regards to the additional detail provided for in FIG. 3, which illustrates in a cross-sectional view the wire pathways, shows at 26 the preferred plurality of ports positioned behind the molten metal particle stream (not shown) and which ports are preferably arranged in a substantially semi-circular pattern. This in effect provides what can be termed a hoop pattern to the arc ball. Preferably, the plurality of semi-circular patterns are arranged at 0.18, 0.25 and 0.31 in radial inches from the tip of the wire electrodes, which provides a plurality of hoop patterns, the inner hoop tending to atomize the consumable electrodes, and the outer hoops tending to consolidate the spray pattern for radial coating. Finally, it is to be noted that preferably it has been found that the gas flow out of these semi-circular ports are arranged in the range of about 50-75 cfm.
FIG. 4 illustrates a cross-sectional view of the air pathways and shows at 27 a needle valve assembly for adjusting axial air flow in relation to the radial air flow provided by the deflecting gas valve assembly. FIG. 5 illustrates an end view of the spray head, and at 28 can be seen the negative pressure compensator. It is to be noted that, as shown, the negative pressure compensator may be part of the tip positioner, or the compensator itself can be located at position 29 as illustrated on FIG. 4.
FIG. 6 illustrates at 40 the previously noted and preferred semi-circular pattern providing a hoop pattern to the consumable electrodes, now more clearly shown at 42. Also shown at 44 and 46 is the placement of the preferred orphic configuration ports which provides a second flow of gas not directed at the tip of the electrodes 42, but rather at that area between the wicket (the area immediately behind the consumable electrodes, shown at 48 and the deflecting gas valve base. By so placing the ports 44 and 46, the arc ball which will appear generally in the region of 42 will not deposit on the semi-circular pattern 40 of the valve. Finally, shown at 47 is the gas flow chamber which provides an axial gas flow to drive forward the particle stream formed by the consumable electrodes for radial deflection.
With regards to air flow 47, preferably, the gas flow is set at about 10 cfm with 5-20 psi pressure. However, this gas flow may be modified to accommodate the consumable electrode wire composition and modify the desired spray pattern. Spray patterns can be altered by modifying the voltage, and the axial pressure. Whereas voltage adjustments cause subtle changes in the spray pattern but major changes in the coating, modifying the axial pressure causes major changes in the spray pattern but minor changes in the coating. Low axial pressure constricts the spray pattern into a small diameter, 1.0 inches plus at 3.5 inches with a spray angle of 90 degrees. High axial pressure both widens the diameter of the pattern from 1.0 inches plus, to 2.5 inches plus at 3.5 inches, and increases the spray angle from 90 degrees to 100 or 120 degrees. In addition, start-up of the spray while the air knife is rotating can be greatly facilitated by increasing the axial flow to about 60 psi, reducing it to the spray parameter for the cycle.
FIG. 7 illustrates the placement of the bearing 50 so that the deflecting valve assembly, now shown at 56, can be readily rotated. Shown at 54 is the chamber for air flow to the deflecting gas valve assembly, enclosed by tube wall 52. Shown at 58 is one of the individual gas ports within the plurality of semi-circular patterns and at 60 a side view of one of the preferred orphic configuration ports. FIG. 8A illustrates in greater detail the preferred deflecting gas valve assembly or air knife, with the preferred plurality of individual gas ports 62 configured in a plurality of semi-circular patterns. A blow-up of this pattern is illustrated in FIG. 8B. As illustrated, the ports are preferably staggered from one another and positioned 15° apart in their preferred configuration. This pattern is positioned so as to surround the arc ball and focus the deposition of the consumables without disrupting the axial air flow, thus working together with said axial air flow to properly direct and atomize the molten consumables. Finally, FIG. 8C which is a cross-section of FIG. 8B, illustrates at 64 the preferred air flow through the atomizer in, and at 66 the air flow for feeding the negative pressure compensator.
In a preferred application of both the method and apparatus herein disclosed, the internal surfaces of a plurality of spaced apart bores may be coated. For example, an engine block may include two, four, six or eight parallel bores. Where the engine block is aluminum, the bores are preferably coated with a hard metal coating to reduce wear. As alluded to above, it is inconvenient to rotate the engine block about each bore, which would be necessary with a conventional thermal spray device of the prior art. The thermal spray apparatus of the present invention is conveniently operated to direct the spray radially into the bore and along with axial movement, the spray pattern is directed through-out the length of the bore. Accordingly, by adjustment of the amperage flowing through the consumable electrodes, together with the deflecting valve gas assembly disclosed herein, uniform coating thickness can now be achieved in coated cylinder bores made in accordance with the rotating arc spray system as disclosed herein.
While the above invention has been described in terms of various preferred embodiments, it will be appreciated that other forms could readily be adapted by one skilled in the art. It is therefore appreciated that within the scope of the appended claims, the invention may be practiced otherwise than described.
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An apparatus for coating a part with a metallic coating comprising at least two consumable electrically conductive metallic wire electrodes converging to converging point at their ends, an electric current into said wires creating an arc and melting said wire ends forming an arc ball, an atomizing gas supply supplying gas to said converging point of said wires to convert said arc ball into a molten particle stream, and a deflecting gas valve assembly disposed outwardly of said consumable wires, said deflecting gas valve assembly deflecting gas from a direction which is rotatable relative to said two wires, said deflecting gas valve assembly containing a plurality of ports relative to and behind said molten particle stream supplying a steady flow of deflecting gas thereby deflecting said molten metal particle stream radially outward towards a surface to be coated.
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REFERENCE TO PRIOR APPLICATIONS
[0001] The benefits of priority of Provisional Application No. 61/627,291, filed Oct. 7, 2011, and of regular utility application no. 13629989, filed Sep. 28, 2012, are hereby claimed.
FIELD OF THE INVENTION
[0002] The present invention relates to pumps and pertains particularly to motor driven micro-sized fluid metering pumps. The disclosed pump can be operated at high rotary speeds, has the capability to electronically set and maintain required flow regardless of fluid temperature, and has system condition (“health”) monitoring features. It is particularly suited for use in remotely-piloted “drone” aircraft.
BACKGROUND OF THE ART
[0003] Motor driven fuel pumps have found uses in the fuel systems of internal combustion and gas turbine engines. Typically, these motor driven fuel pumps contain a rotary positive displacement pumping element, a DC motor, and an electronic motor controller.
[0004] The higher the rotary speed of the DC motor the more flow a pump can produce for a given size. The rotary speed of positive displacement pumping elements is limited by the allowable sliding velocities of the chosen pumping element material(s). Miniature high speed positive displacement pumps often use costly hardened materials for wear resistance.
[0005] A pump's electronic motor controller transmits pulse-width-modulation (PWM) signals to the DC motor to set the pump speed and thus its discharge flow. Analog electronic controllers are typically used to create PWM whose minimum and maximum duty cycles are determined by resistor values and cannot easily be adjusted to meet a range of flow requirements unless bulky potentiometers are used.
[0006] Many small vehicles, such as Unmanned Aerial Vehicles, operate in large ambient and fuel temperature ranges and also have a need to maximize their vehicle's range or mission duration. To accomplish this, their propulsion engines require a pump with good flow metering capability, and it would be desirable to maintain a constant burn flow to their engines regardless of ambient and internal fuel temperature variations.
[0007] Unmanned Aerial Vehicle manufacturers also want to reduce overall system cost and to improve system reliability and mission readiness. A pump that incorporates health monitoring features and automatically adjusts for internal wear to maximize its useful life is desirable.
[0008] Embodiments disclosed include an electric motor driven, positive displacement rotary pump that is capable of achieving approximately twice the rotary speed of state-of-the-art positive displacement rotary pumps, using less costly materials than current pumps, with the capability of meeting multiple flow requirements, using common hardware parts, maintains a constant mass flow rate, and has health monitoring and flow compensation capabilities. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.
SUMMARY OF THE INVENTION
[0009] It is an object of this invention to provide a high power density, motor driven, positive displacement pump, using common hardware elements, to accommodate a wide variety of engine fuel flow requirements. The pump is capable of maintaining a constant mass flow rate. It can communicate its health information at periodic intervals during operation as well as provide specific desired information at any time by replying to a query command.
[0010] In one aspect, the invention provides a means of decreasing the weight and size of a rotary piston pump by minimizing the relative velocity and Hertzian contact stress between the pump pistons and the pump cam. The cam is attached to, and is free to spin on, a rotating element bearing that is rotated by the pistons as they contact it. This contact generates a concave groove in the cam inner surface which conforms to the pistons' spherical radius tips. By allowing the eccentric circular cam to spin with the rotor and decreasing the Hertzian contact stress between the pistons and the cam, high and variable rotational rotor speeds can be achieved without substantial wear of the cam or piston faces.
[0011] In another aspect, the invention provides a means of adjusting the motor speed to provide the minimum and maximum flows required, by modifying two variables set within the pump's microprocessor code. The pump contains a temperature sensor that measures the fluid temperature, which is fed back into the microprocessor. The microprocessor then adjusts the speed of the motor to account for fluid type, density, and viscosity so that a constant mass flow rate can be maintained for a given input command.
[0012] In another aspect, the invention provides a means of communicating the remaining life of the pump back to the vehicle and to ground control so that is can be replaced at the appropriate maintenance interval. The microprocessor monitors the output flow electrical signal against the expected flow electrical signal and adjusts the motor speed accordingly. This intelligence allows the pump to compensate for internal wear and compares the required motor speed against the maximum allowable motor speed. This ratio is then used to predict the remaining life of the pump.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an exploded view of a pump assembly according to one embodiment of the invention;
[0014] FIG. 2 is an exploded view of a pumping element according to one embodiment of the invention;
[0015] FIG. 3 is an exploded view of the installation of the rolling element bearing and cam, according to one embodiment of the invention;
[0016] FIG. 4 is a plan view of a cam eccentric to a manifold and showing pistons contacting said cam, according to one embodiment of the invention;
[0017] FIG. 5 is a diagram depicting the uploading of the motor-driven pump firmware into the microprocessor, according to one embodiment of the invention;
[0018] FIG. 6 is a chart depicting a flow set-up calibration procedure of one embodiment of the invention;
[0019] FIG. 7 is a block diagram depicting the calibration procedure for the motor-driven fluid pump health monitoring system, according to one embodiment of the invention.
[0020] FIG. 8 is a block diagram depicting the motor-driven fluid pump health monitoring and flow compensation system according to an embodiment of the invention.
[0021] FIG. 9 is a sectional view through the central rotor and the cam ring, showing the concave groove formed in the cam ring by sliding action of the pistons during break-in of the pump.
[0022] While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications, and equivalents as included within the spirit and scope of the invention, as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0023] An exploded view of a motor-driven fluid pump 100 according to one embodiment of the invention is shown in FIG. 1 . In this embodiment the motor-driven fluid pump 100 includes three main sub-assemblies, a positive displacement pumping element 102 , a driving motor 104 , and an electronic control module 106 . The electronic control module 106 receives an external flow demand input signal that is sent electrically to a microprocessor 108 . The microprocessor 108 transmits a pulse-width-modulation signal that causes motor 104 to rotate. Motor 104 drives or rotates the positive displacement pumping element 102 .
[0024] The positive displacement pumping element 102 , according to an embodiment of the invention, is depicted in more detail in FIG. 2 . The positive displacement pumping element 102 includes a stationary manifold 110 which consists of a fluid film bearing 120 that supports the rotor 112 as it rotates. The rotor 112 has radially oriented chambers that contain and support pistons 114 for radial movement as they rotate and traverse or engage the cam surface.
[0025] FIG. 3 shows the installation of a rolling element bearing 116 and a cam 118 according to an embodiment of the invention. Rolling element bearing 116 has a diameter 138 that fits onto and is located by manifold 110 diameter 136 . The stroke of each of the pistons 114 is determined by the eccentricity between diameter 136 and that of the manifold 110 fluid film bearing 120 . Cam 118 diameter 142 fits onto and is located by the rolling element bearing 116 diameter 140 .
[0026] FIG. 4 illustrates a cross section depicting the rotational mechanics of the cam 118 according to an embodiment of the invention. The rotor 112 which contains the pistons 114 is rotated about the center point 144 of the manifold 110 fluid film bearing 120 . The rolling element bearing 116 diameter 140 ( FIG. 3 ), along with the cam 118 , rotate about the center shown by point 146 . When the rotor 112 is rotated, the pistons 114 are initially centrifugally loaded against the inner cylindrical surface 147 of cam 118 . To minimize contact stress and side loading the pistons 114 have a spherical radius machined on their end surfaces that contact the cam 118 cylindrical surface 147 . Due to the eccentricity between the center of the cam 118 and the center of the rotor 112 , the pistons 114 stroke radially outward between 0° and 180° (inlet arc) and are pushed radially inward by the cam 118 surface 147 between 180° and 0° (discharge arc). The manifold 110 contains an inlet flow port 122 and an outlet flow port 124 . As the pistons 114 move radially outwardly fluid is drawn in behind them via the inlet flow port 122 . As the pistons 114 move radially inwardly fluid is expelled via the outlet flow port 124 . Because the expelled fluid is usually being forced through a downstream orifice, pressure is generated in the outlet flow port 124 area. This discharge pressure creates an additional radial hydraulic force between the pistons 114 and cam 118 while traveling in the discharge arc. The centrifugal and hydraulic forces exerted by the piston 114 cause the cam 118 to rotate about its center point 146 . As a result, the relative rotational surface velocity between the pistons 114 and cam 118 is kept to a minimum, whereas, in prior art pumps the cam 118 is stationary.
[0027] The material hardness of pistons 114 is higher than the material hardness of cam 118 , so during breaking in of the motor-driven fluid pump 100 the spherical radius ends on pistons 114 generate a concave groove 119 into the inner surface of cam 118 . When motor-driven fluid pump 100 is initially started, the Hertzian contact stress between pistons 114 and cam 118 exceeds the allowable value for the chosen cam 118 material. As a result, a concave groove 119 matching the profile of the spherical radius of the heads of the pistons 114 is generated within the inner surface of the cam 118 , as in FIG. 9 . As the depth of the concave groove 119 increases, the surface contact area between the pistons 114 and cam 118 increases, thereby lowering the Hertzian contact stress. Once the Hertzian contact stress reaches the allowable value of the material of cam 118 , which equates to a predetermined concave groove depth, generation of the concave groove 119 stops. Pistons 114 riding in the concave groove 119 are more dynamically stable inside rotor 112 than without the groove.
[0028] The combination of a low relative velocity and a low Hertzian contact stress equates to a lower surface wear factor on pistons 114 and cam 118 , which thereby increases the durability and useful life of the motor-driven fluid pump 100 as well as having the capability to obtain higher rotational speeds than prior art pumps. The end result is that the motor-driven fluid pump 100 has a higher power density than prior art micro fluid pumps, because a higher flow rate is generated for a given pump volume.
[0029] FIG. 5 depicts the motor-driven fluid pump 100 firmware code 130 being uploaded and burned to the microprocessor 108 according to an embodiment of the invention. The firmware code 130 contains:
a) A variable that allows selection of the motor-driven fluid pump 100 operating fluid; b) A parameter that monitors the temperature of the motor-driven fluid pump 100 operating fluid; c) The equation of the fluid viscosity versus temperature for the designated motor-driven fluid pump 100 operating fluid; d) The equation of the fluid density versus temperature for the designated motor-driven fluid pump 100 operating fluid; e) A set of variables that determine the duty cycle of the pulse-width-modulation signal being sent to the motor-driven fluid pump 100 motor 104 ; f) An algorithm that varies the speed of motor 104 based upon the temperature of the fluid; and. g) An algorithm that calculates the remaining life of the motor-driven fluid pump 100 based upon the operating speed history of the motor 104 .
[0037] Vehicles such as Unmanned Aerial Vehicles need the capability to operate their engines on a multitude of fuels and over extreme temperature ranges without sacrificing performance or mission range. For any set condition, the mass flow rate of prior art motor-driven fluid pumps is not constant over varying operating temperatures and fluid types because they lack the intelligence to adjust their motor RPM for fluid density and viscosity automatically.
[0038] FIG. 6 presents a chart depicting the motor-driven fluid pump 100 flow calibration procedure according to an embodiment of the invention. With the motor-driven fluid pump 100 connected to a test stand that is capable of reading fluid flow, and the designated pumping fluid at a known temperature, the highest input command electrical signal corresponding to the maximum required flow rate is provided. Variable 132 , which is set within firmware code 130 , is adjusted until the RPM of motor 104 provides the required maximum flow rate. With the input command electrical signal then set to the minimum required flow rate, variable 134 located within firmware code 130 is adjusted. Once variables 132 and 134 are set, the motor-driven fluid pump 100 will maintain a constant mass flow rate for a given input command regardless of fluid temperature.
[0039] Prior art pumps do not have the flexibility to set their required minimum and maximum flow rates by simply modifying two software variables ( 132 and 134 ). Typically the PWM signal going to their motor 104 is adjusted by modifying the resistance in their electronic control module 106 .
[0040] A block diagram depicting the motor-driven fluid pump 100 logic scheme used to set up the constant mass flow rate according to an embodiment of the invention is shown in FIG. 7 . A temperature sensor 126 which is located within the motor-driven fluid pump 100 measures the motor-driven fluid pump 100 fluid operating temperature and transmits an electrical signal proportional to the measured temperature to the microprocessor 108 .
[0041] FIG. 8 is a block diagram depicting the motor-driven fluid pump 100 health monitoring and flow compensation system according to an embodiment of the invention. A system flow or pressure sensor is required downstream of the motor-driven fluid pump 100 along with a system capability to transmit and receive signals via serial communication. The serial communication protocol resides in the motor-driven fluid pump 100 electronic control module 106 and can be an RS-232, RS-422 or RS-485 device. Once the motor-driven fluid pump 100 microprocessor 108 firmware code 130 has been uploaded and the flow versus input command signal is set as described in FIG. 6 , the health monitoring and flow compensation system operates as follows;
a) An aircraft fluid type 8-bit serial code signal is transmitted through communication protocol to the microprocessor 108 . The microprocessor 108 looks up the serial code in its firmware 130 and sets corresponding fluid density and viscosity algorithms. b) The microprocessor 108 firmware code 130 monitors and compares the flow/pressure output feedback signal being transmitted against the embedded expected signal range or tolerance for the set point variable 132 . c) The microprocessor 108 firmware code 130 constantly monitors fluid temperature feedback signal and motor 104 rotary speed. d) The microprocessor 108 firmware code 130 has embedded in it the maximum permissible speed for the set point established in variable 132 .
[0046] As the positive displacement pumping element 102 components wear, internal leakage occurs between the discharge and inlet pressures, and so the output flow for a given motor 104 RPM decreases. As flow output decreases the flow/pressure sensor feedback signal will become out of tolerance of the expected signal and the microprocessor 108 will increase motor 104 RPM to move feedback signal back into the expected signal range. The microprocessor 108 firmware code 130 compares the new required motor 104 RPM against the maximum permissible motor 104 RPM and calculates the remaining life by using the equation shown below:
[0000]
Life
:=
Max
N
-
Adj
N
Max
N
-
Cal
N
·
MTBF
Where:
[0047]
[0000] Parameter Description Units MaxN Maximum permissible motor speed RPM CalN Motor speed required at variable set point RPM 132 during calibration AdjN Motor speed required from pump wear RPM MTBF Pump useful life Hours Life Remaining pump life Hours
When queried by the system, the remaining pump life will be transmitted to the engine system via an 8-bit serial code.
[0048] Prior art pumps do not have the capability to transmit their remaining life to the vehicle by comparing their current motor 104 speed against their maximum allowable motor 104 speed.
[0049] Many variations may be made in the invention as shown and in its manner of use without departing from the principles of the invention as described herein and/or as claimed as our invention. Minor variations will not avoid use of the invention.
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A motor-driven fluid pump has a positive displacement rotary pumping element with an offset circular cam carried outwardly of the element, the cam being rotated with the pumping element by contact with pistons carried radially by the pumping element. Ends of the pistons are spherical and bear directly on the cam's inner surface. During breaking in of each pump, the piston ends wear a single concave groove in the inner surface of the cam, which helps to stabilize the pistons. The pump maintains a constant mass flow rate for a given input command by adjusting for fluid type, measured fluid operating temperature, and changing motor speed. The pump also maintains a constant flow output for its life by adjusting for internal wear; it also predicts its remaining life by comparing its current motor speed for a given flow against the maximum allowable motor speed.
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BACKGROUND OF THE INVENTION
Traditionally, in the dibenzocycloheptene series of compounds, those with a piperidinylidene group in the 5-position have been considered to be without notable antipsychotic action. Recently, however, 3-cyanocyproheptadine, and particularly the levorotatory enantiomer thereof was found to have antipsychotic activity.
Surprisingly, it has now been found that trifluoromethylthio and trifluoromethylsulfonyl derivatives of cyproheptadine carrying a hydroxyalkyl or cycloalkylalkyl group on the piperidine nitrogen are also potent antipsychotic agents, with a low propensity to induce extrapyramidal side effects.
The antipsychotic activity resides predominantly in the levorotatory enantiomers, whereas the dextrorotatory enantiomers, although lacking in antipsychotic activity, are anticholinergic agents. Each enantiomer is additionally useful as a source of the other by a process of racemization.
It is thus an object of the present invention to provide novel compounds which are potent antipsychotic agents with a very low propensity to induce the extrapyramidal side effects experienced with most major tranquilizers, and to provide novel compounds with anticholinergic activity.
It is a further object of this invention to provide novel processes for the preparation of the novel compounds.
Another object of the invention is to provide novel pharmaceutical compositions comprising the novel compounds as active ingredient.
Another object of the invention is to provide a novel method of treating psychoses by administration of the novel antipsychotic compounds or pharmaceutical compositions thereof to a patient.
Another object of this invention is to provide novel intermediates from which the pharmacologically active compounds are prepared
DETAILED DESCRIPTION OF THE INVENTION
The novel compounds of this invention have the following structural formula: ##STR1## or pharmaceutically acceptable salt thereof, wherein: R 1 represents --SCF 3 or --SO 2 CF 3 ;
R 2 represents ##STR2## and R 3 represents hydrogen, lower alkyl of 1-3 carbon atoms, or fluoro.
A preferred embodiment of the novel compounds is that wherein R 3 is hydrogen
An even more preferred embodiment of the novel compounds is that wherein R 3 is hydrogen, and R 1 is --SCF 3 .
A still more preferred embodiment is that wherein R 3 is hydrogen, R 1 is --SCF 3 in the 3-position, and R 2 is ##STR3##
The novel compounds of this invention, and the preferred embodiments thereof, exist as (-), or levorotatory enantiomers, and as (+), or dextrorotatory enantiomers, and mixtures thereof. Included within the scope of this invention are the levo- and dextrorotory enantiomers and any mixtures thereof including the racemic mixtures.
A more preferred aspect of the novel compounds and the preferred embodiments thereof is the (-), or levorotatory enantiomer.
The pharmaceutically acceptable salts of the novel compounds of this invention are acid addition salts formed from a novel compound and an organic or inorganic acid recognized by the art as providing a pharmaceutically acceptable acid addition salt, such as hydrochloride, hydrobromide, dihydrogen phosphate, sulfate, citrate, pamoate, pyruvate, napsylate, isethionate, maleate, fumarate, or the like.
These salts are readily prepared by mixing solutions of equimolecular amounts of the free base compound and the desired acid in suitable solvents such as water, alcohols, ether or chloroform, followed by recovery of the product by collecting the precipitated salt or evaporation of the solvent.
Another embodiment of this invention is the compound of structural formula: ##STR4## wherein R 2 and R 3 are as previously defined. Preferred aspects of the present embodiment are the levorotatory and dextrorotatory enantiomers thereof. These compounds are useful as starting materials for the pharmacologically active novel compounds of this invention.
The introduction of nuclear substituents into aromatic rings of cyproheptadine derivatives and analogs results not only in significant changes in the biological spectra of these compounds, but also results in the introduction of optical isomerism. Optical isomerism due to restricted rotation is known as atropisomerism. The resulting enantiomers or optical isomers are also known as atropisomers. (Ebnother et al., Helv. Chim. Acta, 48, 1237-1249 (1965)) In the case of cyproheptadine derivatives and analogs that are unsymmetrically substituted, such as the 3-substituted analogs and derivatives, atropisomerism results from the non-bonded interactions between the aromatic protons in the 4- and 6-positions and the allylic protons of the piperidine ring. These non-bonded interactions restrict the inversion of the 7-membered ring in the cyproheptadine derivatives and analogs thus leading to atropisomerism. In the case of these cyproheptadine analogs and derivatives, the free energy barriers to inversion are sufficiently high to allow the isolation and characterization of the atropisomers.
An important novel process for preparing certain of the novel compounds of this invention comprises introduction of the trifluromethylthio group by treating the corresponding iodo or bromo compound with an excess of bis(trifluoromethylthio)mercury and copper powder in an inert organic solvent such as dimethylformamide, hexamethylphosphoramide, or the like at 50 to about 200° C. for 2 to about 24 hours. ##STR5## However, temperatures above about 100° C. and times of reaction longer than about 12 hours are not advisable if the starting material is enriched in one or the other optical isomers, inasmuch as high temperatures can cause racemization thus reducing the isomer purity of the product. If optical purity of the product is not important, temperatures as high as 200° C. and times as long as about 24 hours are not unreasonable. In the previous chemical equation where X is Br, temperatures above 150° C. are recommended.
In the foregoing description, the reagents are indicated to be bis-(trifluoromethylthio)mercury and copper. However, the reagent responsible for introduction of the trifluoromethylthio group in the novel process is in fact trifluoromethylthiocopper formed in situ from the above-named reagents.
Hg(SCF.sub.3).sub.2 + 2Cu → 2CuSCF.sub.3 + Hg.
Another useful process for obtaining some of the novel compounds of this invention is shown schematically as follows: ##STR6## where R.sub.α 2 is ##STR7##
This process comprises heating the starting material with a dehydrating agent such as hydrochloric acid or a mixture of trifluoroacetic acid and trifluoroacetic anhydride, preferably the latter at about 50° C. to reflux temperature for 10 to about 100 hours.
A third process for obtaining racemates of the novel compounds of this invention comprises alkylation of the piperidine nitrogen and is shown as follows: ##STR8##
The process comprises treating the secondary amine starting material with an excess of the reagent R 2 Br in an inert organic solvent such as a lower alkanol, preferably ethanol, in the presence of an acid acceptor such as a basic resin, pyridine, quinoline, or a solid alkali metal bicarbonate such as sodium bicarbonate, and heating the mixture at 50° C. to reflux temperature from 12 to about 48 hours.
In the case wherein R 2 is --CH 2 CH 2 OH, the preferred reagent to employ is ethylene oxide. The process is conducted by treating the secondary amine starting material with an excess of ethylene oxide in a lower alkanol such as methanol or ethanol at about -80° C. and permitting the reaction mixture to warm spontaneously to room temperature and maintaining at room temperature about 10 to 24 hours.
A fourth process of this invention is useful for obtaining the enantiomers of the novel iodo intermediates of this invention and comprises resolution of the racemic iodo starting materials. This process involves forming diastereomeric salts of a mixture of the desired enantiomers with one enantiomer of an optically active acid such as di-(p-toluoyl)tartaric acid, or malic acid, or the like, in a suitable solvent such as a lower alkanol, such as methanol, ethanol, propanol, or benzene, acetonitrile, nitromethane, acetone, or the like, and isolating by crystallization the less soluble diastereomeric salt. The isolated diastereomeric salt, if desired, may be then recrystallized until further recrystallization fails to change the degree of optical rotation. The desired optically active product as the free base is then obtained by treating the diastereomeric salt thereof with a base.
The other enantiomer is obtained from the mother liquors obtained above by crystallization of the diastereomeric salt therefrom, and if desired, repeated recrystallization to constant optical rotation, followed by liberation of the optically active free base.
Alternatively, the contents of the above described mother liquors are concentrated to dryness, the residue is treated with a base to liberate the optically impure free base. This is then treated with the optical antipode of the previously employed optically active acid to form the diastereomeric salt. If desired, this salt may be then purified by repeated recrystallization to constant optical rotation. The free base of the desired compound is then liberated from the diasteriomeric salt by treatment with a base.
Any of the optically enriched free base products obtained as described above can be racemized by heating a solution of the product in an inert solvent until a sample fails to show optical activity. It is convenient to reflux a toluene solution for about 10-30 hours. In this manner, additional quantities of the racemates can be obtained.
The starting materials required for practicing the novel processes of this invention are either known in the prior art or are readily obtained by one or more of the processes outlined below. Details for the illustrated chemical transformations are provided in the Examples. ##STR9##
The novel method of treatment of this invention comprises the administration of one of the novel compounds to a psychotic patient. The route of administration can be oral, rectal, intravenous, intramuscular, or subcutaneous. Doses of 0.1 to 20 mg./kg./day and preferably of 0.5 to 10 mg./kg./day of active ingredient are generally adequate, and if preferred it can be administered in divided doses given two to four times daily.
It is to be noted that the precise unit dosage form and dosage level depend upon the requirements of the individual being treated and, consequently, are left to the discretion of the therapist.
Pharmaceutical compositions comprising a novel compound as active ingredient may be in any art recognized form suitable for oral use, such as tablets, troches, lozenges, aqueous or oil suspensions, dispersible powders, or granules, emulsions, hard or soft capsules, syrups, or elixirs. For intravenous and intramuscular and subcutaneous use the pharmaceutical compositions may be in any art recognized form of a sterile injectable preparation such as a sterile aqueous or oleaginous solution or suspension. The amount of active ingredient incorporated in a unit dosage of the above described pharmaceutical compositions may be from 1 to 400 mg., and preferably from 5 to 250 mg.
For anticholinergic purposes the compound, preferably a dextrorotatory form, is administered in capsule, tablet, fluid suspension, or solution form in the amount of b 0.5 to 1000 mgms. per dose taken 2-4 times daily.
EXAMPLE 1
(-)-1-Cyclopropylmethyl-4-(3-trifluoromethylthio-5H-dibenzo-[a,d]cyclohepten-5-ylidene)piperidine
Step A: Preparation of 1-cyclopropylmethyl-4-piperidyl-magnesium chloride
To an ice-cooled solution of 21.97 g. (0.143 mol) of 4-piperidone hydrochloride hydrate in 80 ml. of water is added dropwise 15.0 g. (0.143 mol) of cyclopropanecarboxylic acid chloride. Simultaneous with the addition of the above acid chloride, 37.53 g. (0.286 mol) of solid potassium carbonate is added in small portions at such a rate that the mixture is basic. When the additions are complete, the solution is stirred 1 hour longer while saturating with solid potassium carbonate. The mixture is extracted with five 100 ml. portions of benzene. The combined benzene phases are dried over magnesium sulfate, filtered, and the benzene removed on a rotary evaporator. The product crystallizes to give 20.78 g. (87%) of 1-(cyclopropanecarbonyl)-4-piperidone, m.p. 69°-72°.
A solution of 20.10 g. (0.120 mol) of 1-(cyclopropanecarbonyl)-4-piperidone in 75 ml. of dry tetrahydrofuran is added dropwise over one hour to a slurry of 9.12 g. (0.240 mol) of lithium aluminum hydride in 100 ml. of dry tetrahydrofuran. The reaction mixture is allowed to warm spontaneously, and then is allowed to stir overnight at room temperature. After cooling the reaction mixture in an ice bath, 40% aqueous sodium hydroxide is added dropwise until a clear, colorless organic phase over a semi-granular, solid aqueous phase is obtained. The organic phase is decanted and the residue is washed with warm tetrahydrofuran. Evaporation of the combined tetrahydrofuran fractions gives 17.81 g. of 1-cyclopropylmethyl-4-piperidinol.
A solution of 16.78 g. (0.141 mol) of thionyl chloride in 160 ml. of benzene is cooled in an ice bath, and while stirring, a solution of 17.55 g. of 1-cyclopropylmethyl-4-piperidinol in 100 ml. of benzene is added dropwise over 30 minutes. The mixture is stirred for 1 hour in the ice bath, 3 hours at room temperature, 2.5 hours at reflux, and overnight at room temperature. The crystalline precipitate is removed by filtration and washed thoroughly with ether. After drying at 65°, there is obtained 19.61 g. (83%) of 1-cyclopropylmethyl-4-chloropiperidine hydrochloride.
A solution of 39.71 g. of 1-cyclopropylmethyl-4-chloropiperidine hydrochloride in 100 ml. of water is cooled in an ice bath and is treated with solid potassium carbonate until the solution is saturated. This mixture is extracted with three 300 ml. portions of ether. The combined ether extracts are dried over magnesium sulfate, filtered, and the ether is removed on a rotary evaporator. The residue if fractionally distilled in vacuo to give 28.64 g. of 1-cyclopropylmethyl-4-chloropiperidine, b.p. 93°-109°/17-18 mm.
Into a flame-dried, nitrogen filled flask equipped with stirrer, condenser, and dropping funnel is placed 4.01 g. (0.165 mol) of magnesium turnings and 20 ml. of tetrahydrofuran. The flask is warmed at 50°-60°, and, while stirring, a solution of 28.64 g. (0.165 mol) of 1-cyclopropylmethyl-4-chloropiperidine in 60 ml. of tetrahydrofuran is added dropwise at such a rate that when the external heating is removed, gentle refluxing occurs. After the Grignard reagent is formed, the mixture is refluxed for one additional hour. Titration of the resulting solution shows it to be 1.20 M 1-cyclopropylmethyl-4-piperidylmagnesium chloride in tetrahydrofuran solution.
Step B: Preparation of 3-amino-5H-dibenzo[a,d]cyclohepten-5-one
3-Bromo-5H-dibenzo[a,d]cyclohepten-5-one (25 g., 0.088 mol), copper turnings (1.14 g., 0.018 mol), cuprous chloride (0.94 g., 0.009 mol), and concentrated aqueous ammonia (50 ml.) are agitated together at 195° in a steel bomb for 24 hours.
The cooled mixture is removed from the vessel, and the large solid mass broken up mechanically and dissolved in warm chloroform (ca. 150 ml.). The aqueous residue from the reaction is extracted once with chloroform, and the combined chloroform fractions are washed with water, dried over sodium sulfate, filtered, and evaporated in vacuo to give 18.9 g. or crude yellow solid.
The crude product is ground in a mortar and recrystallized from ethanol (ca. 200 ml.). The solid obtained is dissolved in warm chloroform, treated with ca. 8 g. of silica gel, filtered, and evaporated in vacuo to give 16 g. of 3-amino-5H-dibenzo[a,d]cyclohepten-5-one.
Following the procedure of Step B, but substituting for the 3-bromo-5H-dibenzo[a,d]cyclohepten-5-one used therein an equimolecular amount of 3-bromo-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-one and 3-bromo-7-methyl-5H-dibenzo[a,d]cyclohepten-5-one, there are produced respectively 3-amino-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-one and 3-amino-7-methyl-5H-dibenzo[a,d]cyclohepten-5-one.
Step C: Preparation of 3-iodo-5H-dibenzo[a,d]cyclohepten-5-one
3-Amino-5H-dibenzo[a,d]cyclohepten-5-one (50 g., 0.226 mol) is slurried in 150 ml. of concentrated hydrochloric acid. Ice (150 ml.) is added, and the stirred mixture cooled in an ice bath and diazotized by dropwise addition of sodium nitrite solution (17 g., 0.248 mol in 80 ml. of water) over 45 minutes. The temperature is held below 5° throughout the addition. The mixture is stirred for an additional 15 minutes and poured slowly into a stirred solution of 160 g. (1 mole) of potassium iodide in 100 ml. of water. The mixture is stirred at room temperature for 1 hour, then stored overnight in the refrigerator.
The resulting slurry is filtered and the filtrate is extracted once with chloroform. The solids are extracted several times with hot chloroform, and the combined chloroform fractions washed with dilute sodium bisulfite and with water, and dried over sodium sulfate. Residual solid from the chloroform extraction is discarded.
The chloroform solution is combined with 100 g. of silica gel, evaporated in vacuo, then stirred with 1:1 chloroform/hexane and added to a column of 1 kg. of silica gel. The column is packed and eluted with 1:1 chloroform hexane. The product fraction, which is eluted after about 3.5 liter of fore-run, is evaporated in vacuo to give 3-iodo-5H-dibenzo[a,d]cyclohepten-5-one (39.7 g., 53%) as a white solid, m.p. 97.5°-99°.
Following the procedure of Step C but substituting for the 3-amino-5H-dibenzo[a,d]cyclohepten-5-one used therein an equimolecular amount of 3-amino-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-one and 3-amino-7-methyl-5H-dibenzo[a,d]cyclohepten-5-one, there are produced respectively, 3-iodo-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-one and 3-iodo-7-methyl-5H-dibenzo[a,d]cyclohepten-5-one.
Step D: Preparation of (±)-1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene) piperidine
To an ice-cooled solution of 10.00 g. (0.030 mol) of 3-iodo-5H-dibenzo[a,d]cyclohepten-5-one in 60 ml. of dry tetrahydrofuran is added dropwise 30 ml. of 1.20 M 1-cyclopropylmethyl-4-piperidylmagnesium chloride in tetrahydrofuran. The solution is stirred 2 hours, and then the tetrahydrofuran is removed on a rotary evaporator. The red-oily residue that remains is dissolved in benzene and water is added dropwise until a clear benzene supernatant and a gelatinous aqueous phase is obtained. The benzene phase is decanted and the gelatinous aqueous phase is extracted with two 100 ml. portions of hot benzene. The combined benzene extracts are washed with five 200 ml. portions of water, dried over magnesium sulfate, filtered, and the benzene is removed on a rotary evaporator. The residue that remains is placed on a silica gel column packed in chloroform. The column is eluted with chloroform which causes a by-product of the reaction, 3-iodo-5H-dibenzo[a,d]cyclohepten-5-ol, to be eluted. (This by-product may be oxidized to provide the starting material, 3-iodo-5H-dibenzo[a,d]cyclohepten-5-one). When all of the by-product has been eluted, the column is eluted with 1% methanol in chloroform. The eluate is concentrated to give 6.03 g. of an oil which is mainly 1-cyclopropylmethyl-4-(3-iodo-5-hydroxy-5H-dibenzo[a,d]cyclohepten-5-yl)piperidine.
A solution of 4.67 g. of the above oil in 45 ml. of trifluoroacetic acid and 35 ml. of trifluoroacetic anhydride is refluxed for 20 hours. The solution is concentrated on a rotary evaporator and the residue is made basic with 20% sodium hydroxide. The oil that precipitates is extracted into benzene, and this benzene phase is washed with water, dried over magnesium sulfate, filtered, and the benzene removed on a rotary evaporator. The residue, which crystallizes rapidly, is triturated with acetonitrile and collected by filtration. There is obtained 2.58 g. of product, which, when recrystallized from acetonitrile, gives 2.54 g. of (±)-1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 139°-141°.
Anal. Calcd. for C 24 H 24 IN: C, 63.58; H, 5.34; N, 3.09; I, 27.99. Found: C, 63.78; H, 5.57; N, 3.02; I, 28.08.
Similarly prepared is (±)-1-cyclobutylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine by substituting an equimolecular amount of 1-cyclobutylmethyl-4-piperidylmagnesium chloride for the 1-cyclopropylmethyl-4-piperidylmagnesium chloride.
Following the procedure of Example 1, Step D, but substituting for the 3-iodo-5H-dibenzo[a,d]cyclohepten-5-one used therein an equimolecular amount of 3-iodo-7-methyl-5H-dibenzo[a,d]cyclohepten-5-one or 3-iodo-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-one, there is produced (±)-1-cyclopropylmethyl-4-(3-iodo-7-methyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine or (±)-1-cyclopropylmethyl-4-(3-iodo-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, respectively.
Step E: Resolution of (±)-1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
1. Levorotatory Isomer: To a solution of 11.57 g. (0.0255 mol) of (±)-1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine in 245 ml. of hot absolute ethanol is added 9.86 g. (0.0255 mol) of di-p-toluoyl-d-tartaric acid dissolved in 60 ml. of hot absolute ethanol. The solution is stirred and concentrated by boiling to 150 ml. The crystalline precipitate that forms on cooling is removed by filtration, washed with cold absolute ethanol, and dried at 100° in vacuo to give 8.41 g. of material, designated A. The clear ethanol filtrate and washings are designated B.
The 8.41 g. of A is recrystallized from absolute ethanol four times to give a product that has a constant rotation, m.p. 147°-149°; [α] 589 25 = -128°; [α] 578 25 = -136°, [α] 546 25 = -161°, [α] 436 25 = -369°, (C = 0.00314 g./ml. pyridine). This material, 3.70 g., is suspended in a small amount of water and is treated with 5% sodium hydroxide solution. The free base that precipitates is extracted into ether, washed with water, and dried over magnesium sulfate. After filtering, the ether is removed on a rotary evaporator. The white solid that remains is dried at 100° to give 1.89 g. of (-)-1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 135°-136.5°; [α] 589 25 = -141°, [α] 578 25 = -150°, [α] 546 25 = -180°, [α] 436 25 = -431°, (C = 0.0041 g./10 ml. CHCl 3 ).
2. Dextrorotatory Isomer -- The ethanol filtrate and washings, designated B, are concentrated on a rotary evaporator. The residue is treated with 5% sodium hydroxide solution. The free base that precipitates is extracted into chloroform. Evaporation of the chloroform gives 10.09 g. of 1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine that is rich in the dextrorotatory isomer. This material is dissolved in 240 ml. of hot absolute ethanol and is treated with 9.02 g. of di-p-toluoyl-1-tartaric acid monohydrate dissolved in 60 ml. of hot absolute ethanol. The solution is stirred and concentrated by boiling to 125 ml. The crystalline precipitate that forms on cooling is removed by filtration, washed with cold absolute ethanol, and dried at 100° in vacuo to give 9.86 g. of material. This material is recrystallized from absolute ethanol three times to give a product that has a constant rotation, m.p. 146°-147°; [α] 589 25 = +128°, [α] 578 25 = + 135°; [α] 546 25 = +161°, [α] 436 25 = +365°, (C = 0.00309 g./ml. pyridine). This material, 5.29 g., is suspended in a small amount of water and is treated with 5% sodium hydroxide solution. The free base that precipitates is extracted into ether, washed with water, and dried over magnesium sulfate. After filtering, the ether is removed on a rotary evaporator. The white solid that remains is dried at 100° to give. 2.65 g. of (+)-1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 135°-136.5°; [α] 589 25 = +138°, [α] 578 25 +147°, [α] 546 25 = +176°, [α] 436 25 = +422°, (C - 0.00433 g./ml. CHCl 3 ).
In a similar manner there are produced the (-) and (+) isomers of each of 1-cyclopropylmethyl-4-(3-iodo-7-methyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine and 1-cyclopropylmethyl-4-(3-iodo-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, and 1-cyclobutylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine from their respective racemic mixtures.
Step F: Preparation of (-)-cyclopropylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
A mixture of 2.88 g. (0.0454 mol) of copper dust, 4.32 g. (0.0107 mol) of bis-(trifluoromethylthio)mercury, 1.89 g. (0.00417 mol) of (-)-1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, and 20 ml. of dimethylformamide is stirred and heated on the steam bath for 6 hours. The mixture is cooled in ice, and 40 ml. of chloroform and 25 ml. of concentrated ammonium hydroxide is added. The mixture is stirred overnight at room temperature and then filtered through a pad of Filter-Cel. The filtrate and chloroform washings are combined and separated from the deep blue aqueous phase. The chloroform phase is washed with water, dried over magnesium sulfate, filtered, and the chloroform is removed on a rotary evaporator. The residue crystallizes rapidly. It is triturated with cold acetonitrile and collected by filtration. This material is recrystallized from acetonitrile to give 1.20 g. (67%) of (-)-1-cyclopropylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 143°-144°; [α] 589 25 = -64.1°, [α] 578 25 = -68.0°, [α] 546 25 = -82.8°, [α] 436 25 = -212°, (C = 0.00513 g./ml. CHCl 3 ).
Anal. Calcd. for C 25 H 24 F 3 NS: C, 70.23; H, 5.66; N, 3.28; F, 13.33. Found: C, 70.40; H, 5.81; N, 3.29, F, 13.04.
Following the procedure of Example 1, Step F, but substituting for the starting material used therein an equimolecular amount of (-)-1-cyclopropylmethyl-4-(3-iodo-7-methyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, (-)-1-cyclopropylmethyl-4-(3-iodo-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-ylidene piperidine, or (-)-1-cyclobutylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, there are produced respectively (-)-1-cyclopropylmethyl-4-(3-trifluoromethylthio-7-methyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, (-)-1-cyclopropylmethyl-4-(3-trifluoromethylthio-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, and (-)-1-cyclobutylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine.
EXAMPLE 2
(+)-1-Cyclopropylmethyl-4-(3-trifluoromethylthio-5H-benzo[a,d]cyclohepten-5-ylidene)piperidine
A mixture of 4.05 g. (0.0637 mol) of copper dust, 6.05 g. (0.0150 mol) of bis-(trifluoromethylthio)mercury, 2.65 g. (0.00584 mol) of (+)-1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, and 30 ml. of dimethylformamide is stirred and heated on the steam bath for 6 hours. The mixture is cooled in ice, and 40 ml. of chloroform and 25 ml. of concentrated ammonium hydroxide is added. The mixture is stirred overnight at room temperature and then filtered through a pad of Filter-Cel. The filtrate and chloroform washings are combined and separated from the deep blue aqueous phase. The chloroform phase is washed with water, dried over magnesium sulfate, filtered, and the chloroform is removed on a rotary evaporator. The residue crystallizes rapidly. It is triturated with cold acetonitrile and collected by filtration. This material is recrystallized from acetonitrile to give 1.37 g. (55%) of (+)-1-cyclopropylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 143°-144°; [α] 589 .sup. 25 = +64.2°; [α] 578 25 = +68.9°; [α] 546 25 = +83.5°; [α] 436 25 = +213° (c) = 0.00515 g./ml. CHCl 3 .
Anal. Calcd. for C 25 H 24 F 3 NS: C, 70.23; H, 5.66; N, 3.28; F, 13.33. Found: C, 70.85; H, 5.78; N, 3.33; F, 13.55.
Following the procedure of Example 2, but substituting for the starting material used therein an equimolar amount of (+)-1-cyclopropylmethyl-4-(3-iodo-7-methyl-5-H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, (+)-1-cyclopropylmethyl-4-(3-iodo-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine or (+)-1-cyclobutylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, there are produced respectively (+)-1-cyclopropylmethyl-4-(3-trifluoromethylthio-7-methyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, (+)-1-cyclopropylmethyl-4-(3-trifluoromethylthio-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine and (+)-1-cyclobutylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine.
EXAMPLE 3
(±)-1-Cyclopropylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Step A: Preparation of 3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-one
A mixture of 42.56 g. of bis(trifluoromethylthio)mercury, 17.27 g. of 3-bromo-5H-dibenzo[a,d]cyclohepten-5-one, 28 g. of electrolytic copper dust, 98 ml. of quinoline and 84 ml. of pyridine is stirred and heated from 100° to 195° C. for 18 hours. The mixture is shaken with 400 ml. of 6 N hydrochloric acid and 400 ml. benzene. The organic phase is washed with 5 × 300 ml. of 3 N hydrochloric acid and 5 × 300 ml. of water, dried over magnesium sulfate, filtered and concentrated to dryness. The crystalline residue is recrystallized from 100 ml. of methanol to give 14.83 g. (78% ) of 3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-one, m.p. 87°-88° C.
Following the procedure of Example 3, Step A, but substituting for the starting material used therein an equimolar amount of 3-bromo-7-methyl-5H-dibenzo[a,d]cyclohepten-5-one and 3-bromo-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-one, there are produced respectively 3-trifluoromethylthio-7-methyl(and 7-fluoro)-5H-dibenzo[a,d]cyclohepten-5-one.
Step B: Preparation of (±)-1-cyclopropylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
To an ice-cooled solution of 10.0 g. (0.0326 mol) of 3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-one in 60 ml. of dry tetrahydrofuran is added dropwise 29 ml. of 1.14 M 1-cyclopropylmethyl-4-piperidylmagnesium chloride in tetrahydrofuran. The solution is stirred for 2 hours while being allowed to warm to room temperature, and then the tetrahydrofuran is removed on a rotary evaporator. The red-oily residue that remains is dissolved in benzene and water is added dropwise until a clear benzene supernatant and a gelatinous aqueous phase is obtained. The benzene phase is decanted and the gelatinous aqueous phase is extracted with two 100 ml. portions of hot benzene. The combined benzene extracts are washed with four 150 ml. portions of water, dried over magnesium sulfate, filtered, and the benzene is removed on a rotary evaporator. The remaining residue is placed on a silica gel column packed in chloroform. The column is eluted with chloroform which causes a by-product of the reaction, 3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ol, to be eluted. (This by-product may be oxidized to provide the starting material, 3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-one). When all of the by-product has been eluted, the column is eluted with 2% methanol in chloroform. The eluate is concentrated to give 7.0 g. of an oil which is mainly 1-cyclopropylmethyl-4-(3-trifluoromethylthio-5-hydroxy-5H-dibenzo[a,d]cyclohepten-5-yl)piperidine.
A solution of 7.0 g. of the above oil in 40 ml. of trifluoroacetic acid and 50 ml. of trifluoroacetic anhydride is refluxed overnight. The solution is concentrated on a rotary evaporator and the residue is made basic with sodium hydroxide solution. The oil that precipitates is extracted into ether, and this ether phase is washed with water, dried over magnesium sulfate, filtered, and the ether removed on a rotary evaporator. The residue, which crystallizes rapidly, is triturated with acetonitrile and collected by filtration. The material is recrystallized from acetonitrile, collected, and dried at 100° to give 4.26 g. of (±)-1-cyclopropylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 122°-123°.
Anal. Calcd. for C 25 H 24 F 3 NS: C, 70.23; H, 5.66; N, 3.28, S, 7.50. Found: C, 70.07; H, 5.31; N, 3.04; S, 7.38.
Following the procedure of Example 3, Step B, but substituting for the 3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-one used therein, an equimolecular amount of 7-fluoro(and 7-methyl)-3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-one respectively, there is produced (±)-1-cyclopropylmethyl-4-(7-fluoro-3-trifluoromethyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine and (±)-1-cyclopropylmethyl-4-(7-methyl-3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine.
Following the procedure substantially as described in Example 3, Step B, but substituting for the 1-cyclopropylmethyl-4-piperidylmagnesium chloride used therein, an equimolecular amount of 1-methyl-4-piperidylmagnesium chloride, there is produced (±)-1-methyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 115°-116.5° C.
EXAMPLE 4
(±)-1-Cyclopropylmethyl-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Step A: Preparation of 3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-one
A solution of 6.00 g. of 3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-one in 240 ml. of acetic acid at 17°-18° C. is treated dropwise with 54 ml. of 30% hydrogen peroxide with stirring. The mixture is stirred at room temperature for 192 hours. The mixture is poured into 1.5 liters of water and extracted with five 125 ml. portions of chloroform. The combined chloroform extracts are washed with 4 × 200 ml. of water and 200 ml. of saturated sodium carbonate and 3 × 200 ml. of water. The chloroform is dried over magnesium sulfate, filtered, and evaporated to dryness. The residue is triturated with ethanol. The solids are collected on a filter and dried to give 3.90 g. of crude product. This material is chromatographed on a silica gel (300 g.) column by elution with benzene. The appropriate fractions were combined and concentrated to dryness to give 2.5 g. of 3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-one, m.p. 145° -149° C.
step B: Preparation of (±)-1-cyclopropylmethyl-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Employing the procedure substantially as described in Example 3, Step B, but substituting for the 3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-one used therein an equimolecular amount of 3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-one, there is produced 8±)-1-cyclopropylmethyl-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m. p. 125°-127° C.
Following the procedure substantially as described in Example 4, Step B, but substituting for the 1-cyclopropylmethyl-4-piperidylmagnesium chloride used therein an equimolecular amount of 1-cyclobutylmethyl-4-piperidylmagnesium chloride, there is produced (±)-1-cyclobutylmethyl-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 101°-106° C.
Following the procedure of Example 4 but substituting for the 3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-one used in Step A thereof, an equimolecular amount of 3-trifluoromethylthio-7-methyl (and 7-fluoro)dibenzo[a,d]cyclohepten-5-one followed by treatment of the products with 1-cyclopropylmethyl-4-piperidylmagnesium chloride, there is produced respectively (±)-1-cyclopropylmethyl-4-(3-trifluoromethylsulfonyl-7-methyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine and (±)-1-cyclopropylmethyl-4-(3-trifluoromethylsulfonyl-7-fluoro-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine.
EXAMPLE 5
(±)-1-Cyclobutylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Step A: Preparation of 1-cyclobutylmethyl-4-piperidylmagnesium chloride
Employing the procedure substantially as described in Example 1, Step A, but substituting for the cyclopropanecarboxylic acid chloride used therein, an equimolecular amount of cyclobutanecarboxylic acid chloride, there is produced a tetrahydrofuran solution of 1-cyclobutylmethyl-4-piperidylmagnesium chloride.
Step B: Preparation of (±)-1-Cyclobutylmenthyl-4-(3-trifluromenthylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Employing the procedure of Example 3, Step B, but substituting for the 1-cyclopropylmethyl-4-piperidylmagnesium chloride used therein, an equivalent amount of 1-cyclobutylmethyl-4-piperidylmagnesium chloride, there is produced (±)-1-cyclobutylmethyl-4-(3-trifluoromethylthio-5-H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 114.5°-116° C. after recrystallization from acetonitrile.
EXAMPLE 6
(±)-1-Cyclobutylmethyl-4-(3-trifluoromethylsulfonyl-5-H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Following the procedure substantially as described in Example 4, Step B, but substituting for the 1-cyclopropylmethyl-4-piperidylmagnesium chloride, an equimolecular amount of 1-cyclobutylmethyl-4-piperidylmagnesium chloride, there is produced (±)-1-cyclobutylmethyl-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 126°-128° C.
EXAMPLE 7
(±)-1-Methylenecyclopropylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Step A: Preparation of 4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
A solution of 3.78 g. of 1-methyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine in 35 ml. of benzene is added dropwise over 45 minutes to a stirred solution of 1.3 g. of cyanogen bromide in 35 ml. of benzene. After stirring at room temperature overnight the solution is evaporated to dryness and coevaporated with acetonitrile.
To the oily residue is added 100 ml. of acetic acid, 12 m. of concentrated hydrochloric acid, and 50 ml. of water. This mixture is refluxed for 16 hours. The mixture is concentrated to dryness in vacuo. The residue is dissolved in chloroform and made basic by addition of sodium bicarbonate solution. The aqueous phase is extracted well with chloroform and the combined organic layers are washed with water, dried and filtered. The filtrate is concentrated to dryness in vacuo to give 3.73 g. of 4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 151.5°-154.5° C.
step B: Preparation of (±)-1-methylenecyclopropylmethyl-(±)-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
A mixture of 2 g. of the product from Step A, 0.5 g. of sodium bicarbonate and 0.778 g. of (±)-methylenecyclopropylmethylbromide in 60 ml. of absolute ethanol is refluxed overnight. An additional amount of 0.132 g. of the bromide is added and refluxing is continued for 6 more hours when another 0.132 g. of bromide is added followed by refluxing overnight. The cooled mixture is filtered and the filtrate is concentrated to dryness in vacuo. The residue is partitioned between water and chloroform. The separated water phase is extracted again with chloroform. The combined chloroform extracts are washed with water, dried over magnesium sulfate and concentrated to dryness. Recrystallization of the residue from acetonitrile gives (±)-1-methylenecyclopropylmethyl-(±)-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 86°-89° C.
Employing the procedure substantially as described in Example 7, Step B, but substituting for the (±)-methylenecyclopropylmethyl bromide used therein, an equimolecular amount of (-)-methylenecyclopropylmenthyl bromide, there is produced (-)-1-methylenecyclopropylmethyl-(±)-4-(3-trifluromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 91°-93° C.
Employing the procedure substantially as described in Example 7, Step B, but substituting for the methylenecyclopropyl bromide used therein, an equimolecular amount of cyclopropylmethyl bromide, cyclobutylmethyl, and ethylenebromohydrin, there are produced respectively:
(±)-1-cyclopropylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine;
(±)-1-cyclobutylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, and
(±)-1-hydroxyethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine.
EXAMPLE 8
(±)-1-Methylenecyclopropylmethyl-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Employing the procedure substantially as described in Example 7 but substituting for the 3-trifluoromethylthio compound used in Step A thereof an equimolecular amount of the corresponding 3-trifluoromethylsulfonyl compound, there is produced:
(±)-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 189.5°-192.5;°;
which upon treatment with (-)-methylenecyclopropylmethyl bromide, cyclopropylmethyl bromide, cyclobutylmethyl bromide or ethylene bromohydrin in accordance with Example 7, Step B, produces respectively:
(±)-1-methylenecyclopropylmethyl-(±)-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 132°-141° C.;
(±)-1-cyclopropylmethyl-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine;
(±)-1-cyclobutylmethyl-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, or
(±)-1-hydroxyethyl-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine.
EXAMPLE 9
(±)-1-Hydroxyethyl-4-(3-trifluoromethylsulfonyl5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
A solution of 0.244 g. of ethylene oxide of 30 ml. of methanol at dry-ice temperature is added to an ice cold solution of 2.55 g. of 4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine in 15 ml. of chloroform and 75 ml. of methanol. The solution is stirred at ambient temperature overnight. A second quantity (0.25 g.) of ethylene oxide is added as before and the mixture is again stirred overnight. The mixture is concentrated to dryness and the residue is coevaporated in vacuo several times with acetonitrile. The product is recrystallized several times from acetonitrile to give (±)-1-hydroxyethyl-4-(3-trifluoromethylsulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 141°-144° C.
Employing the procedure substantially as described in Example 9 but substituting for the trifluoromethylsulfonyl compound used therein, an equimolecular amount of the corresponding trifluoromethylthio compound, there is produced (±)-1-hydroxyethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, m.p. 116°-118° C., clearing at 127° C. EXAMPLE 10
(±) and (-)-1-Hydroxyethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Step A: Preparation of (±)-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Following the procedure of Example 7, Step A, but substituting for the (±)-1-methyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene) piperidine used therein an equimolecular amount of (±)-1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, there is produced (±)-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine.
Step B: Preparation of (±)-1-hydroxyethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Following the procedure substantially as described in Example 9 but substituting for (±)-4-(3-trifluoromethysulfonyl-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, and equimolecular amount of (±)-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, there is produced (±)1-hydroxyethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine.
Step C: Preparation of (±) and (-)-1-hydroxyethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Following the procedure of Example 1, Step E, for the resolution of the optical isomers but substituting for the racemic mixture used therein, an equimolecular amount of the racemate from Step B of this example, there is produced (±) and (-)-1-hydroxyethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine.
Step D: Preparation of (±) and (-)-1-hydroxyethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Following the procedure substantially as described in Example 1Step F, but substituting for the (-)-1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine used therein, an equimolecular amount of the (±) and (-)-1-hydroxyethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine respectively, there is produced (±)-1-hydroxyethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine and (31 )-1-hydroxyethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-4-ylidene)piperidine.
EXAMPLE 11
(±)-1-Methylenecyclopropylmethyl-(±) and (-)-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Step A: Preparation of (±)-1-methylenecyclopropylmethyl-(±)-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Following the procedure of Example 7, Step B, but substituting for the 4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine used therein, an equimolecular amount of (±)-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine, there is produced (±)-1-methylenecyclopropylmethyl-(±)-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine.
Step B: Preparation of (±)-1-methylenecyclopropylmethyl-(±) and (-)-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Following the procedure of Example 1, Step E, for the resolution of the optical isomers but substituting for the racemic mixture used therein an equimolecular amount of the racemate from Step A of this example, there is produced (±)-1-methylenecyclopropylmethyl-(±) and (-)-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine.
Step C: Preparation of (±)-1-methylenecyclopropylmethyl-(±) and (-)-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
Following the procedure substantially as described in Example 1, Step F, but substituting for the (-)-1-cyclopropylmethyl-4-(3-iodo-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine used therein an equimolecular amount of (±)-1-methylenecyclopropylmethyl-(+) and (-)-4-(3-iodo-5H-dibenzo[a, d]cyclohepten-5-ylidene)piperidine respectively, there is produced:
(±)-1-methylenecyclopropylmethyl-(±)-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine and
(±)-1-methylenecyclopropylmethyl-(-)-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine
EXAMPLE 12
Pharmaceutical Compositions
A typical tablet containing 100 mg. of (-)-1-cyclopropylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]cyclohepten-5-ylidene)piperidine per tablet is prepared by mixing together with the active ingredient calcium phosphate, lactose and starch in the amounts shown in the table below. After these ingredients are thoroughly mixed, the appropriate amount of magnesium stearate is added and the dry mixture blended for an additional three minutes. This mixture is then compressed into tablets.
Tablet Formula______________________________________Ingredient Mg. per Tablet______________________________________(-)-1-cyclopropylmethyl-4-(3-trifluoromethylthio-5H-dibenzo[a,d]-cyclohepten-5-ylidene)piperidine 100 mg.Calcium phosphate 52 mg.Lactose 60 mg.Starch 10 mg.Magnesium stearate 1 mg.______________________________________
Similarly prepared are tablets comprising as active ingredient any of the antipsychotic compounds described herein.
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Cyproheptadine derivatives substituted with a trifluoromethylthio or trifluoromethylsulfonyl group in one of the benzo rings and having a hydroxyalkyl or cycloalkylalkyl group on the piperidine nitrogen are potent antipsychotic agents, with a low propensity to induce extrapyramidal side effects that are experienced with most major tranquilizers. The tranquilizing activity is predominantly in the levorotatory enantiomers, whereas the dextrorotatory enantiomers have anticholinergic activity. Each enantiomer is useful as a source of the other by racemization. The novel compounds are prepared by treatment of the corresponding iodo or bromo compound with bis(trifluoromethylthio)mercury and copper powder.
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FIELD OF INVENTION
[0001] This invention relates generally to the manufacture of magnetic memory disks and to an improved procedure for plating a metal substrate with improved electroless nickel (EN) chemistry. The invention reduces defects in the deposited metal coating by inhibiting co-deposition of nonmetallic particles which may be generated in situ or introduced from an external source into an electroless or electrolytic plating solution.
BACKGROUND OF THE INVENTION
[0002] Modifications of and chemical refinements to autocatalytic chemical reduction processes, in particular, electroless nickel (EN) plating solutions, are not uncommon. Many of these modifications address concerns related to the bath itself and its inherent properties of stability, plating rate and effective pH operating range for the plating environment. For example, U.S. Pat. No. 2,658,841 teaches the use of soluble organic acid salts as buffers for EN baths. U.S. Pat. No. 2,658,842 teaches the use of short chain, dicarboxylic acids as exaltants to EN baths. U.S. Pat. No. 2,762,723 teaches the use of sulfide and sulfur bearing additives to an EN bath for improved bath stability. U.S. Pat. No. 2,847,327 teaches the use of fatty acid compounds as stabilizers and mild exaltants for EN baths. This latter patent describes the use of numerous surfactants including organic compounds from the class of fatty acids and water-soluble salts thereof, amino compounds, and sulfates and sulfonates of fatty acids and fatty alcohols. What all of these patents have in common, is the use of a compound or class of compounds for the purpose of modifying the inherent properties of the plating bath itself (i.e. its plating rate, stability or useful pH operating range).
[0003] Further progress in autocatalytic plating since the U.S. Pat. No. 2,847,327 teaching has introduced other means of stabilizing an EN plating bath. These include the use of higher purity starting materials; more effective stabilizers from the class of heavy metals such as Pb, Sb, Bi, Cu and Se; inorganic compounds such as iodates, and thio compounds; organic compounds such as unsaturated alkenes and alkynes and others. Additionally, improvements in plating bath equipment, such as improved pumping and filtration methods and design, such as air sparging, improved methods of adding the replenishment chemistry to the plating tank and the use of anodic protection circuitry has further reduced concerns over bath stability. This invention is distinguished from U.S. Pat. No. 2,847,327 in that an additive is introduced into the plating bath for the purpose of improving the quality of the metal deposit by preventing, or at least very substantially inhibiting, co-deposition of non-metallic particles in the deposit. The function of the organic compounds in U.S. Pat. No. 2,847,327 is to act upon the bath solution. The function of the organic additive in this invention is to act upon the plated deposit not on the bath. Furthermore, not every organic compound taught in U.S. Pat. No. 2,847,327 will work in the practice of this invention, but only those having a sufficiently high zeta potential that it enables repulsion between the non-metallic, particles and the plating surface.
[0004] This invention has particular usefulness in the production of rigid memory disks that are quite commonly used in today's laptop and desktop computers. Details of the construction of thin film magnetic media are taught in U.S. Pat. No. 5,405,646. Media is built up in layers, each of which performs a specific task. The substrate of the disk can be glass, plastic, metal or any other rigid material. Commercially, both glass and aluminum have been widely used. The preferred practice for this invention is for an aluminum substrate. As shown in FIG. 1 , an aluminum alloy, typically undergoes at least six wet chemical process steps to build up a hard, corrosion resistant, NiP coating layer. This serves as the underlayer for the subsequent application of magnetic media. It is this magnetic media which ultimately enables storage and deletion of data by electromagnetic currents produced and detected by read/write heads in today's hard-disk drives.
[0005] Prior to the application of magnetic media in the production of rigid memory disks, a few more treatments to the NiP coating are required. The plated disks are baked and polished. The polishing step produces an extremely flat and smooth surface for the subsequent sputtering steps and enables the very close fly heights (typically 30 nanometers) for the read/write heads in a finished hard-disk drive. Any slight aberrations or asperities (deviations from flatness) in the deposited coating (whether protrusions above or depressions below the otherwise flat surface) introduce susceptibilities to head crashes between the read/write heads and the surface of the hard-disk. This ultimately reduces the expected service life of these drive components.
[0006] It is in the electroless plating step where the present invention provides benefit by significantly reducing the potential for plating defects. During the wet chemical processing steps, the ground, aluminum disks, are racked on a plating fixture. Plating fixtures are very common in metal plating processes. The fixtures can be made from metal, plastic, glass or ceramics. The material chosen depends on many factors. In the production of memory disks, fixtures are commonly made from plastics. Engineering plastics are chosen from those that can withstand the heat and chemistry used in the electroless nickel plating process. These may include: fluorinated plastics, such as polyvinylidene fluoride (PVDF) and polytetrafluoroethylene (PTFE); polysulfone (PSU); polyether ether ketone (PEEK) and polybisimidazole (PBI) among others.
[0007] Constant solution exchange at the surface of every disk is essential to refresh the plating chemistry at the surface and to produce a plated article of uniform and consistent composition which is of considerable importance in the memory disk industry. This is afforded by physical movement of both the plating fixture within the bath and vigorous solution mixing. The continuous mechanical movement of the plating fixture (on which the disks are mounted) can be translational, e.g., up and down or side-to-side, rotation and orbital motion of mounting spindles and mandrels, or that provided by some other means, e.g. ultrasonic motion. Solution movement or mixing can be provided by any type of fluid movement, e.g., due to recirculation pumps, cascading flow, jet nozzles, inductors, air sparging or any other means known to those in metal plating art and practice. The tank design can be of any physical shape, size or design as would be needed so that the parts can be contacted with the plating chemistry in such a manner that the metal required is built up and deposited on the object to be plated.
[0008] These different types of movement will cause the articles being plated to continually rub and potentially abrade small particles of plastic off the racking fixtures. These particles, having been created within the bath, or even introduced to the plating solution from some other source, be it internal or external, now have the possibility of being directed toward the plating surface. If this particle remains at the surface long enough, it now has the possibility of being encapsulated by the metal being deposited, i.e., built into the deposit and reducing the absolute purity of the coating due to the presence of an undesired, i.e. foreign, particle.
[0009] Due to the high degree of solution movement and mechanical motion within the plating tank, there is also a constant rubbing of the aluminum disks across the surface of the PVDF spindle and the polysulfone rod. This continual abrading action in a hot plating bath for nearly two hours at thousands of contact points between metal disks and plastic spindles and rods can cause small plastic particles to be detached and introduced into the plating solution. If these particles come in contact with a plating surface and remain there long enough, they can be plated into the growing NiP coating. Plated-in defects like these are known to occur and are of grave concern to production engineers. Once embedded, these particles can become exposed at the surface during the subsequent production step of polishing. A plastic particle located at the surface of the NiP layer can then become completely or partially dislodged when the final magnetic media is applied during the sputtering steps where heat (ca. 200-250° C.) is momentarily encountered.
[0010] When an asperity such as this is produced (i.e., a plastic protrusion or inclusion), hard disk reliability cannot be guaranteed because of the extremely low fly heights of the read/write heads over the surface of the spinning disk and the potential for head crashes. The head crash can be the result of either direct physical contact with the particle or a protrusion caused by it or due to a turbulent air flow pattern, as might be produced from a cavity or depression in the surface wherein a particle that once resided in the deposit as a foreign object has been produced due to a subsequent production step in the manufacture of the hard disk prior to the completed assembly of the final product. When this type of plating defect is found, even in just one disk from a plating batch of several thousand, the entire batch of disks is discarded and substantial losses are incurred.
[0011] To substantially avoid this type of inclusion, or vestige of its former presence, indicates that substantially no particles are detected in any article examined. In the hard disk industry “substantially” indicates no particles are allowed, i.e., the count frequency must be zero among those parts that are inspected. In other industries where particle dimension are even smaller than those encountered in the memory disk industry, e.g. some nano-engineering industry wherein foreign particles on a nanometer or picometer scale are of great commercial concern, the term “substantially” allows for a finite frequency of particles but it would be demonstrably, and statistically less than the number of foreign particles found when compared with a metal plating process by any commonly used statistical method for determining the purity (i.e., absence of the foreign particle) of the plated deposit.
[0012] One way of addressing this issue, relies on the high solution turnover and the use of in-line filtration to remove these particles. However, since the particles are generated within the plating tank, the possibility always remains that they may come into contact with the plating disks and remain there long enough to be encapsulated into the NiP coating.
[0013] Therefore, it is the object of the present invention to improve the quality of the plated deposit on a metal substrate with an autocatalytic chemistry. Of particular benefit is the application wherein a ground aluminum substrate is coated with an electroless nickel phosphorus alloy as in the manufacturing procedure used to produce rigid memory disks. As an enhancement to the present state of the art, the electroless nickel chemistry is modified with certain additives to nearly completely prevent the likelihood of co-depositing plastic particles in the coating.
SUMMARY OF THE INVENTION
[0014] This invention relates to the use of certain additives in a metal plating bath to improve the quality, i.e., the purity of the deposited coating. In one particular application, the manufacture of rigid memory disks, a certain sulfated fatty acid ester additive, e.g., of castor oil, has been found to be exceptionally useful. It is represented by the formula
[0000]
wherein R 1 is selected from the group consisting of OH, OCH 2 , OCH 2 CH 3 , C 1 -C 7 alkyl, linear or branched;
R 2 is selected from the group consisting of H and C 1 -C 7 alkyl, linear or branched;
m is an integer ranging from 1 to about 5;
n is an integer ranging from 2 to about 30;
o is an integer ranging from 0 to about 10;
M + is a metal or pseudo metal ion or H + .
In the context of the present invention, preferred alkyl groups contain 1 to 7, preferably 1 to 5, more preferably 1 to 3 carbon atoms. Preferred alkyl groups are methyl, ethyl, propyl, isopropyl and butyl.
[0021] o is an integer which can range from 0-10, preferably from 0-3. It cannot exceed 2×(3.5+n)−m due to the valency of the alkyl chain. Both R 1 and SO 4 − can be located at any position of the carbon chain, which is denoted by the drawing above. If the carboxylic acid is a fatty acid as starting product for the sulfation the sulfate group is positioned at either one carbon atom of the former double bond. A pseudo metal ion can for example be NH 4 + . A preferred embodiment of the invention utilizes sulfated esters of caster oil as additive represented by the formulae below:
[0000]
[0000] wherein R 2 is selected from the group consisting of H and C 1 -C 7 alkyl, linear or branched, and M + is a metal or pseudo metal ion or H + .
[0022] This invention further relates to at least one reaction product additive in a mixture produced from the sulfation and esterification of a fatty acid or mixtures and salts thereof used in a metal plating bath represented by the formula
[0000]
wherein R 1 is selected from the group consisting of OH, OCH 2 , OCH 2 CH 3 , C 1 -C 7 alkyl, linear or branched;
R 2 is selected from the group consisting of H and C 1 -C 7 alkyl, linear or branched;
m is an integer ranging from 1 to about 5;
n is an integer ranging from 2 to about 30;
o is an integer ranging from 0 to about 10;
M + is a metal or pseudo metal ion or H + .
having a zeta potential between about −40 and about −150 mV.
[0029] This invention also relates to metal plating composition for substantially avoiding co-deposition of non-metallic particles during deposition of a metal or a metal alloy comprising, at least one reaction product additive from a mixture produced from the sulfation and esterification of a fatty acid or mixtures and salts thereof used in a metal plating bath represented by the formula
[0000]
wherein R 1 is selected from the group consisting of OH, OCH 2 , OCH 2 CH 3 , C 1 -C 7 alkyl, linear or branched;
R 2 is selected from the group consisting of H and C 1 -C 7 alkyl, linear or branched;
m is an integer ranging from 1 to about 5;
n is an integer ranging from 2 to about 30;
o is an integer ranging from 0 to about 10;
M + is a metal or pseudo metal ion or H + .
[0036] This invention additionally relates to metal plating composition for deposition of nickel and nickel alloys comprising,
(i) a source of nickel ions, (ii) at least one reaction product additive from a mixture produced from the sulfation and esterification of a fatty acid or mixtures and salts thereof used in a metal plating bath in an amount effective for substantially avoiding co-deposition of non-metallic particles during deposition of nickel alloys represented by the formula
[0000]
wherein R 1 is selected from the group consisting of OH, OCH 2 , OCH 2 CH 3 , C 1 -C 7 alkyl, linear or branched;
R 2 is selected from the group consisting of H and C 1 -C 7 alkyl, linear or branched;
m is an integer ranging from 1 to about 5;
n is an integer ranging from 2 to about 30;
o is an integer ranging from 0 to about 10;
M + is a metal or pseudo metal ion or H + .
(iii) stabilizing agent;
(iv) complexing agent; and
(v) reducing agent.
[0048] This invention relates to a method for depositing an electroless metal or metal alloy on a substrate for substantially avoiding co-deposition of non-metallic particles comprising, plating the substrate with metal or metal alloy while rendering an anionic character to either or both of the nonmetallic particles and the plating surface of the substrate in an autocatalytic plating bath, the plating bath having at least one reaction product additive from a mixture produced from the sulfation and esterification of a fatty acid or mixtures and salts thereof.
[0049] This method further relates to a method for fabricating a rigid memory disk comprising, depositing an electroless nickel or nickel alloy coating on a substrate substantially avoiding co-deposition of non-metallic particles, plating the substrate with nickel or nickel alloy while rendering the ionic character of the non-metallic particles and the surface of the plated substrate anionic whereby they repel one another in an autocatalytic plating bath, the plating bath having at least one reaction product additive from a mixture produced from the sulfation and esterification of a fatty acid or mixtures and salts thereof.
[0050] This invention also relates to an autocatalytic plated metal or metal alloy coated substrate substantially free of non-metallic particles prepared by a process comprising: plating a ground substrate with metal or metal alloy in an autocatalytic plating bath containing non-metallic particles and at least one reaction product additive from a mixture produced from the sulfation and esterification of a fatty acid or mixtures and salts thereof; rendering the non-metallic particles anionic to substantially inhibit deposition of the non-metallic particulates within the coating of the substrate; whereby a level, essentially non-metallic, asperity-free, coated substrate being prepared; the coated surface of substrate having an average roughness of about 21 nm; the coated substrate being used for magnetic media applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] Other features of the invention will be apparent and pointed out below. The descriptions are not considered limiting:
[0052] FIG. 1 . Flow Chart of Rigid Memory Disk Production;
[0053] FIG. 2 . Depiction of EN Coating on Al Substrate Plated from a Non-Contaminated, High-P, EN Bath. The Bath did not contain any Additive;
[0054] FIG. 3 . Depiction of EN Coating on Al Substrate Plated from a High-P EN Bath that was Intentionally Contaminated with 200 nm Plastic Particles. The Bath did not contain any Additive.
[0055] FIG. 4 . Depiction of EN Coating on Al Substrate Plated from a High-P EN bath that was Intentionally Contaminated with 200 nm Plastic Particles and the Additive of the Present Invention (Example 1);
[0056] FIG. 5 . Polysulfone Particle Embedded in Electroless Nickel Coating;
[0057] FIG. 6 . Mixture Separation of the Sulfated, Fatty Acid Ester (Additive) by Ion Chromatography Showing Retention Time on the Column in Minutes;
[0058] FIG. 7 . Ion Chromatography (time-of-flight) Mass Spectrometry (IC-MS) spectrum of certain fractions contained in additive mixture;
[0059] FIG. 8 . Castor oil is the only known, natural source of ricinoleic fatty acid.
[0060] FIG. 9 . Averages and Ranges of Values from Table 4.
DETAILED DESCRIPTION OF THE INVENTION
[0061] The invention significantly improves eliminating at least one problem encountered in the production of rigid memory disks (RMDs, e.g. magnetic storage media for hard disk drives). Today's hard disk drives are manufactured with “fly heights” of approximately 30 nm, i.e., the distance between the read/write head and the spinning, magnetic, hard disk. During manufacture of these disks, an aluminum substrate is plated with an electroless nickel alloy (NiP) which serves as the underlayer for the magnetic media layers.
[0062] Electroless nickel plating compositions for applying the nickel coatings are well known in the art and plating processes and compositions are described in numerous publications such as U.S. Pat. Nos. 2,935,425; 3,338,726; 3,597,266; 3,717,482; 3,915,716; 4,467,067; 4,466,233 and 4,780,342.
[0063] In general, NiP deposition solutions comprise at least four ingredients dissolved in a solvent, typically water. They are (1) a source of the nickel ions, (2) a reducing agent, (3) an acid or hydroxide pH adjuster to provide the required pH and (4) a complexing agent for metal ions sufficient to prevent their precipitation in solution. A large number of suitable complexing agents for NiP solutions are described in the above noted publications. It will be appreciated by those skilled in the art that the nickel, or other metal being applied, is usually in the form of an alloy with the other materials present in the bath. Thus, if hypophosphite is used as the reducing agent, the deposit will contain nickel and phosphorus. Similarly, if an amine borane is employed, the deposit will contain nickel and boron as shown in U.S. Pat. No. 3,953,654, supra. Thus, use of the term nickel includes the other elements normally deposited therewith.
[0064] The nickel ion may be provided by the use of any soluble salt such as nickel sulfate, nickel chloride, nickel acetate, nickel methyl sulfonate and mixtures thereof. The concentration of the nickel in solution may vary widely and is about 0.1 to 60 g/l, preferably about 2 to 50 g/l, e.g., 4 to 10 g/l.
[0065] The reducing agent, especially for memory disks, is usually the hypophosphite ion supplied to the bath by any suitable source such as sodium, potassium, ammonium and nickel hypophosphite. Other reducing agents such as amine boranes, borohydrides and hydrazine may also suitably be employed. The concentration of the reducing agent is generally in excess of the amount sufficient to reduce the nickel in the bath.
[0066] The baths may be acid, neutral or alkaline and the acid or alkaline pH adjustor may be selected from a wide range of materials such as ammonium hydroxide, sodium hydroxide, hydrochloric acid and the like. The pH of the bath may range from about 2 to 12, with acid baths being preferred. A pH range of 4 to 5, e.g., 4.3 to 4.6, being preferred.
[0067] The complexing agent may be selected from a wide variety of materials such as those containing anions such as acetate, citrate, glycollate, lactate, malate, succinate, pyrophosphate and the like, with mixtures thereof being suitable. Ranges for the complexing agent, based on the anion, may vary widely, for example, about 1 to 300 g/L, preferably about 5 to 50 g/l.
[0068] The electroless nickel plating baths may also contain other ingredients known in the art such as buffering agents, bath stabilizers, rate promoters, brighteners, etc. Stabilizers such as compounds containing lead, antimony, bismuth, mercury, tin, selenium, sulfur, and oxy compounds such as iodate may be employed.
[0069] A suitable plating composition may be formed by dissolving the ingredients in water and adjusting the pH to the desired range.
[0070] The zinc coated aluminum part pay be plated to the desired thickness and deposit quantity by immersing the part in the nickel plating bath which is maintained over a temperature range of about 30 to 100° C., e.g., boiling, preferably 82 to 93° C. A thickness up to 50 microns, or higher may be employed, with a range of about 6 to 14 microns being used for most applications.
[0071] It will be appreciated by those skilled in the art that the rate of plating may be influenced by many factors including (1) pH of the plating solution, (2) concentration of reductant, (3) temperature of the plating bath, (4) concentration of soluble nickel, (5) ratio of volume of bath to the are plated, (6) presence of soluble fluoride salts (rate promoters) and (7) the method and design of solution agitation, and that the above parameters are only provided to give general guidance for practicing the invention.
[0072] A high phosphorus NiP alloy is herein defined as a metallic coating containing less than 90% Ni and more than 10% P. (However, the invention is not limited to NiP coatings of this composition only. Coatings with phosphorus contents ranging from 0 to 15% should also benefit equally well.) A nickel-phosphorus (NiP) alloy containing more than about 10.5% phosphorus is known as a high phosphorous NiP coating and is paramagnetic (non-magnetic) as plated. During the plating operation, circular disks of ground aluminum are racked (mounted) on spindles. These spindles are typically constructed from a chemically inert plastic such as polyvinylidene fluoride (PVDF) or polytetrafluoroethylene (PTFE), and they are mounted on a mandrel. The Al disks are kept separated from one another by groves on the spindles. To keep the disks into their respective groves and prevent them from jumping out of their grove and “mating” with the next disk, a long polysulfone rod is inserted between the spindle and the center hole of the Al disk. (This rod eliminates the possibility of the two adjacent disks from coupling and preventing access of the chemistry to both sides of every disk.) Thus, there is intimate contact, by nature of the racking operation, between the center edges of the aluminum disks and the polysulfone (PSU) rod. Due to this contact, and the continuous revolving motion of the spindle on its own axis, the orbital axis of the mandrel and the side-to-side movement of the disks due to rapid, laminar fluid flow of the EN chemistry within the plating tank, plastic particles of PSU can be abraded off the polysulfone rod or the PVDF spindle.
[0073] These plastic particles are now free floating in the EN plating solution and can approach and touch the plating surfaces of the substrate. If the particles maintain contact with the surface of the disk long enough they may be plated into the NiP alloy. If this occurs, it causes entire loads of parts to be reduced to scrap. The incorporated particles are known to render the RMD vulnerable to “head crashes” and unreliable data retrieval. An example of an embedded polysulfone particle is shown in FIG. 5 . Preventing the inclusion of these plastic particles and other forms of minute contamination into the EN coating, is of absolute concern to hard disk substrate manufacturers. A particular additive discussed herein (a sulfated fatty acid ester) has been found to substantially avoid this co-deposition (incorporation or encapsulation) of plastic particles into EN coatings.
[0074] The additives according to the present invention have particular ionic attributes. They have a zeta potential of less than −30 mV, preferably less than −40 mV, and alternatively less than −50 mV. The reason for this is the mode of action according to the present invention. As the scale of the foreign object to be excluded from the coating becomes ever smaller, the preferred zeta potential will become increasingly more negative. Surfactants according to the present invention have ionic attributes different from that of the additive.
[0075] It has been found that the use of this additive in electroless nickel (EN) plating yields a highly beneficial result for the rigid memory disk (RMD) industry. The benefit provided is two-fold: (1) it has been demonstrated to prevent so-called, inclusion plating defects by rejecting plastic particulates (and possible other foreign particles) in the plating bath from being co-deposited into the EN alloy and (2) it is believed to have a leveling effect on the deposited layer.
[0076] This additive is the reaction product obtained from the sulfulation of butyl oleate. The butyl oleate is itself a reaction product from the esterification of a naturally occurring fatty acid, i.e., from castor oil. For simplicity, the additive will herein be referred to as sulfated, butyl oleate or more generally, as a sulfated fatty acid ester. This additive is actually a complex mixture as it is derived from a natural oil that is itself a mixture of saturated and unsaturated fatty acids and the mixture is very difficult to purify into a single, pure compound. This additive has been demonstrated to provide the benefits described above at a concentration range between 0.5 and 30 ppm and the most preferred concentration is from 1 to 10 ppm. See FIGS. 2 , 3 and 4 , the legends for which are self-explanatory.
[0077] The additive of this invention is a complex mixture of different esterified and sulfated, long chain (mostly C16 and C18) fatty acids. At least 15 components have been identified in the additive. Two such components that have structures consistent with the MS data are:
[0000]
[0000] wherein R 2 is selected from the group consisting of H and C 1 -C 7 alkyl, linear or branched, and M + is a metal or pseudo metal ion or H + .
[0078] In FIG. 6 , a series of peaks eluted off a liquid chromatography column at different retention times is shown. Each peak is associated with a different, “pure” compound within the mixture. To further characterize this mixture, these eluted compounds were subsequently ionized and introduced into a Mass Spectrometer to determine and their specific molecular weights. This technique of chemical analysis is known as Ion Chromatography (time-of-flight) Mass Spectrometry (IC-TOF-MS). From an interpretation on the data using this method ( FIG. 7 ) various chemical species in the additive mixture were identified. The substances found in the analysis include unsaturated and saturated sulfo-oxy-fatty acids and esters thereof (most probably butyl-esters), unsaturated and saturated hydroxy-fatty acids and esters thereof (most probably butyl-esters), unsaturated and saturated fatty acids and esters thereof (most probably butyl-esters), alkyl ether of hydroxyl-fatty acid-ester. Thus, the additive is a complex mixture of oils, fatty acid (or carboxylated) oils and sulfated/sulfonated fatty acid oils, Furthermore, the signature of the components from the IC-TOF-MS spectra highly suggest the starting fatty acid was castor oil. The primary fatty acid in castor oil is ricinoleic acid. It is also the only known, natural source this fatty acid (see FIG. 8 ). The complexity of a sulfated fatty acid (or its esters) is further described in U.S. Pat. Nos. 2,743,288; 4,086,256; 4,226,796; 4,261,916; British Patent No. 999,300 and the Encyclopedia of Chemical Technology (Kirk-Othmer, Encyclopedia of Chemical Technology, Fourth Ed. p 308-309).
[0079] The IC-MS (Ion Chromatography-Mass Spectrum) shown in FIG. 6 for this additive is consistent with a starting material of ricinoleic acid as the starting fatty acid. When this fatty acid is esterified and then sulfated, a complex mixture of components can be expected 1 . Ricinoleic acid is found naturally in castor oil. This oil is believed to be the only naturally occurring source of ricinoleic acid. At the present time, it is not know which fraction (or fractions) of the parent additive is responsible for the benefit effected in the EN bath, or whether it is the entire mixture itself. Further testing will be done with related materials to help identify the mechanism. At the present time, it is believed that a high zeta potential is at the crux of the invention.
[0080] Zeta potential relates to the ionic charge (sign) and magnitude of a surface in a liquid medium. Negatively charged species are referred to as anionic. Positively charged species are referred to as cationic. Zero charged species are referred to as non-ionic and there is another class, which has both a positive center of charge and a negative center of charge. These doubly charged species are called amphoteric or zwitterions.
[0081] It is well known that species having the same charge on them are electrostatically repelled from each other and those of opposite charge are attracted. In the EN plating bath, chemical reduction occurs at the plating surface. This process creates a negative charge on that surface. Additionally, if the additive introduced into the EN solution adsorbs to the metal surface, it will become further negative charged.
[0082] The additive of this invention has a zeta potential less than or equal to −40 mV. This classifies it as an anionic species with a fairly strong negative charge. Zeta potential can be measured using a NanoSizer ZS from Malvern. Having a high zeta potential on the particles as induced by the additive is believed to gives rise to its effectiveness for enhancing the quality of the deposited metal.
[0083] Zeta potential has to do with how large and how quickly the electrical potential at the surface of a substrate or particle changes over distance between that surface and the liquid medium it touches. This property influences the ability of particles to coalesce or avoid each other in that particular system. As a result, the zeta potential is a function of several parameters, some of which are temperature, pH, conductivity, solution viscosity, particle size, concentration, sample preparation and sample measurement history. For this reason, a standardized method of measuring this property for comparing one surfactant or additive to another is necessary.
[0084] The zeta potentials reported for the additives in these examples were measured with a Malvern NanoSizer ZS in the following way: A stock solution electrolyte was prepared by adding 5 ml of the High-Phosphorus, electroless nickel bath at 2.5 MTOs (metal turnovers) to 1 liter of water. The resulting electrolyte had conductivity of 1.5 milli-Siemens and a pH of approximately 4.8. A test sample was then prepared by adding 1 ml of a 1 g/l aqueous solution of the test additive to 9 ml of the stock electrolyte, thus producing a 100 ppm solution. The 10 ml mixture was hand shaken in a 15 ml plastic vial and introduced into a disposable, 1 ml zeta cell as supplied by Malvern. Three aliquots of the 100 ppm additive test solution, each of approximately 3 ml, were successively passed through a 0.02 micron syringe filter (ANOTOP 6908-2002 aluminum oxide membrane) and through the flow through dip cell. After inspection, to ensure no bubbles were in the “u” tube, the zeta cell was placed into the NanoSizer ZS for measurement. The measurements were taken at 25° C. and the fluid viscosity is essentially that of water.
[0085] The measurement routine consisted of a subroutine of one particle size measurement, one zeta potential measurement and one 30 second pause which was repeated for two consecutive cycles. The particle size measured is that which is produced from the first zeta measurement cycle. The zeta potentials measured on the second run were selected for comparisons and are reported in the Table below. (Triton DF-16 and allyltriphenyl phosphonium bromide were not measured.)
[0000]
Zeta
Potential,
Additive
mV
Sulfated butyl oleate
−48.3
Ethomeen C25
−4.8
Petro Powder 22
−13.3
Plurafac C17
+11.5
Triton DF-20
−16.4
Mirataine JC-HA
−24.5
Chemeen C2
+29.4
[0086] Non-metallic particles which can be created in a plating bath due to mechanical abrasive action of plating fixtures and the articles being plated can become coated with the additive (or a component of the additive) which shrouds this particle with a negative charge. Since both the article being plated and the non-metallic particle are sufficiently negatively charged, these two solid bodies have a tendency to avoid each other. Also, because the number of non-metallic particles created over time may be small, only a small amount of the effective anionic species may be required. These negatively charged particles are repelled from the likewise negatively charged article being plated and remain in the bulk solution long enough for them to be completely transported out of the plating solution by solution turnover. They can then be removed from the plating solution downstream by filtration cartridges.
[0087] Because there are some unreacted oils in the additive, there is an upper limit to the useful concentration. At too high a concentration, gas pitting on the plating surface occurs. One such industrial trial wherein the additive concentration was 30 ppm, produced an unacceptable level of gas pits. The most effective concentration range is believed to be between 1 and 30 ppm. The most preferred is concentration is between 2 to 10 ppm of the sulfated, fatty acid which was commercially supplied at 65% solids. The other 35% being water.
EXAMPLES
[0088] The following experiments are considered to describe the invention but are viewed as non-limiting embodiments.
[0089] The compositions and process of the present invention will now be more fully illustrated by the following specific examples, which are illustrative and in no way limiting and wherein all parts and percentages are by weight and temperatures in degrees Celsius unless otherwise noted.
Example 1
[0090] 5056 aluminum alloy disks were double zincated and plated with ENP using the following procedure (a cold water rinse followed each of the steps):
(1) Immerse in an alkaline soak cleaner for 5 minutes at 60° C.; (2) Immerse in an acid cleaner for 2 minutes at 60° C.; (3) Immerse in 50% by volume HNO 3 for 1 minute at room temperature; (4) Immerse in an alkaline zincate solution for 35 seconds at room temperature; (5) Immerse in 50% by volume HNO 3 for 1 minute at room temperature; (6) Immerse in an alkaline zincate solution for 16 seconds at room temperature; (7) Immerse in EN plating without the additive for 110-120 minutes at 86° C., (pH 4.4-4.5).
Specific examples of pretreatment chemistry in steps (1) to (6) can be found in a standard metal finishing handbook. The EN bath contains nickel sulfate hexahydrate, sodium hypophosphite, and other ingredients as discussed above.
Example 2
[0098] Example 1 was repeated except that a reaction mixture derived from sulfating the butyl ester of castor oil was added at 10 ppm. No plastic particles were found in the nickel-phosphorus coating. The additive was added over the side of the plating tank to a commercial EN chemistry. It was found to produce a dramatic and beneficial property of excluding small particles in the deposited NiP alloy. This benefit is of significant value in applications where small particle incorporation is a major source of unacceptable defects, e.g. in rigid memory disks. In this application, all types of “foreign particles” are desired to be excluded from the deposited EN coating. In the particle use of this invention, these particles can include, but are not limited to, plastics such as polysulfone, polytetrafluoroethylene, poly(vinylidene fluoride), polypropylene; non-plastics such as, nickel orthophosphite, ferric or ferrous orthophosphate, dust particles, carbonaceous contaminants, etc. The reduction in these inclusions, specifically, polysulfone and fluorinated plastics is essentially complete. That is 100% exclusion of these types of particles. This was a requirement for this chemistry during the production trials where rigid memory disks were plated. In the event that even one plastic inclusion to the NiP alloy was found, the entire lot of plated aluminum substrates were scrapped and not processed any further.
Example 3
[0099] Example 1 was repeated except that a reaction mixture derived from sulfating the butyl ester of castor oil was added at 30 ppm. The plated aluminum disks had an unacceptable high amount of gas pits. Analysis for included particles was not done.
Example 4
[0100] An electroless nickel coating composition comprising nickel, a reducing agent, a complexing agent, a metallic stabilizer and a non-metallic, pre-aging salt may be improved by a chosen additive as a particle, co-deposition inhibitor, preferably in an amount from about 1 to about 10 milligrams per liter (mg/l). The non-metallic, pre-aging salt may or may not be added and the effectiveness of the invention is not compromised. This orthophosphate salt is a natural by-product of the chemical reduction process when hypophosphite is used as the reducing agent. The amount of this by-product in the EN bath is related to how long the bath has been used. This bath age is referred to in the plating industry as the number of metal turnovers or MTOs of the bath. When an electroless nickel bath is used, nickel salt and a reducing agent must be replenished as nickel is plated, so as to continue the effective use (or life) of the bath. When the amount of the nickel salt added back is equal to the initial amount of nickel contained in the original plating solution, the bath is said to have plated one metal turnover, MTO.
[0101] To test the effectiveness of various additives to be used as a particle, deposition inhibitors, an electroless nickel bath was used containing:
[0000]
TABLE 1
Composition of the Electroless Nickel Bath
Component
g/l
Nickel sulfate hexahydrate
22.4
(salt)
Sodium Orthophosphite
60.0
(pre-aging salt)
Lactic acid (90%)
14.4
(complexor/chelator)
Malic Acid
19.8
(complexor/chelator)
Succinic Acid
6.1
(complxor/chelator)
Sodium Hypophosphite Monohydrate
24.0
(reducing agent)
Lead Nitrate
0.00076
(stabilizer)
[0102] The bath pH was adjusted to 4.8 with ammonium hydroxide heated to 88° C. A ground aluminum disk of the type used in the manufacturing of rigid memory disks was used. It was first prepared by carefully cutting it into 12 pie-wedge pieces having essentially the same dimensions. All 12 pieces had a small ⅛ inch hole punched in them and were suspended from a plastic rod using a short piece of aluminum wire. These same 12 parts were then identically pretreated using a typical, double zincate process well known in the metal finishing industry. This process consists of immersing the parts in a mild alkaline soak cleaner, an acid cleaner, an alkaline zinc bath (first zincate), a nitric acid strip, and finally a second alkaline zinc bath (the second zincate). The parts were rinsed with running water after each pretreatment process step. After the final rinsing step the parts were placed into an electroless nickel bath.
[0103] Two liters of the EN bath shown in Table 1 were prepared and filtered through a 0.45 micron filter. Inside a laminar flow hood, 100 ml of the EN bath was poured off into a 100 ml graduated cylinder and placed in a water bath regulated at 88° C. This was the first control bath which contained no deliberately introduced polysulfone particles.
[0104] One milliliter of an aqueous dispersion of polysulfone (PSU) particles was added to the remaining 1900 ml of EN bath chemistry. The dispersion was a suspension of synthetically produced, 200 nanometer polysulfone particles. Thus, the remaining bath was deliberately contaminated with a material known to be incorporated in the EN deposit during the production of rigid memory disks.
[0105] One liter of the deliberately contaminated EN bath from above was portioned out into ten, 100 ml graduated cylinders. One additive was added to nine of ten test solutions. No additive was added to the tenth solution and this was the second control bath containing the synthetically produced PSU contamination particles. Nine additives were evaluated at a concentration level of 10 ppm. These are shown in Table 2 below:
[0000]
TABLE 2
Surfactants Tested in EN Bath Chemistry
PSU Particles
Example
Additive
Added
C1
None
No
C2
None
Yes
1
Reaction mixture of sulfated butyl oleate
Yes
(from castor oil)
2
Ethomeen C25
Yes
(Tert-amines of fatty acids)
3
Petro Powder 22
Yes
(Sodium alkyl naphthalene sulfonate)
4
Plurafac C-17
Yes
(Alcohols, C10-12, ethoxyl)
5
Triton DF-16
Yes
(Alcohols, C-8-C10, ethoxylated
propoxylated)
6
Triton DF-20
Yes
(Modified ethoxylate, acid form)
7
Allyltriphenyl phosphonium bromide
Yes
8
Mirataine JC HA
Yes
(Alkylaminopropionate)
9
Chemeen C2
Yes
(Ethoxylated coco amine)
[0106] All eleven test solutions were placed in a water bath regulated at 88° C. The aluminum parts pretreated as described above were then immersed in the test solution and plated for 15 minutes, rinsed, dried and examined by eye as well as 5,000× magnification using a SEM.
[0107] Under simple visual examination, the deposit plated from the bath of Example 1 was very noticeably brighter than all ten other deposits. The other ten deposits had a slight haze to them. Example deposit 1 had none.
[0108] Photomicrographs of the different, as-plated deposits (shown in FIGS. 2 , 3 , and 4 ) are magnified 5,000 times in a SEM and compared. Again, there was a striking difference noted for the deposit plated from the bath in Example 1 of Table 2. Compared to all other surfaces, this surface was remarkably free of tiny, circular asperities measuring approximately 1 μm in diameter. These asperities are believed to arise from encapsulated, particles of contamination. A rough counting of the number of asperities observed within 1,500 square μm area was made and the results are shown in Table 3:
[0000]
TABLE 3
Surface Asperities Counted in Plated Deposits per 1,500 μm 2
PSU
Particles
Ionic
Asperity
Sample
Additive
Added
Character
Count
1
Reaction mixture of
Yes
Anionic
12
sulfated butyl oleate
(from castor oil)
2
Ethomeen C25
Yes
Cationic
640
(Tert-amines of fatty
acids sulfonate)
3
Petro Powder 22
Yes
Anionic
560
(Sodium alkyl
naphthalene sulfonate)
4
Plurafac C-17
Yes
Non-ionic
800
(Alcohols, C10-12,
ethoxyl)
5
Triton DF-16
Yes
Non-ionic
640
(Alcohols, C8-C10,
ethoxylated
propoxylated)
6
Triton DF-20
Yes
Anionic
640
(Modified ethoxylate,
acid form)
7
Allyltriphenyl
Yes
Cationic
640
phosphonium bromide
8
Mirataine JC HA
Yes
Amphoteric
500
(Alkylaminopropionate)
9
Chemeen C2
Yes
Cationic
640
(Ethoxylated coco amine)
10
None
No
N/A
360
11
None
Yes
N/A
560
[0109] A significant difference is observed between sample 1 plated from the formulation containing the sulfated, fatty acid ester compared to all other samples, including the two controls, one of which had no PSU particles added to it (sample 10). Because the stock solution that all baths were plated from was only filtered through a 0.45 μm filter, the stock could have contained other none PSU particles. If this was the case, the additive in the bath used to plate sample 1 also prevented those particles from co-depositing.
[0110] Another distinction between sample 1 and all other samples can be made. The grooves from the preparative grinding of the aluminum substrate were much less pronounced in that deposit. That is, the surface of the deposit appears smoother for this sample than all of the others. This smoothness can be quantified by measuring the average roughness, Ra, for each of these coatings. Average roughness is a measure of the average distance between low points and high points on the surface of the sample over a given area of surface. The lower the Ra, the flatter the surface. Using interference microscopy, five roughness measurements for each of the eleven samples in Table 4 were recorded. The area examined on each sample measured 62.4 μm×62.4 μm area. The average roughness, Ra, was then calculated. The raw measurements are shown in the Table 4 and the average value is plotted graphically in FIG. 9 . This data shows that, in fact, the deposit of sample 1 is statistically flatter than both controls and the other eight samples as well.
[0000]
TABLE 4
Average Ra for 11 NiP Deposits
Ra (nm)
sample
1
2
3
4
5
Ø
1
19
20
20
22
22
21
2
30
30
34
43
31
34
3
32
34
34
34
39
35
4
47
39
40
39
47
42
5
33
42
38
32
48
39
6
36
38
36
41
35
37
7
33
37
36
44
48
40
8
36
36
35
35
37
36
9
37
37
43
46
45
42
10
26
38
28
31
30
31
11
36
32
32
33
33
33
[0111] As various changes could be made in the above without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The above cited references are hereby incorporated by reference.
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The present invention is directed to the fabrication of rigid memory disks, including a metal plating composition which impedes deposition of non-metallic particles during a plating process. The plating composition includes at least one sulfated fatty acid ester additive, or mixtures or salts thereof, of formula: wherein R1 is selected from the group consisting of OH, OCH2, OCH2CH3, C1-C7 alkyl, linear or branched; R2 selected from H and C1-C7 alkyl, linear or branched; m=1 to about 5; n=2 to about 30; o=0 to about 10; M+ is a metal or pseudo metal ion or H+. The additive has a zeta potential which impedes deposit of non-metallic particles. The invention is further directed to a method for electroless plating utilizing the additive composition in a bath with at least a stabilizing agent, complexing agent and reducing agent and source of metal ions.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of pending U.S. patent application Ser. No. 12/754,094, filed Apr. 5, 2010, and also claims the benefit of U.S. Provisional Application Ser. No. 61/295,653, filed Jan. 15, 2010, the entire disclosures of both of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to methods of forming enhanced-surface walls for use in apparatae (e.g., heat transfer devices, fluid-mixing devices, etc.) for performing a process, to enhanced-surface walls per se, and to various apparatae incorporating such enhanced-surface walls.
BACKGROUND ART
[0003] It is known to provide enhanced-surface walls for use in heat exchangers and fluid-mixing devices. Such walls typically have a plurality of characters impressed thereon to enhance the surface area, to improve fluid mixing, to promote turbulence, to break up the boundary layer adjacent the surface, to improve heat transfer, etc.
[0004] U.S. Pat. No. 5,052,476 A appears to disclose a heat transfer tube having U-shaped primary grooves, V-shaped secondary grooves, and pear-shaped tertiary grooves to increase turbulence and reflux efficiency. The tube is first formed as a plate, and is then rolled into a tube, after which its proximate ends are welded together. The depth of the secondary grooves is said to be 50-100% of the depth of the primary grooves.
[0005] U.S. Pat. No. 5,259,448 A appears to disclose a heat transfer tube having rectangularly-shaped main grooves and narrow secondary grooves that intersect the main grooves at an angle. The device appears to be formed flat, rolled or curled, and then welded. The depth of the narrow grooves is said to be 0.02 millimeters (mm). The depth of the main grooves is said to be 0.20-0.30 mm.
[0006] U.S. Pat. No. 5,332,034 A appears to disclose a heat exchanger tube having longitudinally-extending circumferentially-spaced ribs with parallel inclined notches to increase turbulence and to increase heat transfer performance.
[0007] U.S. Pat. No. 5,458,191 A appears to disclose a heat exchanger tube having circumferentially-spaced helically-wound ribs with parallel inclined notches.
[0008] U.S. Pat. No. 6,182,743 B1 appears to disclose a heat transfer tube with polyhedral arrays to enhance heat transfer characteristics. The polyhedral arrays may be applied to internal and external tube surfaces. This reference may teach the use of ribs, fins, coatings and inserts to break up the boundary layer.
[0009] U.S. Pat. No. 6,176,301 B1 appears to disclose a heat transfer tube with polyhedral arrays having crack-like cavities on at least two surfaces of the polyhedrons.
[0010] US 2005/0067156 A1 appears to disclose a heat transfer tube that is cold- or forge-welded, and that has dimpled patterns thereon of various shapes.
[0011] US 2005/0247380 A1 appears to disclose a heat transfer tube of tin-brass alloys to resist formicary (i.e., ant-like) corrosion.
[0012] US 2009/0008075 A1 appears to disclose a heat transfer tube having arrays of polyhedrons, with the second array being arranged at an angle with respect to the first.
[0013] U.S. Pat. No. 5,351,397 A appears to disclose a roll-formed nucleate boiling pate having a first pattern of grooves separated by ridges, and a second pattern of more-shallow groves machined into the ridges. The second pattern depth is said to be about 10-50% of the depth of the first pattern.
[0014] U.S. Pat. No. 7,032,654 B2 appears to disclose a heat exchanger having fins with enhanced-surfaces, and with holes in the fins.
[0015] U.S. Pat. No. 4,663,243 A appears to disclose a heat exchanger surface having flame-sprayed ferrous alloy enhanced boiling surfaces.
[0016] Finally, U.S. Pat. No. 4,753,849 appears to disclose a heat exchanger tube with a porous coating to enhanced heat transfer.
DISCLOSURE OF THE INVENTION
[0017] With parenthetical reference to the corresponding parts, portions or surfaces of one or more of the disclosed embodiments, merely for purposes of illustration and not by way of limitation, the present invention broadly provides: (1) improved methods of forming enhanced-surface walls for use in apparatae (e.g., heat transfer devices, fluid mixing devices, etc.) for performing a process, (2) to enhanced-surface walls per se, and (3) to various apparatae incorporating such enhanced-surface walls.
[0018] In one aspect, the invention provides an improved method of forming an enhanced-surface wall ( 20 ) for use in an apparatus for performing a process, comprising the steps of: providing a length of material ( 21 ) having opposite initial surfaces ( 21 a , 21 b ), the material having a longitudinal centerline (x-x) positioned substantially midway between the initial surfaces, the material having an initial transverse dimension measured from the centerline to a point on either of the initial surfaces located farthest away from the centerline, each of the initial surfaces having a initial surface density, the surface density being defined as the number of characters on an surface per unit of projected surface area; impressing secondary patterns ( 23 a , 23 b ) having secondary pattern surface densities onto each of the initial surfaces to distort the material and to increase the surface densities on each of the surfaces and to increase the transverse dimension of the material from the centerline to the farthest point of such distorted material; and impressing primary patterns ( 25 a , 25 b ) having primary pattern surface densities onto each of such distorted surfaces to further distort the material and to further increase the surface densities on each of the surfaces; thereby to provide an enhanced-surface wall for use in an apparatus for performing a process.
[0019] Each secondary pattern surface density may be greater than each primary pattern surface density.
[0020] The step of impressing the secondary patterns onto each of the initial surfaces may include the additional step of: cold-working the material.
[0021] The step of impressing the primary patterns onto each of distorted surfaces may include the additional step of: cold-working the material.
[0022] The secondary patterns may be the same.
[0023] The secondary patterns may be shifted relative to one another such that a maximum dimension from the centerline to one distorted surface will correspond to a minimum dimension from the centerline to the other distorted surface.
[0024] The step of impressing the secondary patterns onto the material may increase the maximum transverse dimension of the material from the centerline to the farthest point of the distorted material of up to 135% of the maximum transverse dimension from the centerline to the farthest point on the initial surface.
[0025] The step of impressing the secondary patterns onto the material may increase the maximum transverse dimension of the material from the centerline to the farthest point of the distorted material of up to 150% of the maximum transverse dimension from the centerline to the farthest point on the initial surface.
[0026] The step of impressing the secondary patterns onto the material may increase the maximum transverse dimension of the material from the centerline to the farthest point of the distorted material of up to 300% of the maximum transverse dimension from the centerline to the farthest point on the initial surface.
[0027] The step of impressing the secondary patterns onto the material may increase the maximum transverse dimension of the material from the centerline to the farthest point of the distorted material of up to 700% of the maximum transverse dimension from the centerline to the farthest point on the initial surface.
[0028] The step of impressing the secondary patterns onto the material may not reduce the minimum dimension of the material, when measured from any point on one of such distorted surfaces to the closest point on the opposite one of such distorted surfaces, below 95% of the minimum dimension from any point on one of the initial surfaces to the closest point on the opposite initial surface.
[0029] The step of impressing the secondary patterns onto the material may not reduce the minimum dimension of the material, when measured from any point on one of such distorted surfaces to the closest point on the opposite one of such distorted surfaces, below 50% of the minimum dimension from any point on one of the initial surfaces to the closest point on the opposite initial surface.
[0030] The primary patterns may be the same.
[0031] The primary patterns may be shifted relative to one another such that a maximum dimension from the centerline to one further-distorted surface will correspond to a minimum dimension from the centerline to the other further-distorted surface.
[0032] The step of impressing the primary patterns onto the material may not reduce the minimum dimension of the further-distorted material, when measured from the centerline to any point on either of the further-distorted surfaces, below 95% of the minimum dimension of the material, when measured from the centerline to either of the initial surfaces.
[0033] The step of impressing the primary patterns onto the material may not reduce the minimum dimension of the further-distorted material, when measured from the centerline to any point on either of the further-distorted surfaces, below 50% of the minimum dimension of the material, when measured from the centerline to either of the initial surfaces.
[0034] The step of impressing the primary patterns onto each of the surfaces may further increase the dimension from the centerline to the farthest point of the further-distorted material.
[0035] The opposite surfaces of the material may be initially planar.
[0036] The steps of impressing the patterns may include the steps of impressing the patterns by at least one of a rigidizing, stamping, rolling, pressing and embossing operation.
[0037] The method may further comprise the additional steps of: bending the enhanced-surface wall such that the proximate ends are positioned proximate to one another; and joining the proximate ends of the material together; thereby to form an enhanced-surface tube.
[0038] The step of joining the proximate ends of the material together may include the further step of: welding the proximate ends of the material to join them together.
[0039] The method may further comprise the additional step of: providing holes through the material.
[0040] The method may further comprise the additional step of: installing the enhanced-surface wall in a heat exchanger.
[0041] The method may further comprise the additional step of: installing the enhanced-surface wall in a fluid-handling apparatus.
[0042] In another aspect, the invention provides an enhanced-surface wall manufactured by the method defined by any of the foregoing steps.
[0043] The primary patterns may be directional or non-directional.
[0044] The secondary patterns may be directional or non-directional.
[0045] The wall may comply with at least one of the following ASME/ASTM designations: A249/A, A135, A370, A751, E213, E273, E309, E1806, A691, A139, A213, A214, A268, A 269, A270, A312, A334, A335, A498, A631, A671, A688, A691, A778, A299/A, A789, A789/A, A789/M, A790, A803, A480, A763, A941, A1016, A1012, A1047/A, A250, A771, A826, A851, B674, E112, A370, A999, E381, E426, E527, E340, A409, A358, A262, A240, A537, A530, A 435, A387, A299, A204, A20, A577, A578, A285, E165, A380, A262 and A179. The aggregate disclosure of each of these designations is hereby incorporated by reference.
[0046] The material may be homogeneous or non-homogeneous.
[0047] The material may be provided with a coating on at least a portion of one of the initial surfaces.
[0048] At least a portion of one of the initial surfaces may be chemically-treated.
[0049] In another aspect, the invention provides an improved heat transfer device that incorporates the improved enhanced-surface wall.
[0050] In another aspect, the invention provides an improved fluid-handling apparatus that incorporates the improved enhanced-surface wall.
[0051] In another aspect the invention provides an improved enhanced-surface wall ( 20 ) for use in an apparatus for performing a process, which wall comprises: a length of material ( 21 ) having opposite initial surfaces ( 21 a , 21 b ), the material having a longitudinal centerline (x-x) positioned substantially midway between the initial surfaces, the material having an initial transverse dimension measured from the centerline to a point on either of the initial surfaces located farthest away from the centerline, each of the initial surfaces having a initial surface density, the surface density being defined as the number of characters (including zero) on a surface per unit of projected surface area; secondary patterns ( 23 ) having secondary pattern surface densities impressed onto each of the initial surfaces, the secondary patterns distorting the material and increasing the surface densities on each of the surfaces and increasing the transverse dimension of the material from the centerline to the farthest point of such distorted material; and primary patterns ( 25 ) having primary pattern surface densities impressed onto each of such distorted surfaces and further distorting the material and further increasing the surface densities on each of the surfaces.
[0052] Each secondary pattern surface density may be greater than each primary pattern surface density.
[0053] The secondary patterns may be the same.
[0054] The secondary patterns may be shifted relative to one another such that a maximum dimension from the centerline to one distorted surface will correspond to a minimum dimension from the centerline to the other distorted surface.
[0055] The maximum transverse dimension of the material from the centerline to the farthest point of the distorted material may be less than 135% of the maximum transverse dimension from the centerline to the farthest point on the initial surface.
[0056] The maximum transverse dimension of the material from the centerline to the farthest point of the distorted material may be less than 150% of the maximum transverse dimension from the centerline to the farthest point on the initial surface.
[0057] The maximum transverse dimension of the material from the centerline to the farthest point of the distorted material may be less than 300% of the maximum transverse dimension from the centerline to the farthest point on the initial surface.
[0058] The maximum transverse dimension of the material from the centerline to the farthest point of the distorted material may be less than 700% of the maximum transverse dimension from the centerline to the farthest point on the initial surface.
[0059] The minimum dimension of the material, when measured from any point on one of such distorted surfaces to the closest point on the opposite one of such distorted surfaces, is at least 95% of the minimum dimension from any point on one of the initial surfaces to the closest point on the opposite initial surface.
[0060] The minimum dimension of the material, when measured from any point on one of such distorted surfaces to the closest point on the opposite one of such distorted surfaces, may be at least 50% of the minimum dimension from any point on one of the initial surfaces to the closest point on the opposite initial surface.
[0061] The primary patterns may be the same or different.
[0062] The primary patterns may be shifted relative to one another such that a maximum dimension from the centerline to one further-distorted surface will correspond to a minimum dimension from the centerline to the other further-distorted surface.
[0063] The minimum dimension of the further-distorted material, when measured from the centerline to any point on either of the further-distorted surfaces, may be at least 95% of the minimum dimension of the material, when measured from the centerline to either of the initial surfaces.
[0064] The minimum dimension of the further-distorted material, when measured from the centerline to any point on either of the further-distorted surfaces, may be at least 50% of the minimum dimension of the material, when measured from the centerline to either of the initial surfaces.
[0065] The impressed primary patterns may further increase the dimension from the centerline to the farthest point of the further-distorted material.
[0066] Accordingly, one object is to provide improved methods of forming enhanced-surface walls for use in an apparatus for performing a process.
[0067] Another object is to provide improved enhanced-surface walls.
[0068] Still another object is to provide an improved apparatus that incorporates an improved enhanced-surface wall.
[0069] These and other objects and advantages will become apparent from the foregoing and ongoing written specification, the drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0070] FIG. 1A is a schematic top plan view of a length of material showing the Secondary 1 and Primary 1 patterns being impressed thereon.
[0071] FIG. 1B is a side elevation of the structure schematically shown in FIG. 1A .
[0072] FIG. 2A is an enlarged top plan view of the Secondary 1 pattern, as shown in FIGS. 1A-1 B, impressed into the material.
[0073] FIG. 2B is an enlarged top plan view of the Primary 1 pattern impressed into a sheet of supplied material, the scale of FIG. 2B being the same as the scale of FIG. 2A
[0074] FIG. 2C is a top plan view of the superimposed Primary 1 and Secondary 1 patterns, as shown in FIGS. 1A-1B , impressed into the material, the scale of FIG. 2C being the same as the scale of FIGS. 2A-2B .
[0075] FIG. 3A is a greatly-enlarged fragmentary transverse vertical sectional view of the material prior to impressing the Secondary 1 patterns thereon, this view being taken generally on line 3 A- 3 A of FIG. 1A .
[0076] FIG. 3B is a greatly-enlarged fragmentary transverse vertical sectional view thereof, taken generally on line 3 B- 3 B of FIG. 2A , showing the Secondary 1 patterns impressed onto the material.
[0077] FIG. 3C is a greatly-enlarged fragmentary transverse sectional view, taken generally on line 3 C- 3 C of FIG. 2B , showing the Primary 1 patterns impressed into the material.
[0078] FIG. 3D is a greatly-enlarged fragmentary transverse sectional view thereof, taken generally on line 3 D- 3 D of FIG. 2C , showing the Primary 1 and Secondary 1 patterns impressed into the material.
[0079] FIG. 4 is a schematic transverse vertical sectional view thereof, showing how the Secondary 1 patterns are impressed into the material.
[0080] FIG. 5A is a schematic view, showing how the point-to-point wall thickness of a plain sheet is measured.
[0081] FIG. 5B is a schematic view, showing how the point-to-point wall thickness of the material is measured after the Secondary 1 patterns have been impressed therein.
[0082] FIG. 5C is a schematic view showing how the point-to-point wall thickness of the Primary 1 patterns is measured.
[0083] FIG. 5D is a schematic view showing how the point-to-point wall thickness of the finished enhanced-surface material is measured, this material having the super imposed Primary 1 and Secondary 1 patterns impressed thereon.
[0084] FIG. 6A is a schematic view showing how the area thickness of a plain sheet is measured.
[0085] FIG. 6B is a schematic view showing how the area wall thickness is measured after the Secondary 1 patterns have been impressed thereon.
[0086] FIG. 6C is a schematic view showing how the area wall thickness is measured after the Primary 1 patterns have been impressed thereon.
[0087] FIG. 6D is a schematic view showing how the area wall thickness of an enhanced-surface wall is measured after the Primary 1 and Secondary 1 patterns have been impressed thereon.
[0088] FIG. 7A is a top plan view showing another primary pattern, designated the Primary 2 pattern, impressed on a sheet.
[0089] FIG. 7B is a fragmentary transverse vertical sectional view thereof taken on line 7 B- 7 B of FIG. 7A .
[0090] FIG. 7C is a fragmentary transverse horizontal sectional view thereof, taken generally on line 7 C- 7 C of FIG. 7A .
[0091] FIG. 8A is a top plan view of a third primary pattern, designated the Primary 3 pattern, impressed on a sheet of material.
[0092] FIG. 8B is a fragmentary transverse vertical sectional view thereof, taken generally on line 8 B- 8 B of FIG. 8A .
[0093] FIG. 8C is a fragmentary transverse horizontal sectional view thereof, taken generally on line 8 C- 8 C of FIG. 8A .
[0094] FIG. 9A is a top plan view of another primary pattern, designated the Primary 4 pattern, impressed into a sheet of material, this pattern having a character surface density of 0.5.
[0095] FIG. 9B is a view similar to FIG. 9A , but showing a variant form of the Primary 4 pattern having a character surface density of 1.0.
[0096] FIG. 9C is a view similar to FIGS. 9A and 9B , but showing another variant form of the Primary 4 pattern having a character surface density of 2.0.
[0097] FIG. 10A is a top plan view of another primary pattern, designated the Primary 5 pattern, impressed on a sheet of material.
[0098] FIG. 10B is a fragmentary transverse vertical sectional view thereof, taken generally on line 10 B- 10 B of FIG. 10A .
[0099] FIG. 10C is a fragmentary transverse horizontal sectional view thereof, taken generally on line 10 C- 10 C of FIG. 10A .
[0100] FIG. 11A is a top plan view of another secondary pattern, designated the Secondary 2 pattern, impressed into the material, this view showing the individual characters as being somewhat oval-shaped.
[0101] FIG. 11B is a fragmentary transverse vertical sectional view thereof, taken generally on line 11 B- 11 B of FIG. 11A .
[0102] FIG. 11C is a fragmentary transverse horizontal sectional view thereof, taken generally on line 11 C- 11 C of FIG. 11A .
[0103] FIG. 12A is a top plan view of another secondary pattern, designated the Secondary 3 pattern, impressed onto a length of material, this view showing the individual characters as being somewhat lemon-shaped.
[0104] FIG. 12B is a fragmentary transverse vertical sectional view thereof, taken generally on line 12 B- 12 B of FIG. 12A .
[0105] FIG. 12C is a fragmentary transverse horizontal sectional view thereof, taken generally on line 12 C- 12 C of FIG. 12A .
[0106] FIG. 13A is a top plan view of another primary pattern, designated the Primary 6 pattern, impressed into a length of material.
[0107] FIG. 13B is a fragmentary transverse vertical sectional view thereof, taken generally on line 13 B- 13 B of FIG. 13A .
[0108] FIG. 14A is still another example of a criss-crossed directional primary pattern, designated the Primary 7 pattern, impressed on a length of material, this pattern being directional in both the longitudinal and transverse directions.
[0109] FIG. 14B is fragmentary transverse vertical sectional view thereof, taken generally on line 14 B- 14 B of FIG. 14A .
[0110] FIG. 14C is a fragmentary transverse horizontal sectional view thereof, taken generally on line 14 C- 14 C of FIG. 14A .
[0111] FIG. 15A is a fragmentary view of another pebble-like non-directional pattern, designated as Secondary 4 pattern, impressed on a length of material.
[0112] FIG. 15B is a fragmentary transverse vertical sectional view thereof, taken generally on line 15 B- 15 B of FIG. 15A .
[0113] FIG. 15C is a fragmentary transverse horizontal sectional view thereof, taken generally on line 15 C- 15 C of FIG. 15A .
[0114] FIG. 16A is a top plan view of yet another honeycomb-like non-directional pattern, designated Secondary 4 pattern, impressed on the length of material.
[0115] FIG. 16B is a fragmentary transverse vertical sectional view thereof, taken generally on line 16 B- 16 B of FIG. 15A .
[0116] FIG. 16C is a fragmentary transverse horizontal sectional view thereof, taken generally on line 16 C- 16 C of FIG. 16A .
[0117] FIG. 17 is a schematic view of one process for making enhanced-surface tubes.
[0118] FIG. 18A is a side elevation of a round tube having an optional coating on its outer surface.
[0119] FIG. 18B is a right end elevation of the round tube shown in FIG. 18A .
[0120] FIG. 18C is an enlarged detail view of the round tube, taken within the indicated circle in FIG. 18B , and particularly showing the coating on the outer surface of the tube.
[0121] FIG. 19A is an isometric view of a rectangular tube.
[0122] FIG. 19B is a fragmentary transverse vertical sectional view, taken generally on line 19 B- 19 B of FIG. 19A , of the rectangular tube.
[0123] FIG. 19C is an enlarged detail view of a portion of the wall of the rectangular tube, this view being taken within the indicated circle in FIG. 19B .
[0124] FIG. 20A is a side elevation of a U-shaped tube.
[0125] FIG. 20B is a slightly-enlarged fragmentary transverse vertical sectional view thereof, taken generally on line 20 B- 20 B of FIG. 20A .
[0126] FIG. 20C is a further-enlarged detail view of a portion of the tube wall, this view being taken within the indicated circle of FIG. 20B .
[0127] FIG. 21A is a side elevation of a helically-wound coil formed of a round tube having enhanced inner and outer surfaces.
[0128] FIG. 21B is a top plan view of the coil shown in FIG. 21A .
[0129] FIG. 21C is an enlarged fragmentary vertical sectional view thereof, taken generally on line 21 C- 21 C of FIG. 21A , showing the tube in the coil.
[0130] FIG. 21D is a further-enlarged detail view, taken within the indicated circle of FIG. 21C , showing of a portion of the tube wall.
[0131] FIG. 22 is a schematic view of one process for making an enhanced-surface fin.
[0132] FIG. 23A is a front elevation of a first enhanced-surface fin having primary and secondary patterns impressed thereon, and having cooler tube and flow-through openings.
[0133] FIG. 23B is a fragmentary vertical sectional view thereof, taken generally on line 23 B- 23 B of FIG. 23A .
[0134] FIG. 24A is a front elevation of a second enhanced-surface fin having primary and secondary patterns impressed thereon, and having cooler tube and flow-through openings.
[0135] FIG. 24B is a fragmentary vertical sectional view thereof, taken generally on line 24 B- 24 B of FIG. 24A .
[0136] FIG. 25A is a front elevation of a third enhanced-surface fin having cooler tube openings and smaller flow-through openings.
[0137] FIG. 25B is a front elevation of a fourth enhanced-surface fin having cooler tube openings and intermediate flow-through openings.
[0138] FIG. 25C is a front elevation of a fifth enhanced-surface fin having cooler tube openings and larger flow-through openings.
[0139] FIG. 25D is a front elevation of a sixth enhanced-surface fin having cooler tube openings and one combination of smaller, intermediate and larger flow-through openings.
[0140] FIG. 25E is a front elevation of a seventh enhanced-surface fin having cooler tube openings and another combination of smaller, intermediate and larger flow-through openings.
[0141] FIG. 26 is a schematic view of an improved heat exchanger having an enhanced-surface heat transfer tube therewithin.
[0142] FIG. 27A is a bottom plan view of an improved fluid cooler having enhanced-surface tubes therewithin.
[0143] FIG. 27B is a fragmentary horizontal sectional view thereof, taken generally on line 27 B- 27 B of FIG. 27A .
[0144] FIG. 27C is a side elevation of the improved cooler shown in FIG. 27A , with the cover in place.
[0145] FIG. 27D is a fragmentary vertical sectional view thereof, taken generally on line 27 D- 27 D of FIG. 27C , showing a bottom plan view of one of the fins.
[0146] FIG. 27E is an enlarged detail view of a portion of one of the fins, this view being taken within the indicated circle of FIG. 27D .
[0147] FIG. 28 is a schematic view of a fluid flow vessel incorporating enhanced surfaces therewithin.
[0148] FIG. 29A is a top plan view of a heat exchanger plate incorporating enhanced surfaces therewithin.
[0149] FIG. 29B is an enlarged detail view of a portion of the heat exchanger plate, this view being taken within the indicated circle in FIG. 29A .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0150] At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions or surfaces consistently throughout the several drawing figures, as such elements, portions or surfaces may be further described or explained by the entire written specification, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read (e.g., cross-hatching, arrangement of parts, proportion, degree, etc.) together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up” and “down”, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly” and “outwardly” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate. Unless otherwise indicated, all dimensions set forth in the present specification, and in the accompanying drawings, are expressed in inches.
[0151] Referring now to the drawings, and more particularly to FIGS. 1-3 thereof, the present invention broadly provides an improved method of forming an enhanced-surface wall 20 for use in an apparatus for performing a process. The apparatus may be a heat transfer device, a type of fluid mixing apparatus (either with or without a pertinent heat exchange function), or some other form of apparatus.
[0152] This application discloses multiple embodiments of enhanced-surface walls having various primary and/or secondary patterns. The first embodiment is illustrated in FIGS. 1A-6D , the second in FIGS. 7A-7C , the third in FIGS. 8A-8C , the fourth in FIGS. 9A-9C , the fifth in FIGS. 10A-10C , the sixth in FIGS. 11A-11C , the seventh in FIGS. 12A-12C , the eighth in FIGS. 13A-13B , the ninth in FIGS. 14A-14C , the tenth in FIGS. 15A-15C , and the eleventh in FIGS. 16A-16C . These various patterns may be used in various combinations with one another, and are not exhaustive of all patterns falling within the scope of the appended claims.
[0153] One process of making an enhanced-surface tube is schematically shown in FIG. 17 , and several variations of such tubes are depicted in FIGS. 18A-21D .
[0154] One process for making an enhanced-surface fin is schematically shown in FIG. 22 , and several variations of such fins are shown in FIGS. 23A-25E .
[0155] An improved heat exchanger incorporating the enhanced-surface tubes is schematically shown in FIG. 26 .
[0156] A cooler incorporating such enhanced-surface fins is depicted in FIGS. 27A-27E .
[0157] Another fluid flow vessel incorporated enhanced surfaces is depicted in FIG. 28 .
[0158] Finally, an improved plate having various enhanced surfaces is shown in FIGS. 29A-29B .
[0159] These various embodiments and applications will be described seriatim herebelow.
First Embodiment (FIGS. 1 A- 6 D)
[0160] The improved method broadly begins with providing a length of material, of which a fragmentary portion is generally indicated at 21 . This material may be a piece of plate-like stock, may be unrolled from a coil, or may have some other source or configuration. The material may be rectangular having planar upper and lower initial surfaces 21 a , 21 b , respectively, and may have a longitudinal transverse centerline x-x positioned substantially midway between these initial surfaces. As shown in FIG. 3A , the thickness of the material between initial surfaces 21 a - 21 b may be about 0.035 inches, and the nominal spacing from the centerline to either of the surfaces may therefore be about 0.0175 inches.
[0161] The leading edge of the material in this first embodiment is then passed rightwardly (in the direction of the indicated arrow in FIG. 1A ) between a pair of upper and lower first rolls or dies 22 a , 22 b , respectively, which impress the Secondary 1 patterns into the upper and lower surfaces, respectively, of the material. The upper and lower surfaces of the material after the Secondary 1 patterns have been impressed thereon are indicated at 23 a , 23 b respectively. The material is then translated rightwardly between a second pair of upper and lower rolls or dies 24 a , 24 b respectively, which impress Primary 1 patterns onto the upper and lower surfaces, respectively of the material.
[0162] FIGS. 2A and 3B show the shape and configuration of the material after the Secondary 1 patterns have been impressed thereon. The Secondary 1 patterns have the shape of an array of interlocking paving blocks when seen in top plan ( FIG. 2A ), but have undulating or sinusoidal shapes when seen in cross-section ( FIG. 3B ).
[0163] FIGS. 2B and 3C show the shape of the Primary 1 patterns if such patterns were impressed into a sheet of plain stock material, without the Secondary 1 patterns impressed thereon. As shown in FIGS. 2B and 3C , the Primary 1 patterns are in the form of a series of repeating step-like functions. In FIGS. 2B and 3C , the upper surface of the material is indicated at 25 a , and the lower surface thereof is indicated at 25 b.
[0164] Thus, the material exiting the second dies has the Primary 1 and Secondary 1 patterns superimposed and impressed thereon. These upper and lower surfaces of the material containing the superimposed Primary 1 and Secondary 1 patterns are indicated at 26 a , 26 b , respectively.
[0165] As shown in FIGS. 3A-3B , the step of impressing the Secondary 1 patterns onto the material increases the minimal initial area wall thickness of the material from about 0.035 inches to about 0.045 inches. As shown in FIGS. 3A and 3C , the step of impressing the Primary 1 patterns into the initially supplied material would increase the initial area wall thickness from about 0.035 inches to about 0.050 inches. However, as shown in FIG. 3D , when the Primary 1 patterns are superimposed on the Secondary 2 patterns, the thickness of the material, as distorted by the Secondary 1 patterns (i.e., 0.045 inches), is further distorted to a dimension of about 0.052 inches.
[0166] In the accompanying drawings, FIGS. 2A-2C are drawn to the same scale (as indicated by the 6.0×6.0 dimensions thereon), and are enlarged with respect to the structure shown in FIG. 1A . FIGS. 3A-3D are also drawn to the same scale, which is further-enlarged with respect to the scale of FIGS. 2A-2C , and is greatly enlarged with respect to the scale of FIGS. 1A-1B .
[0167] FIG. 4 shows how the Secondary 1 patterns are impressed into the material. To this end, the top and bottom rolls 22 a , 22 b impart the undulating sinusoidal Secondary 1 patterns that are vertically aligned with one another such that the peak of one is aligned with the valley of the other. The material 21 is only partially deformed by the two rolls. Thus, the material will have a series of dimple-like concavities indicated at 27 , separated by intermediate arcuate convexities, severally indicated at 28 . In an alternative process, the material could be fully deformed, or “coined”, between the upper and lower rolls.
[0168] In the preferred embodiment, the steps of impressing the primary and secondary patterns into the material has the effect of cold-working the material. However, in an alternative process, the material could be heated, and the process could include the step of hot-working the same. The secondary patterns may be the same, or may be different from one another. The step of impressing the secondary pattern onto the material increases the maximum transverse dimension of the material from the centerline to the farthest point of the distorted material of up to 135% in one case, 150% in another case, 300% in a third case, and 700% in a fourth case, of the maximum transverse dimension from the centerline to the farthest point of the initial surfaces. The steps of impressing the primary and secondary patterns into the material does not materially reduce the minimum dimension of the material, when measured from any point on one of the distorted surfaces to the closest point on the opposite one of the distorted surfaces, below 95% in one case, and 50% in a second case, of the minimum dimension from any point on one of the initial surfaces to the closed point on the opposite initial surface.
[0169] The primary patterns impressed into the opposite sides of the material may be the same, or may be different. The step of impressing the primary patterns into the material does not reduce the minimum dimension of the further-distorted material, when measured from the centerline to any point on either of the further-distorted surfaces, below 95% of the minimum dimension of the material, when measured from the centerline to either one of the initial surfaces.
[0170] The primary patterns impressed into the opposite sides of the material may be the same, or may be different. The step of impressing the primary patterns into the material does not reduce the minimum dimension of the further-distorted material, when measured from the centerline to any point on either of the further-distorted surfaces, below 50% of the minimum dimension of the material, when measured from the centerline to either one of the initial surfaces.
[0171] In one aspect, the step of impressing the primary patterns onto each of the surfaces may further increase the dimension from the centerline to the farthest point of the further-distorted material.
[0172] The initial surfaces may be planar or may be supplied with some pattern or patterns impressed thereon. The step of impressing the primary and secondary patterns onto the material may be by a rigidizing operation, a stamping operation, a rolling operation, a pressing operation, an embossing operation, or by some other type of process or operation. Similarly, the material may be supplied with cooler tube openings and/or with flow-through openings of whatever pattern is desired.
[0173] The method may further include the additional step of bending the enhanced-surface wall such that the proximate ends are positioned adjacent one another, and jointing the proximate ends of the material together, as by welding to form an enhanced-surface tube. The method may include the further step of providing holes through the material.
[0174] As indicated above, the enhanced-surface wall may be installed in heat exchanger, in some type of fluid-handling apparatus or in still other forms of apparatus as well.
[0175] The primary patterns may be directional or non-directional. The enhanced-surface wall complies with at least on of the following ASME/ASTM designations: A249/A, A135, A370, A751, E213, E273, E309, E1806, A691, A139, A213, A214, A268, A 269, A270, A312, A334, A335, A498, A631, A671, A688, A691, A778, A299/A, A789, A789/A, A789/M, A790, A803, A480, A763, A941, A1016, A1012, A1047/A, A250, A771, A826, A851, B674, E112, A370, A999, E381, E426, E527, E340, A409, A358, A262, A240, A537, A530, A 435, A387, A299, A204, A20, A577, A578, A285, E165, A380, A262 and A179. Each of the foregoing designations is hereby incorporated by reference.
[0176] The material may be provided with a coating (e.g., a plating, etc.) on at least a portion of one of its initial surfaces, or such initial surface(s) may be chemically treated (e.g., electro-polished, etc.). Such coating and/or chemical treatment may be applied before, during or after the formation of the enhanced surfaces thereon. As used herein, the term “portion” includes a range of from 0-100%.
[0177] The invention also includes an enhanced-surface wall formed by the forgoing method.
[0178] FIG. 5A-5D show how the point-to-point wall thickness is measured during various stages of the method. As used herein, the term “point-to-point wall thickness” means the thickness of the material from a point on one surface thereof to the closest point on the opposite surface thereof. Thus, FIG. 5A shows a micrometer as measuring the initial thickness between planar surfaces 21 a , 21 b . FIG. 5B shows the micrometer as measuring the wall thickness after the Secondary 1 patterns have been impressed thereon. This view schematically shows two measuring orientations, one being of the vertical thickness and the other being at an angle, such that the lesser of the two measured thicknesses may be used. FIG. 5C shows how the point-to-point wall thickness would be measured when the primary pattern is impressed into the material. Finally, FIG. 5D show the micrometer as measuring the point-to-point wall thickness of the material after the Primary 1 and Secondary 1 patterns have been impressed thereon. Here again, the lesser of the two measured thicknesses is used as the measure of the minimum wall thickness. These two illustrations of the orientation of the micrometer are not exhaustive of all possible orientations thereof.
[0179] FIG. 6A-6D shows how the area thickness of the material is measured at various stages during the performance of the method. The thickness is measured by measuring the peak-to-peak distance of the opposed surfaces, and, usually, by encompassing several peaks along each of the two surfaces. Thus, FIG. 6A shows the micrometer is measuring the thickness of the initially-supplied material having planar upper and lower surfaces 21 a , 21 b , respectively. Since these surfaces are planar, the micrometer can simply measure the distance therebetween. FIG. 6B shows the micrometer as measuring the thickness of the material after the Secondary 1 pattern has been impressed thereon. Note that the micrometer is measuring the peak-to-peak thickness of the amplitudes of both surfaces. FIG. 6C shows the micrometer as measuring the thickness of the material if the Primary 1 patterns were to be impressed on the initially-supplied material. In this view, the micrometer is again measuring the peak-to-peak thickness across multiple characters impressed on the surfaces. Finally, FIG. 6D shows the micrometer as measuring the wall thickness of the material after the Primary 1 and Secondary 1 patterns have been impressed thereon.
[0180] Because the “point-to-point wall thickness” means the thickness of the material fro a point on one surface thereof to the closest point on the opposite surface thereof, it is sometimes required to measure such dimension both vertically and at various angles to determine which is the minimum thickness. However, because the “area thickness” refers to a peak on one surface to a peak on the opposite surface dimension, this can usually be measured vertically. The “area thickness” preferably encompasses multiple peaks on each surface.
Second Embodiment (FIGS. 7 A- 7 C)
[0181] A second primary pattern, designated the Primary 2 pattern, is illustrated in FIGS. 7A-7C , and is generally indicated at 30 . This pattern somewhat resembles a raised honeycomb, and has an upper surface 31 a and a lower surface 31 b . This pattern is directional in the vertical direction, but non-directional in the horizontal direction. The vertical and horizontal transverse cross-sections are shown in FIGS. 7B-7C .
Third Embodiment (FIGS. 8 A- 8 C)
[0182] FIGS. 8A-8C show another furrow-like primary pattern, designated the Primary 3 pattern. This pattern is generally indicated at 32 . This pattern is directional in the vertical direction, but is non-directional in the horizontal direction. The vertical and horizontal transverse cross-sections are shown in FIGS. 8B-8C . This pattern has sinusoidal undulations, albeit of different periods, in each of the two orthogonal transverse directions on its upper and lower surfaces.
Fourth Embodiment (FIGS. 9 A- 9 C)
[0183] FIGS. 9A-9C show another secondary pattern designated the Secondary 2 pattern. This pattern comprises of a series of dimple-like indentations on one surface, and vertically-aligned convexities on the opposite surface. These dimples can be staggered or in-line, as desired. This pattern is generally indicated at 34 in FIG. 9A , and is shown as having an upper surface 35 a.
[0184] FIGS. 9B-9C show density variations on the pattern shown in FIG. 9A . In FIG. 9A , the pattern is indicated at 34 ′, and the upper surface is indicated at 35 a ′. The surface density of the dimple-like characters in pattern 34 shown in FIG. 9A is 0.5 of that for the modified pattern 34 ′ shown is in FIG. 9B , and 0.25 of that for the further-modified pattern 34 ″ shown in FIG. 9C . Thus, the surface density of the dimple-like characters in FIG. 9B is twice that shown in FIG. 9A . Similarly, surface density of the dimple-like characters in FIG. 9C is twice the surface density of the characters in FIG. 9B , and four times the surface density of the characters shown in FIG. 9A .
[0185] FIGS. 9A-9C are drawn to the same scale, as indicated by the 6.0×6.0 dimensions.
Fifth Embodiment (FIGS. 10 A- 10 C)
[0186] FIGS. 10A-10C show another chevron-like primary pattern designated the Primary 4 pattern. This pattern is non-directional in both the horizontal and vertical directions. The pattern is generally indicated at 36 , and has upper and lower surfaces 38 a , 38 b.
Sixth Embodiment (FIGS. 11 A- 11 C)
[0187] FIGS. 11A-11C show another form of secondary pattern designated the Secondary 2 pattern, impressed into the material. In this form, the individual dimples or characters are somewhat oval-shaped. Note that the period of the dimples is different in the two orthogonal directions, as shown in FIGS. 11B-11C . This pattern is generally indicated at 39 , and is shown as having upper and lower surfaces 40 a , 40 b , respectively.
Seventh Embodiment (FIGS. 12 A- 12 C)
[0188] FIGS. 12A-12C show still another type of secondary pattern, designated the Secondary 3 pattern. The dimples or characters of this pattern appear to be somewhat lemon-shaped. Here again, note that the periods of the patterns is different in each of the two orthogonal transverse directions, as shown in FIGS. 12B-12C . This pattern is generally indicated at 41 , and is shown as having upper and lower surfaces 42 a , 42 b , respectively.
Eighth Embodiment (FIGS. 13 A- 13 B)
[0189] FIGS. 13A-13B are used to illustrate a directional pattern, designated the Primary 6 pattern. This pattern is generally indicated at 43 , and is shown as having upper and lower surfaces 44 a , 44 b , respectively Note that the pattern appears to have a series of step functions on its opposite surfaces, as shown in FIG. 13B . Note also, and the characters are aligned such that each projection on one surface corresponds with an indentation on the other surface. This pattern is directional in the horizontal direction, but not in the vertical direction.
Ninth Embodiment (FIGS. 14 A- 14 C)
[0190] FIGS. 14A-14C show a criss-crossed pattern designated the Primary 7 pattern, impressed on the material. This pattern is generally indicated at 45 , and is shown as having an upper surface 46 a and a lower surface 46 b . This pattern is directional (i.e., not interrupted) in both the horizontal and vertical directions. Note that the period of the characters is the same in both orthogonal transverse directions.
Tenth Embodiment (FIGS. 15 A- 15 C)
[0191] FIGS. 15A-15C show an irregular pebble-like, albeit repeating, non-directional secondary pattern impressed on the material. This pattern is designated the Secondary 4 pattern. This pattern is generally indicated at 48 , and has upper and lower surfaces 49 a , 49 b , respectively. The cross-sections in the orthogonal axes are shown in FIGS. 15B-15C , respectively. In FIGS. 15B-15C , note that the indentation on one surface is vertically aligned with a projection on the other surface. This pattern is non-directional in the sense that the pattern is interrupted in each of the horizontal and vertical directions. As used herein, the term “directional” with respect to a pattern means that the lines of the pattern are continuous and not interrupted along a direction, whereas the term “non-directional” means that the lines of the pattern are interrupted along a direction, even though the pattern may repeat.
Eleventh Embodiment (FIGS. 16 A- 16 C)
[0192] FIGS. 16A-16C show still another honeycomb-like non-directional secondary pattern, designated the Secondary 5 pattern impressed on a material. This pattern is generally indicated at 50 , and is shown as having upper and lower surfaces 51 a , 51 b , respectively. This pattern is non-directional in the vertical and horizontal directions.
Method of Making an Enhanced-Surface Tube (FIG. 17)
[0193] FIG. 17 depicts one method of making a round tube having enhanced surfaces. According to this process, a coil 52 having the primary and secondary patterns (and, optionally, whatever cooler tube and flow-through openings are desired) is unwound. The leading edge of the material passes through a series of rollers and roller dies, severally indicated at 53 , within which the planar sheet material is rolled into a round tube with the two longitudinal edges being arranged closely adjacent, or, preferably, abutting, one another. The rolled tube is then passed through a preheating unit 54 and a welding unit 55 to weld the longitudinal edges together. The welded tube is then passed through a secondary heating unit 56 to anneal the weld and the material, and is then cooled in a cooling unit 58 . The cooled welded tube is then passed through a deburrer to smooth the weld edges, and is further advanced rightwardly by rollers 60 , 60 .
Round Tube (FIGS. 18A-18C)
[0194] Tubes may have many different shapes and cross-sections. FIGS. 18A-18C depict a length of welded round tube that may be manufactured by the process indicated in FIG. 17 . The tube, generally indicated at 62 , is shown as having primary and secondary patterns. As best shown in FIG. 18B , tube 62 has a thin-walled circular transverse cross-section.
[0195] The tube outer wall is also shown as having a coating 63 thereon. This coating may be a plating, or some other form of coating or lamination. This coating is optional and may be provided on any of the enhanced surfaces disclosed herein. The coating can be provided on the inner or outer surface of a tube, as desired.
Rectangular Tube (FIGS. 19A-19C)
[0196] As noted above, not all tubes have a round transverse cross-section. Some tubes have oval-shaped cross-sections, polygonal cross-sections, or the like.
[0197] FIGS. 19A-19C depict a tube 64 having a generally-rectangular transverse cross-section, with primary and secondary patterns on its inner and outer surfaces. This tube may, if desired, be formed with a coating or may be chemically treated.
U-Shaped Tube (FIGS. 20A-20C)
[0198] FIGS. 20A-20C depict a round tube which is bent to have a U-shape, when seen in elevation. This tube, generally indicated at 65 , has primary and secondary patterns on its inner and outer surfaces.
Coil Formed of Round Tube (FIGS. 21A-21D)
[0199] FIGS. 21A-21D depict a helically-wound coil formed from a length of round tubing. This coil, generally indicated at 66 , has primary and secondary patterns on its inner and outer surfaces.
Method of Making an Enhanced-Surface Fin (FIG. 22)
[0200] FIG. 22 is a schematic view of one process for forming enhanced-surface fins. In this process, a coil 68 of material with primary and secondary patterns is unrolled. The leading edge of the material passes around idler rollers 69 a , 69 b, c 9 c , and is then passed between an opposed pair of roller dies 70 a , 70 b , which punch or form various holes (e.g., cooling tube holes and/or flow-through holes in whatever pattern is desired) in the material. The leading edge is then passed through a second pair of roller dies 71 a , 71 b , which form flanges on the material. The leading edge is then passed under a cut-off shear 72 , where individual fins, severally indicated at 73 , are cut from the roll material. These fins are moved rightwardly by the action of rollers 74 .
Fins Having Cooler Tube Openings and Flow-Through Openings (FIGS. 23A-25E)
[0201] FIGS. 23A-25E show different forms of improved fins having different combinations of primary and secondary patterns, and having cooler tube openings and variously-sized flow through openings.
[0202] A first form of fin is generally indicated at 75 in FIGS. 23A-23B . In this first form, the individual characters of the primary and secondary patterns are indicated at 76 ′, 76 ″, respectively. The cooling tube openings (i.e., the openings in the fins to accommodate passage of various cooling tubes (not shown)) are severally indicated at 77 , and the relatively-small flow-through openings are severally indicated at 78 .
[0203] A second form of fin is generally indicated at 79 in FIGS. 24A-24B . In this second form, the individual characters of the primary and secondary patters are again indicated at 76 ′, 76 ″, respectively. The cooling tube openings and the relatively-small flow-through openings are again indicated at 77 , 78 , respectively. Notice that second fin 78 is thinner, and more deeply distorted than first fin 75 .
[0204] Five different fins are illustrated in FIGS. 25A-25E . In each of these figures, the cooling tube openings or holes are indicated at 77 . The salient difference between these five figures lies in the size and configuration of the flow-through openings. In FIG. 25A , a third form of fin, generally indicated at 79 , is shown as having a plurality of smaller-sized flow-though openings, severally indicated at 80 . In FIG. 25B , a fourth form of fin, generally indicated at 79 ′, is shown as having intermediately-sized flow-through openings, severally indicated at 80 ′. In FIG. 25C , a fifth form of fin, generally indicated at 79 ″, is shown as having larger-sized flow-through openings, severally indicated at 80 ″. FIG. 25D illustrates a sixth form of fin having various vertical columns of small, intermediate and large flow-through holes. FIG. 25E illustrates a seventh form of fin having another combination of small, intermediate and large flow-through holes. In each of these cases, the fin has primary and secondary patterns.
Improved Heat Exchanger (FIG. 26)
[0205] An improved heat exchanger, generally indicated at 81 , is shown in FIG. 26 as having an outer shell 82 . A serpentine enhanced-surface heat transfer tube 83 extends between a hot inlet and a hot outlet on the shell. Cold fluid is admitted to the shell through a cold inlet, and flows around the tube toward a cold outlet, through which it exits the shell. The inlet and outlet connections and/or the tube geometry may be changed, as desired.
Improved Cooler (FIGS. 27A-27E)
[0206] FIGS. 27A-27E depict an improved cooler, generally indicated at 84 . This cooler is shown as having a plurality of enhanced-surface tubes, severally indicated at 85 , that penetrate a bottom 86 and that rise upwardly through a plurality of vertically-spaced fins, severally indicated at 88 . The tubes wind through the fins in a serpentine manner. Here again the fluid connections and/or the tube geometry may be changes, as desired. Each fin is shown as having a plurality of cooler tube openings 89 to accommodate passage of the tubes. Each fin has primary and secondary patterns, and may optionally have a number of flow-through openings in whatever pattern is desired.
[0207] FIG. 27A depicts a plan view of the cooler bottom. FIG. 27B is a fragmentary vertical sectional view of the cooler, taken generally on line 27 B- 27 B of FIG. 27A , and shows the tubes as passing upwardly and downwardly through aligned cooler tube openings in the fins. FIG. 27C is a side elevation of the cooler. FIG. 27D is a fragmentary horizontal sectional view through the cooler, taken generally on line 27 D- 27 D of FIG. 27C , and shows a bottom plan view of one of the fins. Finally, FIG. 27E is an enlarged detail view of the lower right portion of the fin, this view being taken within the indicated circle in FIG. 27D .
Improved Fluid-Flow Vessel (FIG. 28)
[0208] An improved fluid-flow vessel is generally indicated at 90 in FIG. 28 . This vessel is shown as including a process column, generally indicated at 91 , that includes a plurality of vertically-spaced enhanced surface walls, severally indicated at 92 . Vapor rises upwardly through the column by sequentially passing through the various walls, and liquid descends through the column by also passing through the various walls. Vapor at the top of the column passes via conduit 93 to a condenser 94 . Liquid is returned to the uppermost chamber within the column by a conduit 95 . At the bottom of the process column, collected liquid is supplied via a conduit 96 to an enhanced-surface reboiler 98 . Vapor leaving this reboiler is supplied to the lowermost chamber of the column via a conduit 99 .
Improved Heat Exchanger Plate (FIGS. 29A-29B)
[0209] FIG. 29A depicts an improved heat exchanger plate, generally indicated at 100 . A plurality of such plates may be stacked on top of one another, and adjacent plates may be sealingly separated by a gasket (not shown) to define flow passageways therebetween. FIG. 29B shows that portions of the heat exchanger plate may have enhanced surfaces thereon so as to facilitate heat transfer. FIG. 29B clearly shows that the illustrated portion of the plate may have primary patterns 101 and secondary patterns 102 .
[0210] Therefore, the present invention broadly provides an improved method of forming an enhanced-surface wall for use in an apparatus for performing a process, an improved enhanced-surface wall, and uses thereof.
MODIFICATIONS
[0211] The present invention contemplates that many changes and modifications may be made. For example, while it may be preferred to form the material of stainless steel, other types of material(s) (e.g., various alloys of aluminum, titanium, copper, etc, or various ceramics) may be used. The material may be homogenous or non-homogenous. It may be coated or chemically treated, either before, during or after the method described herein. As illustrated above, the primary and secondary patterns may have a variety of different shapes and configurations, some regular and directional, and others not. The same types or configurations of characters may be used in the primary and secondary patters, with the difference residing in the depth and/or surface density of such characters. The various heat transfer devices disclosed herein may be complete in and of themselves, or may be portions of larger devices, which may have shapes other than those shown.
[0212] Therefore, while the improved method and apparatus has been shown and described, and several modifications and changes thereof discussed, persons skilled in this art will readily appreciated the various additional changes and modification may be made without departing from the spirit of the invention, as defined and differentiated by the following claims.
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This invention relates generally to: (1) methods of forming enhanced-surface walls ( 20 ) for use in apparatae (e.g., heat transfer devices, fluid mixing devices, etc.) for performing a process, (2) to enhanced-surface walls per se, and (3) to various apparatae incorporating such enhanced-surface walls.
The method improved method broadly comprises the steps of: providing a length of material ( 21 ) having opposite initial surfaces ( 22 a, 22 b ), said material having a longitudinal centerline (x-x) positioned substantially midway between said initial surfaces, said material having an initial transverse dimension measured from said centerline to a point on either of said initial surfaces located farthest away from said centerline, each of said initial surfaces having a initial surface density, said surface density being defined as the number of characters on an surface per unit of projected surface area; impressing secondary patterns ( 23 a, 23 b ) having secondary pattern surface densities onto each of said initial surfaces to distort said material and to increase the surface densities on each of said surfaces and to increase the transverse dimension of said material from said centerline to the farthest point of such distorted material; and impressing primary patterns ( 25 a, 25 b ) having primary pattern surface densities onto each of such distorted surfaces to further distort said material and to further increase the surface densities on each of said surfaces; thereby to provide an enhanced-surface wall for use in an apparatus for performing a process.
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BACKGROUND OF THE INVENTION
This invention relates to a liquid developer monitoring device for monitoring the physical properties of a liquid developer for use as in a wet image forming apparatus such as electrophotographic printer or a copying machine. This invention also relates to a liquid developer controlling system using the liquid developer monitoring device mentioned above. This invention further relates to an image forming apparatus using the liquid developer monitoring device mentioned above.
The electrophotographic process which produces a visible image by developing an electrostatic latent image formed on a photosensitive member with an electrically charged toner is known in two major types, i.e. the dry developing method which directly uses the toner in the form of a powder and the wet developing method (liquid developing method) which uses a developer having the toner dispersed in a liquid medium.
The wet developing method generally develops the electrostatic latent image on the surface of the photosensitive member by immersing the surface of the photosensitive member in the liquid developer. Generally, the wet developing method is capable of producing an image possessing high resolution and excelling in gradient of tone because it is allowed to use a toner of a smaller particle diameter than the toner which is used by the dry developing method. It further has such advantages as permitting easy fixation of the image of toner on a recording medium such as paper.
In recent years, demand for images with increasingly high fineness has been growing. The toner has been consequently urged by this demand toward marked decrease in particle diameter. In the dry developing method, however, the toner developed to date for practical use therefor has an average particle diameter of about 6 μm.
In contrast, the wet developing method uses the toner as dispersed in a liquid medium and consequently permits the toner to have a particle diameter of the order of submicrons, for example, and accordingly enjoys the advantage of vesting images with high quality and high fineness.
Since the liquid developer contains at least a toner and a liquid medium for dispersing the toner, however, it suffers the balance between the toner and the liquid medium therein to be ultimately upset after protracted use thereof and entails the problem of altering the characteristic properties thereof and exerting an adverse effect on the produced images. This trend conspicuously manifests itself particularly when the liquid developer contains a charge controlling agent for controlling the electric charge of the toner.
In the wet developing method, for the purpose of precluding the problem mentioned above and enabling the liquid developer to retain stable properties at all times, therefore, it is necessary to adjust the quantitative balance of such components of the liquid developer as toner, liquid medium, and charge controlling agent by ensuring suitable replenishment of the components. For this reason, U.S. Pat. No. 4,860,924, for example, has disclosed means to control the amounts of the toner and the charge controlling agent in the liquid developer by measuring the transmittance of the liquid developer and the electroconductivity thereof relative to AC and replenishing the toner and the charge controlling agent based on the results of the measurement.
Generally, when an electric current is passed through a liquid developer for the purpose of measuring the electroconductivity of the liquid developer, namely the magnitude of resistance of the liquid developer, the toner is inevitably electrodeposited on electrodes. The liquid developer, therefore, is compelled to manifest a magnitude of current different from the magnitude which the same developer would manifest in the absence of adhesion of the toner to the electrodes. In short, when the electric current is passed through the liquid developer for measuring the magnitude of resistance thereof, the toner is electrodeposited on the electrodes and, as a result, the magnitude of resistance of the liquid developer can no longer be measured accurately. The invention of the U.S. patent specification mentioned above, therefore, contemplates monitoring the magnitude of resistance of a liquid developer while applying an AC electric field meanwhile to the liquid developer so as to preclude the possible adhesion of the toner to the electrodes.
Even when the magnitude of resistance of a liquid developer is measured while an AC electric field is continuously applied thereto, however, the adhesion of toner to the electrodes cannot be completely eliminated. The invention, accordingly, has the problem that the magnitude of resistance (or electroconductivity) cannot be discerned accurately. It also has the problem that the complication of an AC voltage applying circuit and an AC current measuring circuit entrails an addition to the cost of equipment.
SUMMARY OF THE INVENTION
An object of this invention is to provide a novel and useful liquid developer monitoring device which is liberated from the problems mentioned above.
Another object of this invention is to provide a liquid developer monitoring device which is capable of accurately monitoring the physical properties of a liquid developer with a simple construction of circuits.
Another object of this invention is to provide a novel and useful liquid developer controlling system and an image forming apparatus which are liberated from the drawbacks mentioned above.
Another object of this invention is to provide a liquid developer controlling system which is capable of controlling the composition of a liquid developer stably.
Another object of this invention is to provide an image forming apparatus which is capable of producing images of good quality for a long time.
To accomplish the objects mentioned above, a preferred embodiment of this invention is characterized by comprising a liquid developer monitoring device comprising a first electrode which contacts with a liquid developer comprising a liquid medium and electrically charged toner particles dispersed therein, a second electrode which provides a fresh surface and immerses said surface in the liquid developer, an electric power source which applies a bias voltage between said first and second electrodes so as to deposit the toner particles on the second electrode, and a sensor which measures magnitude of current flowing between said first and second electrodes during the deposition of the toner particles.
BRIEF DESCRIPTION OF THE DRAWINGS
The following is a brief description of the accompanying drawings, which show a preferred embodiment of the invention.
FIG. 1 is a cross section showing a liquid developing type electrophotographic printer as one embodiment of this invention.
FIG. 2 is a magnified diagram showing the neighborhood of a liquid developing device in the electrophotographic printer.
FIG. 3 is a diagram showing a liquid path in the electrophotographic printer.
FIG. 4 is a block diagram showing a replenishment control system for a toner replenishing liquid in the electrophotographic printer.
FIG. 5 is a circuit diagram showing a replenishment control system for a toner replenishing liquid in the electrophotographic printer.
FIG. 6 is a block diagram showing a replenishment control system for a charge controlling agent replenishing liquid in the electrophotographic printer.
FIG. 7 is a circuit diagram showing a replenishment control system for a charge controlling agent replenishing liquid in the electrophotographic printer.
FIG. 8 is a block diagram showing a replenishment control system for a liquid medium replenishing liquid in the electrophotographic printer.
FIG. 9 is a circuit diagram showing a replenishment control system for a liquid medium replenishing liquid in the electrophotographic printer.
FIGS. 10A and 10B are flow charts to aid in the description of the liquid replenishing operation in the electrophotographic printer.
FIG. 11 is a diagram to aid in the description of another construction of a liquid developer monitor used in the electrophotographic printer.
FIG. 12 is a block diagram showing a control system for controlling a developing bias based on the results obtained by the liquid developer monitor.
FIG. 13 is a circuit diagram showing a control system for controlling the developing bias based on the results obtained by the liquid developer monitor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, embodiments of this invention will be described below with reference to the accompanying drawings.
<Embodiment 1>
Embodiment 1 represents a case of effecting the development of an image by the use of a liquid developer having a toner, a charge controlling agent, and a liquid medium as main components thereof and using three kinds of replenishing liquid, namely a toner replenishing liquid having the toner and the liquid medium as main components thereof, a charge controlling agent replenishing liquid having the charge controlling agent and the liquid medium as main components thereof, and a liquid medium replenishing liquid solely using the liquid medium. The replenishment of the charge controlling agent replenishing liquid is carried out by measuring the magnitude of electrodeposition current of the toner and thereby monitoring the physical properties of the liquid developer and determining the amount of the charge controlling agent replenishing liquid based on the results of the monitoring.
FIG. 1 is a cross section showing a liquid developing type electrophotographic printer as the first embodiment of this invention, FIG. 2 a partially magnified diagram of a developing device of the printer, and FIG. 3 a diagram to aid in the description of the flow of a liquid developer.
First, the construction and the operation of this electrophotographic printer will be described below.
As shown in FIG. 1, in the printer 100, a cylindrical photosensitive member 1 destined to permit formation of an electrostatic latent image on the surface thereof is disposed so as to be rotated in the direction indicated by an arrow a in the diagram. Around the periphery of the photosensitive member 1 as a latent image carrying member, a laser generator 10 for generating a laser beam based on image data transmitted as from a host computer not shown in the diagram, a liquid developing device 400, a squeeze roller 2, a transfer roller 4, a cleaner 7, an eraser lamp 8, and an electric charger 9 are sequentially disposed in the order mentioned. In the lateral part of the printer, a paper holding cassette 11 for holding papers in the interior thereof, a fixing device 5 for fixing a toner image formed on a paper, and a discharge paper tray 12 for stacking thereon papers discharged out of the printer.
The printer 100 is provided therein with a liquid developer tank 43 for storing the liquid developer, a liquid supply pump 41 for supplying the liquid developer held in the liquid developer tank 43 to the liquid developing device 400, a liquid recovery pump 42 and a residual liquid recovery pump 44 for returning the liquid developer remaining in the liquid developing device 400 to the liquid developer tank 43, a toner replenishing liquid tank 50 for storing a toner replenishing liquid for replenishing the toner component, a charge controlling agent replenishing liquid tank 51 for storing a charge controlling agent replenishing liquid for replenishing the charge controlling agent component, and a liquid medium replenishing liquid tank 52 for storing a liquid medium replenishing liquid for replenishing the liquid medium.
The liquid developer is produced by causing toner particles having a coloring agent dispersed in a binding resin to be dispersed in a liquid medium of high resistance and having a charge controlling agent further incorporated in the resultant dispersion. The toner replenishing liquid is produced by adding toner particles to a liquid medium. The charge controlling agent replenishing liquid is produced by adding a charge controlling agent to a liquid medium. The liquid medium replenishing liquid is formed solely of a liquid medium.
The detailed compositions of the liquid developer and the various replenishing liquids mentioned above and the methods for controlling the replenishment of the replenishing liquids will be described hereinbelow.
The printer described above is operated as follows.
When the photosensitive member 1 held in the printer is set rotating, uniformly charged by the electric charger 9, and then exposed to a laser beam emitted from the laser generator 10, it has an electrostatic latent image formed on the surface thereof. This latent image is developed by the liquid developing device 400. Thereafter, the excess liquid medium which is adhering to the photosensitive member 1 is removed by the squeeze roller 2.
The uppermost of the stack of papers held in the cassette 11 is supplied by a paper supply roller 3 into the printer 100 and then conveyed by a timing roller 13 to the opposed parts of the transfer roller 4 and the photosensitive member 1 as synchronized with the toner image on the photosensitive member 1. The transfer roller 4 induces the toner image to be electrostatically transferred to the paper because it has applied thereto the voltage which is opposite in polarity to the toner. The paper to which the toner has been transferred is dried and, at the same time, caused to fix the toner thereon by the fixing device 5 and delivered onto the discharge paper tray 12. Subsequently, the developer remaining on the surface of the photosensitive member 1 is removed by the cleaner 7 and the latent image remaining on the photosensitive member 1 is removed by the eraser lamp 8, with the result that the sensitive member 1 is reset. When the cycle consisting of the steps of electric charging, exposure, development, squeezing, transfer, cleaning, and erasure mentioned above is completed, the image is formed on the paper.
The construction and the operation of the developing device will be described more specifically below.
FIG. 2 is a magnified diagram of the developing device 400. As shown in FIG. 2, the developing device 400 is provided with a developing roller 402 for carrying the liquid developer on the surface thereof, a frame 406 for supporting the developing roller 402, a developing liquid tank 408 for storing the liquid developer, a liquid recovery tank 409 for recovering the liquid developer overflowing the developer liquid tank 408, a cleaning blade 405 for scraping the liquid developer remaining on the developing roller 402, a nozzle 411 for blowing a cleaning liquid onto the developing roller 402, and a toner recovery tank 413 for recovering the developer scraped by the cleaning blade 405.
The developing roller 402 is a cylindrical metallic part and is disposed parallelly to the longitudinal direction of the photosensitive member 1 and supported by the frame 406 so as to be rotated in the direction indicated by an arrow b in the diagram. The distance between the photosensitive member 1 and the developing roller 402 in their opposed parts (developing part) c is adjusted at 200 μm.
The developing liquid tank 408 is disposed below the developing roller 402 and is provided at the bottom thereof with a liquid supplying aperture 403 connected to the liquid supplying pump 41 shown in FIG. 1. At the outset of the development, the liquid developer is supplied through the liquid supplying aperture 403 and the lower part of the developing roller 402 is immersed in the liquid developer held in the developing liquid tank 408.
Part of the upper end of the wall forming the developing liquid tank 408 approximates closely to the lower part of the developing roller 402 and constitutes itself an edge part f which extends parallelly to the longitudinal direction of the developing roller 402. After the developing liquid tank 408 has been filled to capacity with the liquid developer, the excess liquid developer overflows this edge part f.
The inner wall surface of the developing liquid tank 408 extending from the edge part f through the part opposed to the lowermost point of the developing roller 402 forms a circumferential surface separated by a stated distance from the developing roller 402. This circumferential surface constitutes an electrode (hereinafter referred to as "thin-layer forming electrode") 401 which serves the purpose of causing electrical adhesion of the toner to the surface of the developing roller 402 by application of voltage between itself and the developing roller 402.
In the present embodiment, the developing roller 402 and the electrode 401 concurrently serve as part of means for detecting the amount of electric charge of the liquid developer. To be specific, this detection of the amount of electric charge of the liquid developer is implemented by measuring the magnitude of electric current (electrodeposition current of the toner) flowing between the developing roller 402 and the electrode 401 at the same time that the toner is electrodeposited on the developing roller 402 for the purpose of effecting the development.
The toner recovery tank 413 is approximated closely to the developing liquid tank 408 as disposed on the opposite side to the liquid recovery tank 409. A liquid blocking plate 416 is attached to the upper end of the inner wall surface of the toner recovery tank 413. The liquid blocking plate 416 is extended upwardly to serve as a boundary between the developing liquid tank 408 and the toner recovery tank 413.
The cleaning blade 405 is attached to the upper end of the liquid blocking plate 416. The upper end of this cleaning blade 405 is held in contact with the developing roller 402. The cleaning blade 405 is made of polyurethane and is pressed against the surface of the developing roller 402 with suitable pressure by the liquid blocking plate 416. As respects the material for the blade, rubber or resin, especially polyurethane, proves proper where the developing roller 402 is made of such material as metal or hard resin. A blade made of such material as metal, resin, or ceramic is properly used where the developing roller 402 is made of such a flexible material as, for example, NBR (nitrile rubber).
The liquid blocking plate 416 concurrently serves the purpose of separating the developing liquid tank 408 and the toner recovery tank 413 from each other and supporting the cleaning blade 405. It, therefore, simplifies the construction and proves advantageous in terms of cost.
The nozzle 411 is connected to a cleaning liquid supplying pump 45, disposed above the cleaning blade 405, and provided with a plurality of spouting apertures spaced by a stated interval in the longitudinal direction of the developing roller 402 and directed toward the developing roller 402.
A liquid cutting member 414 for cutting part of the liquid developer held on the developing roller 402 and lowering it to a stated amount is disposed above the liquid recovery tank 409. The liquid cutting member 414, when the cleaning blade 405 scrapes the liquid developer, manifests an effect of containing the removed liquid developer and preventing it from being scattered outwardly. Further, above the nozzle 411 is disposed a liquid splash preventing plate 415 for preventing the liquid developer held in the developing device 400 from being splashed or vaporized.
Now, the operation of the liquid developing device 400 will be described in detail below.
First, the liquid supply pump 41 is set operating to supply the liquid developer through the liquid supply aperture 403 into the developing liquid tank 408. The liquid developer, after being passed between the opposed parts (thin layer forming part) d of the developing roller 402 and the electrode 401 and through the liquid recovery tank 409, is recovered from a liquid recovery aperture 404 into the liquid developer tank 43 by the liquid recovery pump 42 and again supplied thence to the developing device 400 by the liquid supply pump 41. During the development, the liquid developer is circulated within the developing device 400 as described above.
In the developing device 400, the liquid recovery pump 42 is provided with a greater capacity for liquid recovery than the capacity of the liquid supply pump 41 for liquid supply. The level of the liquid developer held in the developing device 400, therefore, is substantially fixed as shown in FIG. 2 at the highest position that is slightly higher than the edge part f (the upper end of the thin-layer forming electrode 401) of the developing liquid tank 408.
Meanwhile, the developing roller 402 begins to rotate in the direction indicated by the arrow b. After the application of a predetermined magnitude of voltage between the thin layer forming electrode 401 and the developing roller 402 has been started and while the liquid developer is passing through the thin layer forming part d, since the electrically charged toner particles in the liquid developer is moved toward the developing roller 402 under the influence of the electrostatic force, a thin layer of the toner is formed on the surface of the developing roller 402 and a layer of liquid medium containing substantially no toner is formed further thereon.
When the length of the thin layer forming part d (the range indicated by an arrow e in FIG. 2) is set in the range of 3-80 mm, preferably 5-50 mm, ample time is secured for the movement of the toner necessary for the formation of the thin layer and the liquid developer is enabled to form a thin layer with high concentration.
When the distance between the thin layer forming electrode 401 and the developing roller 402 (hereinafter referred to as "thin layer forming gap") is set in the range of 0.1-10 mm, preferably 0.3-3 mm, the liquid developer is allowed to flow smoothly to the thin layer forming part d and consequently form a layer of liquid developer composed of a thin layer of toner and a layer of liquid medium.
In the present embodiment, the length of the thin layer forming part d is set at 25 mm and the distance between the thin layer forming electrode 401 and the developing roller 402 at 1 mm.
The voltage to be applied between the thin layer forming electrode 401 and the developing roller 402 is advantageously formed of DC, DC overlapped by AC, or DC overlapped by voltage of the form of pulse for the sake of heightening the effect of uniformly forming the thin layer of toner on the developing roller 402. The present embodiment elects to apply a DC voltage of 1000 V.
When the electric charge put on the toner is small during the formation of the thin layer of toner, the toner deposited on the developing roller 402 has such a low concentration as exerts an adverse effect on the image to be formed. This embodiment, therefore, contemplates adjusting the amount of electric charge of the toner in the liquid developer, as will be specifically described hereinbelow, based on the amount of electric charge of the toner to be found by measuring the magnitude of electric current flowing between the thin layer forming electrode 401 and the developing roller 402 during the electrodeposition of toner.
Since the developing bias is applied to the developing roller 402 on which the thin layer of toner has been formed, the latent image on the photosensitive member 1 is developed with the toner.
Particularly in the present embodiment, the part of the layer containing the toner at a high concentration avoids directly contacting the photosensitive member 1 and the occurrence of fogging in the image can be prevented because the photosensitive member 1 and the developing roller 402 are in such a state as retains a stated gap as mentioned above. From this point of view, the distance between the two components is appropriately set in the range of 0.1-2 mm. Alternatively, a method which implements the development by means of contact between the photosensitive member and the developing roller may be adopted. This method is characterized by permitting the development to be effected at a high speed. Even in this mode, the present invention can be embodied.
The rotational speed of the developing roller 402 is equalized with that of the sensitive member 1. This measure is intended to preclude the possibility that shear strength will act on the toner tending to adhere to the photosensitive member 1 and will consequently disturb the image. The two rotational speeds, when necessary, may be differentiated. The amount of the toner to be supplied to the sensitive member 1 can be increased by giving to the developing roller 402 a higher rotational speed than to the photosensitive member 1. The amount of the toner supplied to the photosensitive member 1 can be decreased by causing the developing roller 402 to be rotated at a lower speed than the photosensitive member 1. The ratio of rotational speed of the developing roller 402 to the photosensitive member 1 is properly in the range of 0.5-10, preferably 0.9-5. Further, the direction of the rotation of the developing roller 402 may be reversed from the direction of the arrow b shown in FIG. 2, namely in the direction contrary to the direction of rotation of the photosensitive member 1 (indicated by the arrow a shown in the diagram). This reversion of the direction of rotation allows a decrease in the amount of liquid suffered to adhere to the photosensitive member 1.
The developer that still remains on the surface of the developing roller 402 after the surface has passed the developing area is scraped by the cleaning blade 405. By the time that the surface of the developing roller 402 reaches the developing liquid tank 408, it has assumed a fresh surface free from adhesion of the toner.
The cleaning liquid is spouted via the nozzle 411 against the developing roller 402. As a result, the possibility that part of the surface of the developing roller 402 will escape being wiped is precluded and, at the same time, the possibility that the rotational torque of the developing roller 402 will be increased is prevented.
In this embodiment, part of the developing liquid returned from the liquid recovery pump 42 to the liquid developer tank 43 is scooped up by the cleaning liquid supply pump 45 and used as the cleaning liquid. As a result, it becomes unnecessary to use an exclusive cleaning liquid or to provide an exclusive container for storing the cleaning liquid. The aforementioned liquid which is used as the cleaning liquid in this embodiment has a small amount of solid content and proves suitable for cleaning.
The cleaning liquid does not need to be limited to the liquid contemplated by this embodiment. Various liquids which are incapable of dissolving the toner can be adopted as the cleaning liquid. It is permissible to scoop up the liquid developer held in the liquid developer tank 43 and use it as the cleaning liquid. It is also allowable to use a replenishing liquid for fixing the toner concentration in the liquid developer at a predetermined level.
The developer which has been scraped by the cleaning blade 405 flows down the liquid blocking plate 416 into the toner recovery tank 413. As a result, the developer which remained on the developing roller 402 has no possibility of flowing directly into the developing liquid tank 408 and consequently altering the toner concentration of the liquid developer held in the developing liquid tank 408.
The liquid developer which has flowed into the toner recovery tank 413 is recovered via a residual liquid recovery aperture 410 and returned to the liquid developer tank 43 by the toner recovery pump 44.
When the development is completed as described above, the application of voltage is terminated and, at the same time, the liquid supply pump 41, the liquid recovery pump 42, and the developing roller 402 are stopped. The liquid developer held in the developing liquid tank 408 is quickly dropped under its own weight toward the liquid developer tank 43 via the liquid supply aperture 403 and the liquid recovery aperture 404.
The surface roughness of the developing roller 402 is set below 5 μm on the ten-point average roughness scale. Owing to this surface roughness, such detriments as the disturbance of image due to the contact between the photosensitive member 1 (image carrying member) and the developing roller 402, the breakage of the thin layer of toner due to the contact between the developing roller 402 and the thin layer forming electrode 401, the uneven development due to the uneven application of an electric field between the photosensitive member 1 and the developing roller 402, and the uneven thin layer of toner due to the uneven interval between the developing roller 402 and the thin layer forming electrode 401 can be precluded. The ten-point average roughness is defined in JIS (Japanese Industrial Standard) B-0601.
Now, the operation for supply of the replenishing liquids will be described below.
The liquid developer in the liquid developer tank 43 is caused to retain a uniform concentration by means of a stirring vane 58 which is rotated by the motive force of a stirring motor 57 as shown in FIG. 3. The liquid supply pump 41 is provided at the leading end part thereof with a concentration sensor 59 adapted to measure the liquid concentration optically. The start of printing sets the liquid supply pump 41 operating to supply the liquid developer to the developing liquid tank 408. The liquid developer is passed through the thin layer forming part d jointly defined by the developing roller 402 and the thin layer forming electrode 401 as described above and is then returned by the liquid recovery pump 42 to the liquid developer tank 43. At this time, the toner concentration of the liquid developer supplied by the liquid supply pump 41 is measured by the concentration sensor 59. When the concentration is found by this measurement to be insufficient, a replenishing pump 53 and a valve 56 are so controlled as to forward the toner replenishing liquid from the replenishing tank 50 to the liquid developer tank 43.
At the outset of the development, photosensitive member 1 and developing roller 402 are rotated by drive motor 67 and developing roller 402 are rotated by drive motor 67 and developing motor 66 respectively, and an electrodeposition power source 64 applies voltage to the thin layer forming part d and the toner is electrodeposited as described above on the developing roller 402. Suitable bias means 63 applies voltage between the developing roller 402 and the photosensitive member 1 and the latent image on the sensitive member 1 is developed with the toner without entraining the phenomenon of fogging. At this time, an electrodeposition current sensor 65 measures the electrodeposition current. If the electrodeposition current fails to reach a predetermined magnitude, the charge controlling agent replenishing liquid will be supplied by a replenishing pump 54 from the replenishing tank 51 into the liquid developer tank 43.
The liquid developer tank 43 is provided with a liquid amount sensor 61. If the amount of liquid fails to reach a predetermined level, the liquid medium replenishing liquid will be supplied by a replenishing pump 55 from the replenishing tank 52.
Here, each operation for supply of the toner replenishing liquid, the charge controlling replenishing liquid and the liquid medium replenishing liquid will be described respectively.
FIG. 4 is a block diagram showing a toner replenishing liquid control system and FIG. 5 is a circuit diagram showing a specific circuit construction for the control system mentioned above. The concentration sensor 59 is composed of an LED and a phototransistor TR1. It determines the toner concentration of the liquid developer by measuring the transmittance of this liquid developer. The concentration sensor 59 measures the toner concentration in the liquid developer tank 43 and emits a signal corresponding to the result of the measurement. The signal from the concentration sensor 59 is amplified by an amplifying circuit (AMP1) 591 and introduced into a comparison circuit 592, specifically a CPU. In the comparison circuit 592, the level of the signal from the concentration sensor 59 is compared with the standard value. When the signal level is found by this comparison to be lower than the standard value, the toner concentration is judged to be insufficient and a drive circuit (TR2) 593 sets the replenishing pump 53 operating so as to induce supply of the toner replenishing liquid into the liquid developer tank 43.
FIG. 6 is a block diagram showing a charge controlling agent replenishing liquid control system and FIG. 7 is a circuit diagram showing a specific circuit of the system mentioned above. The electrodeposition current sensor 65 uses a coil 65a, a magnet 65b, and a Hall element 65c. Since the coil 65a generates a magnetic field corresponding to an electrodeposition current and the Hall element 65c converts the magnetic field into an electric field, the electrodeposition current sensor 65 is enabled to emit an electric signal corresponding to the magnitude of electrodeposition current and monitors the amount of electric charge put on the toner in the liquid developer in the form of an electric signal.
The signal from the electrodeposition current sensor 65 is amplified by an amplifying circuit (AMP2) 651 and introduced into a comparison circuit 652, specifically a CPU. In the comparison circuit 652, the level of the signal from the electrodeposition current sensor 65 is compared with the standard value. When the signal level is found by this comparison to be lower than the standard value, the amount of electric charge put on the toner in the liquid developer is judged to be insufficient and a drive circuit (TR3) 653 sets the replenishing pump 54 operating so as to induce supply of the charge controlling agent replenishing liquid into the liquid developer tank 43. To the Hall element 65c is supplied a DC voltage from a constant current source 670.
The toner electrodeposited on the surface of the developing roller 402, after passing the developing part c, is scraped by the cleaning blade 405 (shown in FIG. 2) as already described in consequence of the rotation of the developing roller 402. By the time that the surface of the developing roller 402 reaches the thin layer forming part d, it has assumed a fresh surface (in a state not allowing adhesion of toner). As a result, the magnitude of electrodeposition current can be always measured accurately at the time that the toner is electrodeposited on the surface of the electrode free from deposition of toner.
Particularly in the present example, since the developing roller 402 and the electrode 401 concurrently serve as part of means to detect the amount of electric charge put on the toner of the liquid developer, neither an electrode nor a power source is provided exclusively for the purpose of monitoring the liquid developer. Owing to the construction described above, the amount of electric charge put on the toner itself to be used for the development is measured and the determination of the amount of electric charge can be accurately carried out.
FIG. 8 is a block diagram showing a liquid medium replenishing liquid control system and FIG. 9 is a circuit diagram showing a concrete circuit for the control system mentioned above. The liquid amount sensor 61 comprises float switches 61a (FSW1) and 61b (FSW2) having different positions of detection. The signals one each from the float switches 61a, 61b are detected by a detection circuit 611, specifically a CPU. When the signal from the float switch 61a is detected, the amount of the liquid in the liquid developer tank 43 is judged to be sufficient. Conversely when the signal from the float switch 61b is detected, the amount of the liquid is judged to be insufficient and, based on this judgment, a drive circuit (TR4) 612 is actuated to drive the replenishing pump 55 and induce supply of the liquid medium replenishing liquid.
FIG. 10A and FIG. 10B are flow charts showing one example of the algorithm for driving the replenishing pumps 53, 54, and 55 based on the results of the monitoring performed in the systems mentioned above. The algorithm will be described below with reference to FIG. 10A and FIG. 10B.
When the start of printing is detected (S1), start of the stirring motor 57, start of a developing motor 66, and application of an electrodeposition bias (turning on of the electrodeposition power source 64) are severally effected (S2).
Then, the replenishing pump 53 for the toner replenishing liquid is judged to decide whether it is being driven or not (S3). When the replenishing pump 53 is not being driven, the LED of the concentration sensor 61 is turned on (S4). When the luminous energy is found to be below the standard level (S5), the replenishing pump 53 is started and, at the same time, the stop timer is set (S6).
When the replenishing pump 53 is found to be being driven at the aforementioned step S3, the stop timer is judged to decide whether or not it has completed counting (S7). The replenishing pump 53 is stopped when the counting is completed (S8). Then, the LED of the concentration sensor 61 is turned off (S9).
Then, the replenishing pump 54 for the charge controlling agent replenishing liquid is judged to decide whether or not this pump 54 is being driven (S10). When the judgment produces a negative answer, the electrodeposition current is judged to decide whether or not it is below the standard level (S11). When the judgment produces an affirmative answer, the replenishing pump 54 for the charge controlling agent replenishing liquid is started and the stop timer is set (S12).
When the judgment at the aforementioned step S10 produces an affirmative answer, the stop timer is judged to decide whether or not it has completed counting (S13). The replenishing pump 54 is stopped when the counting is completed (S14).
Then, the level of the liquid developer is judged to decide whether or not it is above the upper limit float based on the signal from the float switch 61a (S15). When the judgment produces a negative answer, the replenishing pump 55 for the liquid medium replenishing liquid is judged to decide whether or not it is being driven (S16). When this judgment produces a negative answer, the level of the liquid developer is judged to decide whether or not it is below the lower limit float based on the signal from the float switch 61b (S17). When the judgment produces an affirmative answer, the replenishing pump 55 is started and the stop timer is set (S18).
When the judgment at the aforementioned step S16 produces an affirmative answer, the stop timer is judged to decide whether or not it has completed counting (S19). The replenishing pump 55 is stopped when the counting is completed (S20). When the judgment at the aforementioned step S15 produces an affirmative answer, too, the replenishing pump 55 is stopped (S20).
Then, the printer is judged to decide whether or not it has completed printing (S21). When this judgment produces a negative answer, the process extending from the step S3 through the step S21 is repeated. When the judgment produces an affirmative answer, the stirring motor 57 is stopped, the developing motor is stopped, the electrodeposition bias is cut off, and all the pumps are stopped (S22). The processing is returned to the judgment (S1) as to the start of printing.
In the flow charts described above, the steps S3 through S8 for the control of the toner replenishing liquid, the steps S9 through S14 for the control of the electrodeposition controlling agent replenishing liquid, and the steps S15 through S20 for the control of the liquid medium replenishing liquid are depicted as being carried out continuously. Optionally, these groups of controlling steps may be carried out parallelly.
The present example is allowed to effect fine adjustment of the balance of the main components of the liquid developer, i.e. a toner, a charge controlling agent, and a liquid medium, because it uses the three kinds of replenishing liquid one each for the main components mentioned above and supplies these replenishing liquids substantially independently of one another as described above.
Now, the compositions of the liquid developer and the replenishing liquids to be used in this embodiment will be described below.
The liquid developer at least comprises toner particles having such coloring agents as pigment and dye dispersed in a binding resin, a charge controlling agent, and a liquid medium of high resistance for dispersing the toner particles and the charge controlling agent therein. It may, when necessary, further incorporate therein a dispersion stabilizer and other additives in suitable amounts.
The resistance of the liquid developer can be optimized and the occurrence of such detriments as image drift an be minimized by adjusting the volume resistivity of the liquid developer to a level of not less than 10.sup. Ω.cm.
Any kind of liquid medium can be used so long as it possess such a magnitude of resistance as avoids disturbing an electrostatic latent image formed on such an image carrying member such as the photosensitive member. The liquid medium is appropriately a solvent which is substantially free from odor and toxicity and has a relatively high flash point. As typical examples of the liquid medium that fulfills the condition, such isoparaffin type hydrocarbon solvents as IP solvent series (produced by Idemitsu Petrochemical Co., Ltd.) and Isoper series (produced by Esso Oil Company) which exhibit high insulating property and low dielectric property may be cited.
The toner (minute colored particles) to be used for the liquid developer has absolutely no restriction. Preferably, the toner exerts only a sparing effect of the difference in kind of pigment on the developability of the liquid developer. To be specific, it is appropriate for the toner to have at least such coloring materials as dye and pigment dispersed in a thermoplastic binding resin.
The method for producing the toner has no restriction of any sort. In various known methods available for the production, (1) a method which obtains a toner by coloring minute binding resin particles with a coloring agent (dye or pigment) and (2) a method which obtains a toner by melting and kneading a coloring agent (dye or pigment) with a binding resin and pulverizing the resultant colored resin by a varying pulverizing technique may be cited as typical examples.
As concrete examples of the method of (1), a method which comprises preparing minute resin particles by such technique as suspension polymerization, emulsion polymerization, non aqueous dispersion polymerization, seed polymerization, emulsion dispersion granulation, spray drying, dry pulverization, or wet pulverization and applying a pigment fast to the surface of the minute resin particles and a method which comprises coloring minute resin particles with a dye in a solvent substantially incapable of dissolving the minute resin particles and capable of dissolving the dye may be cited. As concrete examples of the device for applying a pigment fast to the surface of minute resin particles, Hybridization System (produced by Nara Kikai Seisakujo K.K.), Angmill (produced by Hosokawa Micron K.K.), and Disper Coat (produced by Nisshin Engineering K.K.) may be typically cited.
As concrete examples of the method of (2), a method which comprises melting and kneading a coloring agent (dye or pigment) and a binding resin thereby obtaining a bulk of colored resin, coarsely pulverizing the bulk of colored resin into particles of a particle diameter of about 1 mm, and finely pulverizing the coarse particles by the use of such a dry pulverizing device as a jet mill and a method which comprises finely dividing the coarse particles in a solvent destined to serve as a liquid medium by the use of such a device as a wet media mill may be cited. As typical examples of the dry pulverizing device, Jet Mill (produced by Nippon Pneumatic Kogyo K.K.) and Cryptron Grinder (produced by Kawasaki Jukogyo K.K.) may be cited. As typical examples of the wet media mill, Mitsubishi UF Mill (produced by Mitsubishi Heavy Industries, Ltd.), Aiger Motor Mill (produced by Aiger Japan K.K.), Ultravisco Mill (produced by Aimex K.K.), and Spike Mill (produced by Inoue Seisakujo K.K.) may be cited.
In the liquid developers using the toner particles obtained by such methods for the production of toner as mentioned above, the liquid developer that uses the toner particles obtained by the method of (2) mentioned above which does not easily allow the kind of pigment to produce a difference in the amount of electric charge is advantageously used. In the methods for the production mentioned above, the method which implements wet pulverization by the use of a media mill in an isoparaffin type solvent capable of serving as a liquid medium proves particularly advantageous.
Appropriately, the volume average particle diameter of the toner is in the range of 0.5-5.0 μm, preferably 1.0-4.0 μm. If the particle diameter of the toner is less than 0.5 μm, the mobility of the toner particles may be unduly small and, as a result, the developing speed may be decreased and the image density may be ultimately lowered in a range of system speed exceeding a certain level. Conversely, if the particle diameter of the toner exceeds 5.0 μm, the resolution may be possibly degraded. The developing speed and the image density are both satisfied by keeping the volume average particle diameter of the toner within the range of 0.5-5.0 μm. The volume average particle diameter and the particle diameter distribution of the toner may be measured by the use of an instrument produced by Shimadzu Seisakusho Ltd. and marketed under product code of "SALD-1100," for example.
As the binding resin for the toner, any of the binding resins which are popularly used for toners of the ordinary grade is suitably used. As concrete examples of the binding resin, thermoplastic resins such as styrene type resins, (meth)acrylic type resins, olefin type resins, polyester type resins, amide type resins, carbonate resins, polyethers, and polysulfones, oligomers and prepolymers of such thermosetting resins as epoxy resins, urea resins, and urethane resins, and polymers partially containing a prepolymer, cross-linking agent, etc. may be cited. These resins may be used either singly or in the form of a mixture of two or more members. In order for the toner particles to manifest a fully satisfactory charging property, it is necessary that the binder resin used therein be possessed of a part allowing ready adsorption of ions in the liquid developer on the surface of the toner particles. Specifically, the binding resin must possess a high acid value. The charging property may be exalted, for example, by blending the toner binder with a polar group-containing polymer or a polar group-containing compound or by modifying the surface of toner particles thereby imparting an improved ion-adsorbing property thereto.
For the purpose of enabling the binder resin to acquire an increased acid number, this resin is copolymerized with an acidic monomer such as (meth)acrylic acid as a copolymerizable monomer when the resin happens to be a styrene-acrylic type resin. When the resin is a polyester type resin, it requires a small amount of the acidic monomer to be graft polymerized thereto. The acid number of the resin can be adjusted by controlling the grafting ratio of the polymerization.
Generally, the acid number of the binding resin is proper in the range of 5-100 mgKOH/g. In this invention, the acid number of the binding resin is determined as follows.
Five (5) g of a given resin is dissolved in 50 ml of a neutral solvent toluene-EtOH (2/1)! and the resultant solution is titrated with 0.04M of a KOH-EtOH solution against phenol phthalein as an indicator.
Acid number=(a-b)×f×2.244/w
wherein a stands for the end point of slightly red color (ml), b for the titer in blank test (ml), f for the titer of the 0.04M KOH-EtOH solution, and w for the amount of sample resin (g)!.
As concrete examples of the other polar group-containing compound to be blended with the resin binder, organic acids such as carboxylic acids, sulfonic acids, and phosophoric acid, higher fatty acids, minute inorganic oxide particles such as minute silica particles, resin acids such as rosin, and derivatives thereof may be cited.
The improvement of the ion-adsorbing property of toner particles by modifying the surface of the toner particles is accomplished, for example, by a method which comprises applying a fine inorganic oxide powder such as fine silica powder fast to the surface of the toner particles. As concrete examples of the device for applying the fine inorganic oxide powder fast to the surface of the toner particles, Hybridization System (produced by Nara Kikai Seisakujo K.K.), Angmill (produced by Hosokawa Micron K.K.), and Disper Coat (produced by Nisshin Engineering K.K.) may be typically cited.
As the coloring agent for the toner, it is advantageous to use organic dyes and pigments and inorganic pigments which come in various colors and carbon black. Particularly, it is proper to use C. I. Pigment Blue 15-3, C. I. Pigment Yellow 17, C. I. Pigment Red 122, and Morgal L. Generally, these coloring dyes and pigments are properly used in an amount in the range of 3-30 parts by weight, preferably 5-20 parts by weight, based on 100 parts by weight of the resin particles. If the amount of coloring agent exceeds 30 parts by weight, the fixing property of the toner will be degraded. Conversely, if this amount is less than 3 parts by weight, the image may not be obtained with amply high density.
As concrete examples of the charge controlling agent which is added to the liquid developer for the purpose of controlling the amount of electric charge put on the toner in the liquid developer, metal salts of fatty acids such as naphthenic acid, octenoic acid, oleic acid, and stearic acid, metal salts of sulfo-succinic esters, metal salts of alkylsulfonic acids, metal salts of phosphoric esters, metal salts of abietic acid and hydrogenated abietic acid, calcium alkylbenzene sulfonates, metal salts of aromatic carboxylic acids or sulfonic acids, nonionic surfactants such as polyoxyethylated alkyl amines, oils and fats such as lecithin and linseed oil, surfactants of organic acid esters of polyhidric alcohols, and sulfonic acid resins may be cited.
It is permissible to use a disperse charge resin possessing an electrically charging property and exhibiting solubility to the aforementioned liquid medium as a charge controlling agent. The examples of the disperse charge resin answering the description will be shown below.
The following are polymers or copolymers which contain a nitrogen-containing monomer as a component thereof and exhibiting solubility to the liquid medium.
A. (Meth)Acrylates containing an aliphatic amino group:
N,N-dimethylaminoethyl (meth)acrylates, N,N-diethylaminoethyl (meth)acrylates, N,N-dibutylaminoethyl (meth)acrylates, N,N-hydroxyethylaminoethyl (meth)acrylates, N-benzyl-N-ethylaminoethyl (meth)acrylates, N,N-dibenzylaminoethyl (meth)acrylates, N-octyl-N-ethylaminoethyl(meth)acrylates, and N,N-dihexylaminoethyl(meth)acrylates.
B. Nitrogen-containing heterocyclic vinyl monomers:
N-vinyl imidazole, N-vinyl indazole, N-vinyl tetrazole, 4-vinyl pyridine, 2-vinyl pyridine, 2-vinyl quinoline, 4-vinyl quinoline, 2-vinyl pyralidine, 2-vinyl benzoxazole, and 2-vinyl oxazole.
C. N-vinyl-substituted cyclic amide monomers:
N-vinyl-2-pyrrolidone, N-vinyl piperidone, and N-vinyl oxazolidone.
D. (Meth)Acrylamides:
N-methyl acrylamide, N-octyl acrylamide, N-phenylmethyl acrylamide, N-cyclohexyl acrylamide, N-phenylethyl acrylamide, N-α-naphthyl acrylamide, N-phenyl acrylamide, N-p-methoxy-phenyl acrylamide, acrylamide, N,N-dimethyl acrylamide, N,N-dibutyl acrylamide, N-methyl-N-phenyl acrylamide, acryl piperidine, acryl morpholine, and methacrylamides homologous thereto.
E. Aromatic substituted ethylene type monomers containing a nitrogen-containing group:
Dimethylamino styrene, diethylamino styrene, diethylamino methyl styrene, and dioctylamino styrene.
F. Nitrogen-containing vinyl ether monomers:
Vinyl-N-ethyl-phenylaminoethyl ether, vinyl-N-butyl-N-phenylaminoethyl ether, triethanolamine divinyl ether, vinyl diphenylaminoethyl ether, vinyl pyrrolidylamino ether, vinyl-β-morpholinoethyl ether, N-vinyl hydroxyethyl benzamide, and m-amino-phenyl vinyl ether.
The polymers formed of these monomers are advantageously copolymerized with such monomers as hexyl (meth)acrylates, cyclo-hexyl (meth)acrylates, 2-ethylhexyl (meth)acrylates, octyl (meth)acrylates, nonyl (meth)acrylates, decyl (meth)acrylates, dodecyl (meth)acrylates, lauryl (meth)acrylates, stearyl (meth) acrylates, vinyl laurate, vinyl stearate, benzyl (meth)acrylates, phenyl (meth)acrylates, styrene, and vinyl toluene so as to assume a state readily soluble in a (iso)paraffin type liquid medium.
The amount of the charge controlling agent and/or the disperse charge resin to be added is appropriately in the range of 0.1-5.0% by weight, based on the liquid medium in the liquid developer. The ratio of the charge controlling agent and/or the disperse charge resin to the toner particles is appropriately in the range of 1.0-80% by weight, preferably 5-70% by weight.
The liquid developer, when necessary, may incorporate therein polymers of such long-chain alkyl group-containing acrylic monomers as 2-ethylhexyl (meth)acrylates, lauryl (meth)acrylates, and stearyl (meth)acrylates, copolymers (such as, for example, random copolymers, graft copolymers, and block co-polymers) of these monomers with other monomers (such as, for example, styrene, (meth)acrylic acids, and methyl, ethyl, and propyl esters thereof), rosin, and rosin-modified resins, as disperse resins for aiding in stabilizing dispersion of the toner.
Appropriately the amount of these disperse resins to be added is in the range of 1-10% by weight, preferably 2-5% by weight, based on the amount of the toner particles.
When the liquid developer obtained as described above is used where the development of an image is effected by causing the toner electrodeposited on the developing roller 402 to be transferred onto the latent image on the latent image carrying member (Photosensitive member 1), high-speed development can be attained because the toner concentration is uniformly retained in the developing area and the electrodeposition on the developing roller 402 is carried out at a high speed.
Now, concrete examples of the liquid developer and the replenishing liquids to be used in the present embodiment will be shown below.
<Production of disperse charge resin A>
A solution of 95 parts by weight of lauryl methacrylate in 200 parts by weight of IP Solvent 1620 (produced by Idemitsu Petrochemical Co., Ltd.) is prepared. Argon gas is blown into the solution for 10 minutes to displace the gas entrained in the entire reaction system with argon gas. Then, benzoyl peroxide is added as a polymerization initiator in an amount of 1 mol % based on the amount of the lauryl methacrylate to the reaction system and the reaction system is kept at a temperature of 80° C. for four hours to induce polymerization of the monomer in the reaction system. Thereafter, the reaction system is cooled to 30° C. and made to add 5 parts by weight of N-vinyl-2-pyrrolidone and further add azobis-isobutyronitrile in an amount of 1 mol % based on the N-vinyl-2-pyrrolidone. The reaction system is heated to and retained at 90° C. for four hours to complete the polymerization. The lauryl methacrylate/N-vinyl-2-pyrrolidone copolymer consequently obtained in the form of a solution is labeled as "disperse charge resin A."
<Production of liquid developer>
Colored coarsely pulverized particles having an average particle diameter of 100 μm are obtained by preparing a mixture composed of the following components, kneading this mixture by the use of two rolls at 180° C. for four hours, cooling the hot blend, and coarsely pulverizing the cooled blend.
Styrene/butyl acrylate/acrylic acid copolymer: 100 parts by weight
Copolymerizing ratio 70/25/5
Acid number 12.3 mgKOH/g
Mn=35000, Mw/Mn=3.0
Carbon black (produced by Columbia Carbon Corp and marketed under trademark designation of "Morgal L") : 20 parts by weight
In a sand mill using soda glass beads of 5.0 mm in diameter as a medium, the colored coarsely pulverized particles in the following composition are preliminarily pulverized and dispersed under the conditions of two hours and 2000 rpm.
Colored coarsely pulverized particles: 30 parts by weight
Disperse charge resin A: 5 parts by weight
IP Solvent 1620 (produced by Idemitsu Petrochemical Co.,
Ltd.): 100 parts by weight
A concentrated liquid developer is obtained by subjecting the preliminarily pulverized and dispersed blend in the sand mill to a wet pulverization and dispersion under the conditions of four hours and 2000 rpm, with the medium changed to soda glass beads of 1.0 mm in diameter.
In the sand mill, the concentrated liquid developer and 900 parts by weight of IP Solvent 1620 added thereto are dispersed for one hour to produce a liquid developer containing toner particles having a volume average particle diameter of 1.5 μm.
<Production of toner replenishing liquid>
Colored coarsely pulverized particles having an average particle diameter of 100 μm are obtained by preparing a mixture composed of the following components, kneading this mixture by the use of two rolls at 180° C. for four hours, cooling the hot blend, and coarsely pulverizing the cooled blend.
Styrene/butyl acrylate/acrylic acid copolymer: 100 parts by weight
Copolymerizing ratio 70/25/5
Acid number 12.3 mgKOH/g
Mn=35000, Mw/Mn=3.0
Carbon black (produced by Columbia Carbon Corp and marketed under trademark designation of "Morgal L") : 20 parts by weight
In a sandmill using soda glass beads of 5.0 mm in diameter as a medium, the colored coarsely pulverized particles in the following composition are preliminarily pulverized and dispersed under the conditions of two hours and 2000 rpm.
Colored coarsely pulverized particles: 300 parts by weight
Disperse charge resin A: 3.5 parts by weight
IP Solvent 1620 (produced by Idemitsu Petrochemical Co., Ltd.): 300 parts by weight
A concentrated toner replenishing liquid is obtained by subjecting the preliminarily pulverized and dispersed blend in the sandmill to a wet pulverization and dispersion under the conditions of four hours and 2000 rpm, with the medium changed to soda glass beads of 1.0 mm in diameter.
In the sand mill, the concentrated toner replenishing liquid and 700 parts by weight of IP Solvent 1620 added thereto are dispersed for one hour to produce a toner replenishing liquid containing toner particles having a volume average particle diameter of 1.5 μm.
<Production of charge controlling agent replenishing liquid>
A concentrated replenishing liquid is obtained by thoroughly mixing a mixture composed of the following components for one hour.
Disperse charge resin A: 7.0 parts by weight
IP Solvent 1620 (produced by Idemitsu Petrochemical Co., Ltd.): 100 parts by weight
A charge controlling agent replenishing liquid is obtained by combining the concentrated replenishing liquid and 900 parts by weight of IP Solvent 1620 and stirring the resultant mixture for one hour.
<Production of liquid medium replenishing liquid>
IP Solvent 1620 (produced by Idemitsu Petrochemical Co., Ltd.) is used in its unmodified form as a liquid medium replenishing liquid. This liquid medium has high electric resistance.
<Embodiment 2>
Embodiment 1 described above is depicted as using the thin layer forming electrode 401 and the developing roller 402 in the developing device 400 for the detection of the amount of electric charge of the toner in the liquid developer as described above. A mechanism adapted exclusively to detect the amount of electric charge put on the toner in the liquid developer may be disposed independently of the developing device 400 instead. This Embodiment 2 contemplates independently disposing an electrode adapted to detect the amount of electric charge put on the toner in the liquid developer inside the liquid developer tank 43 as shown in FIG. 11.
In the present embodiment, the liquid developer tank 43 is provided therein a stationary electrode 81 and a rotary electrode 82 opposed to the stationary electrode 81. The rotary electrode 82 is rotated by drive motor 68, and a power source 84 applies voltage between the stationary electrode 81 and the rotary electrode 82. The current sensor 65 measures the magnitude of current which flows during the electrodeposition of the toner to the rotary electrode 82. The rotary electrode 82 is provided with a cleaning blade 83 which is intended to scrape the electrodeposited toner off the rotary electrode 82. As the rotary electrode 82 is rotated in the direction indicated by the arrow in the diagram relative to the cleaning blade 83, the cleaning blade 83 scrapes the electrodeposited toner and exposes the surface of the rotary electrode 82.
By allowing means for monitoring the physical properties of the liquid developer to be disposed independently of the developing device as described above, the construction of the developing device may be suitably altered to some other mode (such as, for example, a construction using a scooping roller or a construction causing direct immersion of the sensitive member in the liquid developer), with due respect paid to such factors as space and cost.
The construction and the operation of the current sensor 65 in the present example are the same as those of the current sensor 65 of Example 1 already described above with reference to FIG. 6. Another construction shown in FIG. 11 is the same as that of Example 1 described above with reference to FIG. 3.
<Embodiment 3>
The compositions of the liquid developer and the replenishing liquids do not need to be limited to those described in the examples cited above. They are only required to contain at least a replenishing liquid for varying the amount of electric charge put on the toner contained in the liquid developer. Thus, the compositions permit wide variation. For example, the toner component and the charge controlling agent component are not always required to be independent of each other. A replenishing liquid which contains the toner and the charge controlling agent together as shown below may be used.
<Charge controlling agent replenishing liquid>
Colored coarsely pulverized particles: 30 parts by weight
Disperse charge resin A: 70 parts by weight
IP Solvent 1620 (produced by Idemitsu Petrochemical Co., Ltd.): 1000 parts by weight
<Toner replenishing liquid>
Colored coarsely pulverized particles: 300 parts by weight
Disperse charge resin A: 3.5 parts by weight
IP Solvent 1620 (produced by Idemitsu Petrochemical Co., Ltd.): 1000 parts by weight
<Liquid medium replenishing liquid>
IP Solvent 1620 (produced by Idemitsu Petrochemical Co., Ltd.) in its unmodified form is used.
When the composition of the liquid developer is prepared in the form of two separate components, toner and liquid medium, by causing the toner itself to assume an electrically charging property as by the dispersion therein of a coloring agent possessed of an electrically charging property, two replenishing liquids, i.e. a toner replenishing liquid containing the toner and the liquid medium and a liquid medium replenishing liquid formed solely of the liquid medium, are used. The toner replenishing liquid may be supplied based on the result of the measurement of the electrodeposition current.
<Embodiment 4>
The embodiments described above invariably contemplate replenishing the components of the liquid developer based on the result of the monitoring of the physical properties of the liquid developer. This mode of replenishing is not critical. Alternatively, the balance of the components of the liquid developer may be adjusted by controlling the various conditions for the image formation such as the developing bias, the potential on the surface of the photosensitive member, the amount of exposure for writing a recording signal such as of laser, the electrodeposition bias onto the developing roller, and the amount of the liquid developer to be fed to the developing device. Embodiment 4 resides in controlling the developing bias voltage based on the result of the monitoring of the physical properties of the liquid developer.
FIG. 12 is a block diagram showing a developing bias controlling system and FIG. 13 is a concrete circuit diagram of the system.
The signal from the electrodeposition current sensor 65 is amplified by the amplifying circuit 651 and then introduced into a comparison circuit 652, specifically a CPU, which incorporates therein an AD converter. The CPU 652 compares the input signal with the standard value by consulting a lookup table on an ROM 654. Based on the result of this comparison, the CPU 652 injects a relevant signal via the DA converter 655 into a developing bias amplifying circuit 656. The amplifying circuit 656 generates a voltage corresponding to the input signal and applies it to the developing roller 402. Thus, the developing bias is adjusted.
This adjustment of the developing bias is so implemented that, for example, when the magnitude of the electrodeposition current exceeds the standard value by a large margin, the magnitude of electric charge put on the toner in the liquid developer is judged to be unduly large and the absolute value of the developing bias is decreased.
Incidentally, the electrodeposition current sensor 65, the power source 64, the amplifying circuit 651, the CPU 652, and other components involved herein are the same as those described above in Example 1.
Although the present invention has been fully described by way of examples with reference to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art.
Therefore, unless otherwise such changes and modifications depart from the scope of the present invention, they should be constructed as being included therein.
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This invention relates to a liquid developer monitoring device comprising a first electrode which contacts with a liquid developer comprising a liquid medium and electrically charged toner particles dispersed therein, a second electrode being either a developing roller or a separate roller which provides a fresh surface and immerses said surface in the liquid developer, an electric power source which applies a bias voltage between said first and second electrodes so as to deposit the toner particles on the second electrode, and a sensor which measures magnitude of current flowing between said first and second electrodes during the deposition of the toner particles. A cleaning device removes the deposited toner on the second electrode. The sensor includes an electric coil, a magnet inserted in the coil and a Hall element.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on, claims a priority benefit from, and incorporates herein by reference, U.S. Provisional Patent Application No. 61/899,986, filed Nov. 5, 2013, and entitled “Lipid Substitution on Aminoglycoside Based Polymers: Plasmid Delivery, Anticancer Drug Delivery and Transgene Expression.”
SATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] This invention was made with government support under 0964955 awarded by the National Science Foundation. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] A library of lipid modified polymers formed by conjugation of lipid acid chlorides with a polymer, a method of preparing the same, and a use thereof are provided.
BACKGROUND OF THE INVENTION
[0004] Gene therapy is a powerful approach for the treatment of hereditary and acquired diseases. The two main types of delivery systems for gene delivery are the viral and the non-viral systems. Due to the safety concerns associated with viral vectors non-viral systems had attained increasing importance over period of time.
[0005] Cationic liposomes and cationic polymers are two main types of non-viral vectors. Low cost, flexibility in chemical design and safety are some of the advantages of non-viral vectors over viral based vectors. Nevertheless, they also have some disadvantages like low gene expression and toxicity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The invention will be better understood from a reading of the following detailed description taken in conjunction with the drawings in which like reference designators are used to designate like elements, and in which:
[0007] FIGS. 1A-1E recite a listing of aminoglycosides used to synthesize polymers;
[0008] FIG. 2 recites a listing of cross-linkers used to synthesize polymers;
[0009] FIGS. 3A-B recite a listing of lipids used to conjugate to the polymers;
[0010] FIG. 4 graphically illustrates steps involved in lipid modified polymer gene delivery;
[0011] FIG. 5A recites a proton NMR spectrum of a Neomycin-GDE polymer;
[0012] FIG. 5B recites a proton NMR spectrum of a Neomycin-GDE polymer conjugated with hexanoyl chloride;
[0013] FIG. 6A graphically shows hydrodynamic sizes for lipopolymers with Glycerol diglycidyl ether as linker group;
[0014] FIG. 6B graphically shows hydrodynamic sizes for lipopolymers with Resorcinol diglycidyl ether as linker group;
[0015] FIG. 7A graphically shows Zeta potential values of leads of lipopolymers with Glycerol diglycidyl ether as a linker group;
[0016] FIG. 7B graphically shows Zeta potential values of leads of lipopolymers with Resorconol diglycidyl ether as a linker group;
[0017] FIG. 8 graphically illustrates in vitro transfection profiles of Neomycin-GDE polymer, Neomycin-GDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0018] FIG. 9 graphically illustratrates in vitro transfection profiles of Paromomycin-GDE polymer, Paromomycin-GDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0019] FIG. 10 graphically illustratrates in vitro transfection profiles of Apramycin-GDE polymer, Apramycin-GDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0020] FIG. 11 graphically illustratrates in vitro transfection profiles of Neomycin-RDE polymer, Neomycin-RDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0021] FIG. 12 graphically illustratrates in vitro transfection profiles of Paromomycin-RDE polymer, Paromomycin-RDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0022] FIG. 13 graphically illustratrates in vitro transfection profiles of Apramycin-RDE polymer, Apramycin-RDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0023] FIG. 14 graphically illustratrates in vitro transfection profiles of leads of lipid conjugated polymers, polymer lead and pEI at different weight ratios in PC3-PSMA cells;
[0024] FIG. 15A graphically illustratrates in vitro transfection profiles of lipopolymers with Glycerol diglycidyl ether as linker group, conjugated polymers, polymer lead and pEI at different weight ratios in 22RV1 cells;
[0025] FIG. 15B graphically illustratrates in vitro transfection profiles of lipopolymers with Resorcinol diglycidyl ether as linker group, conjugated polymers, polymer lead and pEI at different weight ratios in 22RV1 cells;
[0026] FIG. 16A illustrates green fluorescent image of leads of lipid conjugated polymers and PEI;
[0027] FIG. 16B illustrates green fluorescent image of polymer leads and pEI at higher transgene expression weight ratios in PC3 cells;
[0028] FIG. 17A graphically illustrates serum stability studies of leads of with lipopolymers with Glycerol diglycidyl ether as linker group and pEI at different concentrations of serum added in PC3 cells;
[0029] FIG. 17B graphically illustrates serum stability studies of leads of with lipopolymers with Resorcinol diglycidyl ether as linker group and pEI at different concentrations of serum added in PC3 cells;
[0030] FIG. 18A graphically illustrates DNA binding profiles of leads of lipopolymers with Glycerol diglycidyl ether as linker group and pEI at different concentrations of serum added in PC3 cells; at different weight ratios used for in vitro transfection experiments;
[0031] FIG. 18B graphically illustrates DNA binding profiles of leads of lipopolymers with Resorcinol diglycidyl ether as linker group and pEI at different concentrations of serum added in PC3 cells; at different weight ratios used for in vitro transfection experiments;
[0032] FIG. 19 graphically illustrates in vitro toxicity profiles of Neomycin-GDE polymer, Neomycin-GDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0033] FIG. 20 graphically illustrates in vitro toxicity profiles of Paromomycin-GDE polymer, Paromomycin-GDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0034] FIG. 21 graphically illustrates in vitro toxicity profiles of Apramycin-GDE polymer, Apramycin-GDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0035] FIG. 22 graphically illustrates in vitro toxicity profiles of Neomycin-RDE polymer, Neomycin-RDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0036] FIG. 23 graphically illustrates in vitro toxicity profiles of Paromomycin-RDE polymer, Paromomycin-RDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0037] FIG. 24 graphically illustrates in vitro toxicity profiles of Apramycin-RDE polymer, Apramycin-RDE lipid polymer conjugates with varying lipids and varying molar ratios and pEI at different weight ratios in PC3 cells;
[0038] FIG. 25A recites an AFM image of Micelles of ARDGE Lipid Conjugated Polymer; and
[0039] FIG. 25B recites an AFM image of Micelles of PRDGE Lipid Conjugated Polymer.
DETAILED DESCRIPTION OF THE INVENTION
[0040] This invention is described in preferred embodiments in the following description with reference to the Figures, in which like numbers represent the same or similar elements. Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0041] The described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are recited to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
[0042] To overcome the limitations associated with cationic polymers, several combinations of cationic amines and cationic lipids have been tried. Among them the amphiphilic polymers formed by the conjugation of lipidic moieties on to the polymer are more attractive, since they have the beneficial effects of nucleic acid condensation from cationic polymers and compatibility with cellular membranes from lipid moieties in single carrier system. Cationic polymers substituted with various hydrophobic molecules are found to show improved gene delivery activity when compared to parent polymers. Introduction of hydrophobic chain can not only effect the interaction with the plasma membrane but also can affect at most steps during the whole gene delivery process.
[0043] Applicants identified antibiotics-derived polymers for gene delivery using combinatorial synthesis and cheminformatics modeling. The library of polymers prepared by parallel synthesis was evaluated for in-vitro gene transfection studies in multiple kinds of cancer cells using plasmid DNA. The transfection efficacies of few of the leads were found to be many times higher than poly (ethyleneimine) used as standard. With an insight into further improvisation of transfection profiles of the developed polymers, few of the leads were selected and used for hydrophobic modifications.
[0044] Applicants developed a library of lipid modified aminoglycoside based polymers by simple N-acylation reaction. As those skilled in the art will appreciate, an “aminoglycoside” comprises an amino-modified sugar.
[0045] Hexanoyl chloride, Myristyl chloride and Stearyl chloride were choosen as the hydrophobic segments to synthesize the amphiphilic grafted polymers. The gene delivery efficacies of the developed conjugates were tested in different types of cancer cells. The objective of this study was to elucidate changes in properties of polymer-DNA complexes as a result of lipid substitution and to access the effect of lipid substitution on the effectiveness in transgene expression.
[0046] 1. Synthesis and Characterization of Lipid-substituted Polymers.
[0047] (a) Synthesis of Polymers:
[0048] A library of 54 lipid conjugates of polymers was synthesized with three different lipid acid chlorides in three different molar ratios. The polymers synthesized were dissolved in DMSO(Dimethyl sulfoxide) (2 mL) at room temperature by stirring for 30 min and triethyl amine (in 1:4 molar ratio with respect to polymer) was added to the solution and stirred for an additional 30 min period. The mixture was then cooled to 4° C. and different amounts of alkanoyl cholorides (1:2, 1:5, 1:10 corresponding to different molar ratios with respect to polymer) were added drop wise and the mixture was stirred at room temperature for 12 h. The final product was collected by precipitation in excess ether. The product was further purified by dialysis using a 3500 molecular weight cutoff (MWCO) membrane to remove unreacted polymer, any traces of triethylamine and DMSO. The dialyzed material was lyophilized to obtain the lipopolymer product. Synthetic procedure showing lipid modification of polymers is shown in Scheme 1.
[0049] Scheme 1 summarizes the synthetic procedure for preparing Applicants' polymeric materials.
[0000]
[0050] The structural composition of the lipid-substituted polymers was analyzed by
[0051] 1H NMR (Bruker 300 MHz, Billerica, Mass.) in D 2 O and DMSO. 1H NMR analysis showed the expected alkanoyl protons —CH3 (δ 0.8 ppm), -γ-CH2 (δ 1.26-ppm), -β-CH2 (δ 1.6 ppm), -α-CH2 (δ2.16 ppm), in the obtained polymers. The characteristic resonance shifts corresponding to alkyl chain-CH3 (δ 0.8 ppm), and Polymer (CH— δ 5.6 ppm) were used to obtain the extent of lipid substitution. The number of grafted lipids generally increased with increasing feed ratio. Table 1 shows the feed molar ratios, the ratios calculated from NMR and the degree of lipid substitution of the lead lipid conjugated polymers.
[0052] Gel permeation chromatography (GPC) was employed for determining lipid conjugated polymers molecular weights. A Waters 1515 GPC system, in concert with an ultrahydrogel 250 column (Waters Corporation, MA) and a refractive index detector (Waters 2410), was used. An aqueous solvent containing 0.1% trifloroacetic acid and 40% acetonitrile was used as the mobile phase. The molecular weights of lead lipid conjugated polymers (picked up from in vitro transgene expression screening in PC3 cells) was determined using GPC and is found that the average molecular weights are in the range of 4.0-6.0 kDa. Molecular weights of leads are shown in Table 2. Lead lipid polymer conjugates exhibited varying amine concentrations, which are dependent on the number of amines in the parental polymers. The polydispersities of the lead lipid conjugated polymers range from 1.1-1.3 which shows the lipid conjugated polymers are relatively homogeneous and are found to be more homogeneous when compared to the parent polymers.
[0053] Hydrodynamic sizes and zeta potentials of lipid conjugated polymers and lipid conjugated polymer-pDNA complexes (lipopolyplexes) were determined using a Zetasizer Nanosystems Nano-ZS instrument (Malvern Instruments, Mission Viejo, Calif.). Lead lipopolymer-pDNA complexes were prepared at DNA: lipopolymer weight ratios of 1:5 to 1:50 by adding different amounts of polymers to 100 ng of DNA. Zeta potential and size distribution measurements were carried out in triplicate after mixing the polymer and pDNA solutions for 20 minutes at room temperature.
[0054] Polymer charge plays an important role in polyplex formation; positive charges on the polymer interact with negative charges in pDNA, by means of electrostatic interactions, ultimately resulting in the formation of nanoscale polymer-pDNA complexes or polyplexes. Positively charged polyplexes are efficiently taken up by cells, ultimately resulting in transgene expression. In the present invention we found that the lipid conjugated polymers which have glycerol diglycidyl ether as linker group in their polymer synthesis (Paromomycin-GDE, Neomycin-GDE and Apramycin-GDE) are polydisperse whereas the lipid conjugated polymers which have resorcinol diglycidyl ether as linker group in their polymer synthesis (Paromomycin-RDE, Neomycin-RDE and Apramycin-RDE) are nanoparticles and exhibited micellar properties.
[0055] Hydrophobically grafted polymers assemble into a core-shell micelle structure, creating the potential to load hydrophobic drugs and gene drugs into the different compartments (core and shell) respectively. Some examples include poly(e-caprolactone)-bPEI 1.8 kDa, poly((Nmethyldietheneamine sebacate)-co-[(cholesteryl oxocarbonylamidoethyl)methyl bis(ethylene)ammonium bromide]sebacate), and poly(dimethylaminoethyl methacrylate)-poly(e-caprolactone)-poly(dimethylaminoethyl methacrylate). Other advantages of polymeric micelles include their low critical micelle concentrate (CMC) value which promotes greater stability in aqueous environments. 18 , 19 Thus the emerging polymeric micellar DNA carriers include hydrophobically modified water-soluble polymers.
[0056] The micellar systems developed can have the advantages not only in the field of gene delivery (as studied in the present invention) but also have various other biomedical applications like drug delivery, imaging studies etc. 20 - 12 The sizes and zeta potentials of the leads from two different sets of lipid conjugated polymers based on their particle nature are shown in FIGS. 6,7 .
[0057] In the present invention we found that the hydrodynamic size and zeta potential of pDNA/polymer complexes (using plasmid pGL4.5) showed significant changes as a result of lipid substitution on the polymers. The pDNA/Polymer mass ratio used to form complexes was a significant factor of the hydrodynamic size, more so than the extent of lipid substitution on the polymers. At lower pDNA/polymer ratios (1:5, 1:10) the hydrodynamic sizes of the lipid-substituted complexes were generally larger than the complexes formed with the corresponding native lipid-substituted polymers. At higher pDNA: polymer ratios (1:25, 1:50) the size of all complexes (<100 nm) was uniformly smaller than the native lipid-conjugated polymers.
[0058] The increase in the hydrodynamic size likely reflects the consequences of lower polyamine content necessary for pDNA condensation. The decrease in complex size was presumably driven by the high lipid content in the complexes, facilitating stronger hydrophobic associations among the lipids and resulting in more compact particles.
[0059] The influence of lipid substitution was clearly evident on the zeta potential of complexes. The zeta potential of the native lipid-substituted polymers are found to be higher compared to the pDNA/polymer complexes. The mass ratio of pDNA/Polymer also influenced the zeta potential of complexes (increasing zeta potential with increasing mass ratio).
[0060] The aminoglycoside-based lipopolymer library was screened in parallel for delivering the pGL4.5 control vector (Promega Corp., Madison, Wis.), which encodes for the modified firefly luciferase protein, to different cancer cell lines. The pGL4.5 plasmid DNA (pDNA) was prepared as described previously. Plasmid concentration and purity were determined using a NanoDrop Spectrophotometer (ND-1000; NanoDrop Technologies) by measuring absorbance at 260 and 280 nm.
[0061] Prostate cancer cells (PC3, PC3-PSMA and 22RV1) and bladder cancer cells (MB49) were used for the in vitro transfection experiments. Cells were seeded at a density of 9000 per well in a 96-well plate 18-24 hours before the transfection using RPMI-1640 media. 100 ng of plasmid DNA was complexed with varying amounts of lipopolymers in HEPES buffer for 30 minutes. The weight ratios were varied from 1:5 to 1:50 over these ranges of the polymers. Just prior to transfection, cells plated in the 96-well plate were washed with PBS (2×100 μL) followed by the addition of polyplexes. After 6 h of incubation, 150 μL of Serum containing media was added to the cells.
[0062] After 48 h of further incubation in serum-containing media, cells were lysed, and luciferase protein expression was determined as relative luminescence units (RLU) using the Bright Glo™ Luciferase assay kit (Promega) with a plate reader (Bio-Tek Synergy 2). Cell lysates were then assayed for total protein content using the BCA Protein Assay kit (Pierce, Rockford, Ill., USA). RLU values were normalized by the protein content to yield ‘RLU/mg protein’ values that were employed for comparing different polymers. Untransfected cells and cells transfected with uncomplexed pDNA were used as controls. Luciferase expression efficacies of polymers from the library were compared to that with 25 kDa branched pEI. In all cases, the pEI solution was prepared fresh right before all transfection experiments.
[0063] Preliminary screening of luciferase transgene expression of all the 54 conjugates at varying pDNA/lipopolymer was done with PC3 type of cell line. The transgene expression of all the lipid conjugated polymers were evaluated with respect to the parent polymer and the pEI-25 kDa. Twelve leads were picked up from the initial screening and were further evaluated for transgene expression in other types of cell lines. The data of in vitro transgene expression in PC3 cells is given in FIGS. 8-13 . The data is plotted separately for the two different sets of lipopolymers and their leads based on their particle nature.
[0064] Applicants discovered that, in general, polymers based on glycerol diglycidyl ether as linker group showed better enhancement in transgene expression when conjugated with C18 lipid and polymers based on resorcinol diglycidyl ether showed better enhancement in transgene expression when conjugated with C6 lipids. We also found that the transgene expression also depends on the weight ratios of pDNA/lipopolymer used. We found that the transgene expression is also cell type dependent. The highest transgene expression were found in PC3 type of cells followed by PC3-PSMA FIGS. 14 and 22RV1 cells FIG. 15 .
[0065] Cytotoxicities of the lipid conjugated polymers were assessed by the 3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide (MTT) reduction assay. In the present invention, the cytotoxicity assay was performed in 96-well plates by maintaining the same ratio of number of cells to amount of cationic DNA/lipopolymer complexes, as used in the transfection experiments. Briefly, the cells were incubated with lipopolyplexes for 6 h followed by the addition of 150 μL of serum containing media. After 48 hours of transfection,10 μL MTT (5 mg/mL in PBS) was added to each well and after 3-4 h of incubation at 37° C., 30 μL of the detergent was added to the cells and incubated for overnight. The absorbance was measured at 550 nm and results were expressed as percent viability=[A540 (treated cells)-background/A540 (untreated cells)-background]×100.
[0066] The cytotoxicity studies of the entire 54 lipid conjugated polymers were evaluated in PC3 types of cells and the results were as shown in FIGS. 19-24 . The toxicity profiles of all the lipid conjugated polymers were evaluated with respect to the parent polymer and the pEI-25 kDa. The toxicity profiles of the library of lipid conjugated polymers synthesized in general found to be increase on increasing the grafting ratios. The C18 lipid conjugated polymer is found to be slightly higher toxic to the smaller alkyl chain C6 conjugated polymers. The toxicity studies were conducted under the same conditions of the transfection studies with a DNA:lipopolymer weight ratios of 1:5 to 1:50. The PEI shown here is at a single weight ratio of 1:1 (the same ratio used for the transfection studies) and is found to be non-toxic. We found that the Apramycin based lipid conjugated polymers were the least toxic among all the lipid conjugated polymers.
[0067] Serum stability studies of the lead lipid conjugated polymers were carried out in PC3 types of cells with varying amounts of serum concentrations. The transfection experiments in presence of serum were carried out following the protocol used in in vitro transfection experiments. Only the difference is the cells are incubated with the lipopolyplexes for 6 hours at various concentrations of serum (varying from 0, 10, 30 and 50 percentage of serum). After 6 h of incubation the media is replaced with the 10% serum containing media and the remaining procedure is same as followed in in vitro transfection experiments.
[0068] Applicant found that the lipid conjugated polymers are serum stable. Among the different sets of conjugates the lipopolymers with glycerol diglycidyl ether linker are found to be more serum compatible even at higher concentrations of serum when compared to the lipopolymers with resorcinol diglycidyl ether as linker. We found that the Neomycin glycerol diglycidy ether based lipopolymers were found to be better serum compatible when compared to other leads. The serum stability of the leads from both the sets of lipopolymers is shown in FIG. 17 .
[0069] EF-GFP (enhanced green fluorescent protein)-encoding pDNA (pEFGFP) were delivered as described in in vitro transfection procedure. The transfection experiments were carried out and the green fluorescent protein expressed was observed using fluorescent microscope. FIG. 16 shows the GFP expression of the leads of lipid polymer conjugates, the respective parent polymers and pEI in PC3 types of cells.
[0070] Applicants found that in few conjugates there is a great enhancement in the GFP expression in the cells transfected with lipopolymers when compared to the cells transfected with only polymers. This is in accordance with the luciferase values observed form the in vitro transfection experiments.
[0071] DNA binding studies of the lipid conjugated polymers were studied using EtBr exclusion assay. Intercalation-induced fluorescence increase and competition with lipopolymers to bind to DNA has made EtBr an excellent tool to study lipopolymers-DNA interactions. To assess the representative lipopolymer-DNA interactions of the presently described leads of lipopolymer library, Applicants complexed EtBr:pGL4.5 complex with varying amounts of lipopolymers (using the indicated DNA/lipopolymer weight ratios of 1:5-1:50).
[0072] The data in FIG. 18 shows that all the leads of the lipopolymer library interact strongly with DNA at higher DNA/lipopolymer weight ratios i.e. at 1:25 and 1:50 as seen by their ability to exclude ethidium bromide form DNA. This further supports the results obtained in the invitro transfection experiments showing higher transfection values at the optimal DNA/polymer weight ratio is dependent on the DNA binding profiles of the lipopolymer.
[0073] Applicants have carried out the AFM imaging studies of the lipid conjugated polymers that form the micelles. FIG. 25 shows the AFM images of two different samples of lipid conjugated Polymers that forms micelles. (ARDE polymer with C14 lipid conjugation and PRDE polymer with C14 lipid conjugation). These images are at different magnification. Atomic force microscopy (AFM, NanoScope III, Digital Instrument) equipped with an integrated silicon tip/cantilever with resonance frequency of ˜240 kHz in height and phase image models were utilized for the observation of morphologies.
[0074] Polymer solutions (10 μL) were dropped on a mica sample stage and dried at room temperature for the morphological observation. The AFM images show that the particles are of various sizes. This may arise due to formation of aggregates or sometimes due to degradation during the process of drying.
[0075] In summary, Applicants designed and developed a library of lipid conjugated polymers by the reaction between lipid acid chlorides and the free amines on the lead polymers. A library of 54 lipopolymers were developed using six different polymers, three different acid chlorides and three different molar ratios. The degree of substitution was found to be dependent on the molar feed ratio of polymer to lipid. The screening of all the lipopolymer for luciferase transgene expression revealed that few lipopolymers are many times better in transgene expression when compared to their parent polymers.
[0076] One important observation is that few of the lead lipid conjugated polymers were found to be highly serum compatible even at higher concentrations of serum. This insinuates the possibility of using these leads further for in vivo studies.
[0077] Further the hydrophobic modification of the resorcinol diglycidyl ether based polymers developed supported the formation of micelles. These micelles will have greater applicability in the field of drug delivery, gene delivery and imaging studies. In this invention, we successfully developed various micelle of size ranging from 20-50 nm Taken together, lipid conjugated polymer library developed has potential to use as gene delivery vectors or as a material for drug delivery, imaging studies as well as combined drug and gene delivery.
[0078] Table 1 recites percentage degree of substitution of lead lipid conjugated polymers calculated based on the area under the NMR shifts.
[0000]
TABLE 1
Lipid/
Lipid/
Polymer
Polymer
(Degree
Polymer
Lipid
(mol
(mol
of Subtn
Sample ID
(mmol)
(mmol)
ratio) a
ratio) b
%) c
NGDGE-C18
0.01
0.02
2.0
0.65
9.33
NGDGE-C18
0.01
0.05
5.0
0.98
14
AGDGE-18
0.01
0.02
2.0
0.49
12.27
AGDGE-C18
0.01
0.05
5.0
0.74
18.5
PGDGE-C18
0.01
0.02
2.0
0.45
9
PGDGE-C18
0.01
0.05
5.0
0.8
16
PRGDE-C6
0.01
0.02
2.0
0.43
10.2
PRGDE-C6
0.01
0.05
5.0
0.57
13
PRGDE-C6
0.01
0.02
2.0
0.24
6.7
PRGDE-C6
0.01
0.05
5.0
0.76
16.9
PRGDE-C6
0.01
0.02
2.0
0.34
9.2
PRGDE-C6
0.01
0.05
5.0
0.86
19.8
[0079] Table 2 recites molecular weights and polydispersity index of leads of lipid conjugated polymers.
[0000]
TABLE 2
S. No.
SAMPLE
Mn
Mw
PDI
1
NGDE-C18(1:2)
3138
4088
1.3
2
NGDE-C18( 1:5)
3241
4232
1.3
3
PGDE-C18(1:2)
3228
4345
1.34
4
PGDE-C18(1:5)
3485
4519
1.28
5
AGDE-C18(1:2)
2228
3551
1.59
6
AGDE-C18(1:5)
3118
3777
1.21
7
ARDE-C6(l-2)
2886
3570
1.23
8
ARDE-C6(l-5)
2827
3463
1.22
9
PRDE-C6(l-2)
3843
4962
1.18
10
PRDE-C6(l-5)
4057
5282
1.31
11
NRDE-C6(l-2)
3086
3814
1.16
12
NRDE-C6(l-5)
3489
4063
1.24
[0080] While the preferred embodiments of the present invention have been illustrated in detail, it should be apparent that modifications and adaptations to those embodiments may occur to one skilled in the art without departing from the scope of the present invention.
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A method to form a lipid-containing aminoglycoside-based polymer, where the method includes reacting an aminoglycoside with a diepoxide to form an aminoglycoside-based polymeric material, and then reacting the aminoglycoside-based polymeric material with an acyl chloride to form the lipid-containing aminoglycoside-based polymer.
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This application is a divisional of application Ser. No. 07/797,066, filed Nov. 25, 1991, now U.S. Pat. No. 5,210,270.
FIELD OF THE INVENTION
This invention relates to a novel synthesis of 2-alkoxyisobutylisonitrile, copper isonitrile adducts and radioactive isotope labelling such as 99m Tc.
BACKGROUND OF THE INVENTION
99m Tc labelling isonitrile compounds have been proven to be myocardial perfusion agents. The synthesis of ether isonitrile ligands has been described by Bergstein et al in European Pat. 233368 issued Oct. 26, 1987. The most useful of ether isonitrile compound is 2-methoxyisobutylisonitrile, synthesis of which is described by Bergstein as follows: ##STR1##
In both of the above (A) and (B) synthetic routes, which include 4 and 5 steps respectively, the total yield is only 5.9-8.1%. Van Wyk et al. developed a method to synthesize both 2-methoxyisobutylisonitrile and 2-ethoxyisobutylisonitrile, which was published under the title "Synthesis and 99 Tc Labelling of MMI(MIBI) and its Ethyl Analogue EMI", Appl. Radiat. Isot. 1991, 42:687 ##STR2##
The possible contamination of mercury on the product is a disadvantage of the above process. There is a question of whether or not mercury ace[ate reagent affects products in the second step. Accordingly, we have invented a new simple and efficient method to synthesize 2-alkoxyisobutylisonitrile compounds.
SUMMARY OF THE INVENTION
The main object of the present invention is to provide a new method for synthesis and 99m Tc labelling of 2-alkoxyisobutylisonitrile. Isobutylene is haloalkoxylated with N-halosuccinimide in the presence of alcohol solution to give 2-alkoxyisobutylhalide. This is followed by reaction of potassium phthalimide with 2-alkoxyisobutylhalide, following by hydrazinolysis with hydrazinc to yield 2-alkoxyisobutylamine. Finally, in the basic condition, the reaction of 2-alkoxyisobutylamine with chloroform in the presence of catalyst benzyltriethylammonium chloride produces 2-alkoxyisobutylisonitrile.
The new synthesis method of these isonitriles has also proved to be more clean, more efficient and convenient than known methods in the literature.
The 99m Tc labelling of 2-alkoxyisobutylisonitrile is performed by mixing copper isonitrile adducts with radioactive isotope 99m Tc. Such an adduct is labelled easily and rapidly with 99m Tc and produces good yields. Tetrakis(2-alkoxyisobutylisonitrile)copper(I)tetrafluoroborates can be prepared by the exchange of acetonitrile molecules in tetrakis(acetonitrile) copper(I) tetrafluoroborate with 2-alkoxyisobutylisonitrile ligand at room temperature.
DETAILED DESCRIPTION OF THE INVENTION
The haloalkoxylation of alkenes can be achieved by halogen in alcohol as shown in equation(1). ##STR3##
This procedure provides a convenient and high yields 2 from olefins. Reaction of potassium phthalimide with 2 leads to the N-alkylphthalimide. N-Substituted phthalimides may be converted into the corresponding 3by hydrolysis or hydrazinolysis. Synthesis of 3 may be summarized schematically as equation(2). ##STR4##
It is obvious that 3 formed in this reaction will be uncontaminated by secondary or tertiary amines.
The phase-transfer catalysis method has been utilized effectively for synthesis of isonitriles. ##STR5##
The reaction between 3 and chloroform in NaOH solution and catalyst benzyltriethylammonium chloride gives 4 as shown in equaiton(3). This invention can be further described by the following examples in which the percentages are expressed by weight unless otherwise indicated.
EXAMPLE 1
Synthesis of 2-methoxyisobutylbromide
N-Bromosuccinimide (3.56 g, 0.02 mol) was dissolved in methanol. The solution was cooled to -10° C. in an ice/acetone bath. Isobutylene was slowly introduced and stirred for 5 hours and poured into separatory funnel containing saturated NaCl water. The organic layer was removed and aqueous layer was extracted with three 100 ml portions of dichloromethane. The combined organic extractants was dried over anhydrous magnesium sulfate and filtered, and the solvent was mostly removed by rotary evaporatory. The resulting solution was distilled at atmospheric pressure and the product collected at 140° C. (3.14 g, 94% yield).
IR(neat/ν cm -1 ): 2960, 2920, 2820, 1450, 1415, 1370, 1360, 1090, 1065, 735, 660.
1 HNMR(200 MHz, CDC1 3 /δ ppm): 1.30(s,6H,2CH 3 ), 3.24(s, 3H, OCH 3 ), 3.41(s, 2H, CH 2 ).
13 CNMR(200 MHz, CDC1 3 /δ ppm): 23.71(s, 2CH 3 ), 40.91.(s, CH 2 ), 49.79(s, OCH 3 ), 73.63 ##STR6## .
EXAMPLE 2
Synthesis of 2-methoxyisobutyliodide
N-Iodosuccinimide(4.50 g, 0.02 mol) was dissolved in methanol. This was cooled to -15° C. in an ice/acetone bath. Isobutylene was-slowly introduced and stirred for 4 hours and poured into separatory funnel containing saturated NaCl water. The organic layer was removed and aqueous layer was extracted with three 100 ml portions of dichloromethane. The combined organic extractants was dried over anhydrous magnesium sulfate and filtered, and the solvent was mostly removed by rotary evaporatory. The resulting solution was concentrated under reduced pressure at 10 mm Hg pressure and 50° C. temperature(4.07 g, 95% yield).
IR(neat/ν cm -1 ): 2980, 2950, 2840, 1470, 1420, 1380, 1365, 1095, 1070, 740, 620.
1 HNMR(200 MHz, CDC1 3 /δ ppm): 1.26(s,6H,2CH 3 ), 3.15(s, 3H, OCH 3 ) 3.24(s, 2H, CH 2 ).
EXAMPLE 3
Synthesis of 2-methoxyisobutylamine
Potassium phthalimide(3.70g, 0.02 tool) was added to a solution of 2-methoxyisobutylbromide(3.34 g, 0.02 mol) in 100 ml of dimethylformamide. Stirring and reflux were continued for 4 hours, and the temperature dropped slowly to 25° C. After the addition of 200 ml of chloroform, the mixture was poured into 500 ml of cold water. The aqueous phase was separated and extracted with two 50 ml portions of chloroform. The combined chloroform extractants were washed with 100 ml of 0.2N sodium hydroxide and 100 ml of water. After drying the chloroform was removed. The residue was added to hydrazine (2 g, 0.04 mol) in 100 ml of methanol and was heated under reflux for an hour. The methanol was removed by concentration under reduced pressure. Concentrated hydrochloric acid was added to the residual aqueous solution and the mixture was heated under reflux for an hour. The solution was then concentrated under reduced pressure to remove most of the hydrochloric acid. The moist residue was adjusted pH= 14 using sodium hydroxide and was poured into separatory funnel containing saturated K 2 CO 3 solution. The resulting solution was distilled at atmospheric pressure and the product collected at 125° C. (1.6 g, 78% yield).
IR(neat/ν cm -1 ): 3280, 3065, 2960, 2920, 1640, 1430, 1365, 1075.
1 NHMR(200 MHz, CDC1 3 /δ ppm): 1.13(s,6H,2CH 3 ), 1.17(s, 2H, NH 2 ), 2.61(s, 2H, CH 2 ), 3.2(s, 3H, OCH 3 ).
13 CNMR(200 MHz, CDC1 3 /δ ppm): 22.54(s, 2CH 3 ), 49.39(s, CH 2 ), 50.50(s, OCH 3 ), 74.98 ##STR7## .
EXAMPLE 4
Synthesis of 2-methoxyisobutylisonitrile
A mixture of 2-methoxyisobutylamine(2.06 g,0.02 mol), chloroform (4,80 g, 0.04 mol) benzyltriethylammonium chloride (40 mg,0.17 mmol) in 50 ml of dichloromethane, was added dropwise into a flask containing sodium hydroxide solution (3.2 g NaOH and 5 ml H 2 O). The mixture solution was heated under reflux for two hours. After the reaction mixture was diluted with 100 ml of ice water, the organic layer was separated and retained, and the aqueous layer was extracted with 50 ml of dichloromethane. The dichloromethane solutions were combined and dried over anhydrous magnesium sulfate. The resulting solution was concentrated under reduced pressure at 25 mm Hg pressure and the product collected at 55°-60° C.(1.42 g, 63% yield).
IR(neat/ν cm -1 ): 2980, 2940, 2830, 2150, 1460, 1435, 1390, 1370, 1080.
1 HNMR(200 MHz, CDC1 3 /δ ppm): 1.28(s,6H,2CH 3 ), 3.26(s, 3H, OCH 3 ), 3.38(t, 2H, CH 2 ).
13 CNMR(200 MHz, CDC1 3 /δ ppm): 22.47(s, 2CH 3 ), 49.97.(s, OCH 3 ), 50.57(t, CH 2 ), 73.34 ##STR8## .
EXAMPLE 5
Synthesis of 2-ethoxyisobutylbromide
N-Bromosuccinimide (3.56 g, 0.02 mol) was dissolved in ethanol. The product was obtained by procedures analogous to those described in Example 1(95% yield).
IR(neat/ν cm -1 ): 2980, 2940, 2900, 2880, 1460, 1440, 1380, 1360, 1120, 1068.
1 HNMR(200 MHz, CDC1 3 /δ ppm): 1.19(t,3H, CH 3 ), 1.31(s, 6H, 2CH 3 ), 3.44(m, 4H, CH 2 , and OCH 2 ).
13 CNMR(200 MHz, CdC1 3 /δ ppm): 16.01(s, CH 3 ), 24,48(s, 2CH 3 ), 43.23(s,CH 2 Br),57.31(S,OCH 2 ), 73,52 ##STR9## .
EXAMPLE 6
Synthesis of 2-ethoxyisobutylamine
The product was obtained by procedures analogous to those described in Example 3(75% yield).
IR(neat/ν cm -1 ): 3380, 2980, 2950, 2850, 1660, 1470, 1430, 1398, 1370, 1120, 1075.
1 HNMR(200 MHz, CDC1 3 /δ ppm): 1.15(m, 11H, 2CH 3 , CH 3 and NH 2 ), 2.60(s, 2H, CH 2 ), 3.38(q,2H, OCH 2 ).
13 CNMR(200 MHz, CDC1 3 /δ ppm): 16.26(s, CH 3 ), 23.25(s, 2CH 3 ), 50.92(s, CH 2 ), 56.71(s, OCH 3 ), 73.79 ##STR10## .
EXAMPLE 7
Synthesis of 2-ethoxyisobutylisonitrile
The product was obtained by procedures analogous to those described in Example 4 (60% yield).
IR(neat/ν cm -1 )): 2980, 2930, 2900, 2870, 2150, 1475, 1450, 1385, 1360, 1120, 1070.
1 HNMR (200 MHz , CDC1 3 /δ ppm): 1.14(t, 6H, CH 3 ), 1.28(s, 6H, 2CH 3 ), 3.37(t, 2H, CH 2 ), 3.45(q, 2H, OCH 2 ).
13 CNMR(200 MHz, CDC1 3 /δ ppm): 15.99(s, CH 3 ), 23.22(s, 2CH 3 ), 50. 89(t, CH 2 ), 57.57(s, OCH 3 ), 73.14 ##STR11##
EXAMPLE 8
Synthesis of 2-propoxyisobutylbromide
N-Bromosuccinimide (3.56, 0.02 mol) was dissolved in 1-propanol. The product was obtained by procedures analogous to those described in Example 1 (93% yield).
IR(neat/ν cm -1 ): 2980, 2945, 2880, 1465, 1430, 1380, 1370, 1100, 1080, 675.
1 HNMR(200 MHz, CDC1 3 δ ppm): 0.91(t, 3H, CH 3 ), 1.29(s,6H,2CH 3 ), 1.54(m, 2H, CH 2 ), 3.27(t,2H,OCH 2 ), 3.39(s, 2H, CH 2 Br).
13 CNMR(200 MHz, CDC1 3 /δ ppm): 10.84(s,CH 3 ), 23.72(s,CH 2 ), 24.52(s,2CH 3 ), 41.47(s,CH 2 Br), 63.76(s,OCH 2 ), 73.48 ##STR12## .
EXAMPLE 9
Synthesis of 2-isopropoxyisobutylbromide
N-Bromosuccinimide(3.56 g, 0.02 mol) was dissolved in 2-propanol. The product was obtained by procedures analogous to those described in Example 1 (93% yield),
IR(neat/ν cm -1 ): 2980, 2955, 2880, 1470, 1430, 1380, 1370, 1120, 670.
1 HNMR(200 MHz, CDC1 3 /δ ppm): 1.10 ##STR13## 3.35(s, 2H, CH 2 ), 3.79(m, 1H, CH).
13 CNMR(200 MHz, CDC1 3 /δ ppm): 25.10 and 25.17(s,CH3), 42.21(s,CH 2 ), 64.65(s,OCH), 74.55 ##STR14## .
EXAMPLE 10
Synthesis of 2-propoxyisobutylisonitrile
The product was obtained by procedures analogous to those described in Example 4 (55% yield),
IR(neat/ν cm -1 ): 2980, 2950, 2880, 2160, 1470, 1380, 1370, 1120, 1080.
1 HNMR(200 MHz, CDC1 3 /δ ppm): 0.92(t,3H, CH 3 ), 1.28(s,6H,2CH 3 ), 1.57(m,2H,CH 2 ), 3.28(m,2H,OCH 2 ), 3.36(t,2H,CH 2 --N.tbd.C).
13 CNMR(200 MHz, CDC1 3 /δ ppm): 10.79(s,CH 3 ), 23.21(s,2CH 3 ), 23.64(s,CH 2 ), 50.97(t,CH 2 --N), 63.86(s,OCH 2 ), 73.01 ##STR15## .
EXAMPLE 11
Preparation of tetrakis(2-methoxyisobutylisonitrile) copper(I) tetrafluoroborate
Tetrakis(acetonitrile)copper(I) tetrafluoroborate(0.50 g, 1.6×10 -3 mol) was suspended in 100 ml of ethanol. 2-Methoxy-isobutylisonitrile (0.72 g, 6.4×10 -3 mol) was slowly added and stirred at room temperature for an hour. The solvent was then evaporated completely under reduced pressure. The product was recrystallized from ethanol/ether (0.91g, 95% yield), M.P. 100°-101° C. Anal. Calcd. for C 24 H 44 N 4 O 4 CuBF 4 :C,47.80;H,7.30; N,9.29; Cu,10.54; B,1.79; F,12.62. Found: C,47.69; H,7.40; N,9.05; Cu,10.52; B,1.80; F,12.71.
IR(Nujol mull/ν cm -1 ): 2200.
1 HNMR(200 MHz, CDC1 3 /δ ppm): 1.29(s,6H,2CH 3 ), 3.25(s,3H, OCH 3 ), 3.61(s,2H,CH 2 ).
13 CNMR(200 MHz,CDC1 3 /δ ppm): 22.60(s,2CH 3 ), 50.09(s, OCH 3 ), 51.72(d,CH 2 ), 73.42 ##STR16## .
EXAMPLE 12
Preparation of tetrakis(2-ethoxyisobutylisonitrile)copper(I) tetrafluoroborate
To a stirred suspension of tetrakis(acetonitrile)copper(I) tetrafluoroborate(0.50 g, 1.6×10 -3 mol) in 100 ml of ethanol at room temperature, was slowly added 2-ethoxyisobutylisonitrile (0.81 g, 6.4×10 -3 mol). After the reaction mixture was stirred for 30 minutes to give a clear solution, the solvent was then evaporated to dryness under reduced pressure. The product was recrystallized from ethanol/n-hexane, and the white solids obtained were washed with n-hexane and dried in vacuo; (1.01 g, 96% yield), M.P. 76°-77° C. Anal. Calcd for C 28 H 52 N 4 O 4 CuBF 4 : C,51.04; H,7.90; N,8.51; Cu,9.65; B,1.64; F,11.54. Found: C,51.10; H,7.85; N,8.59; Cu,9.61; B,1.70; F,11.61.
IR(Nujol mull/ν cm -1 ): 2200.
1 HNMR(200 MHz, CDC1 3 /δ ppm): 1.18(t,3H,CH 3 ), 1.29(s,6H,2CH 3 ), 3.43(q,2H, OCH 2 ),3.59(s,2H, CH 2 ).
13 CNMR(200 MHz, CDC1 3 /δ ppm): 16.06(s,CH 3 ) 23.38(s,2CH 3 ), 52.03(s,CH 2 ), 57.66(s,OCH 2 ), 73.18 ##STR17## .
EXAMPLE 13
Preparation of Tc-99m-alkoxyisobutylisonitrile complexes
In a 8 ml-vial are mixed tetrakis(2-methoxyisobutylisonitrile) copper(I)tetrafluoroborate(1-2 mg) or tetrakis(2-ethoxyisobutylisonitrile)copper(I)tetrafluoroborate (1-2 mg) , sodium citrate dihydrate(2.2.-3.2 mg), mannitol(16-26 mg), cysteine hydrochloride(1-3 mg) and stannous chloride(0.05-0.09mg). The vials were sealed and 25-40 mCi(1-2 ml) 99m TcO 4 - obtained by elution of a 99 Mo/ 99m Tc radionuclide generator was added. The vials were heated in a 95°-100° C. water bath for 10-15 min. and allowed to cool to room temperature. Quality assurance of in vitro stability was done on ITLC(SG) with saline and methylethylketone(MEK) to determine 99m TcO 2 (Rf:0), 99m TcO 4 - (Rf:0.9-1.0) and the 99m Tc isonitrile complex (MEK:Rf:MMI 0.45, EMI 0.8; saline:0).
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A new method for synthesizing 2-alkoxyisobutylisonitrile is provided in which isobutylene is used as the starting material. The haloalkoxylation of isobutylene in alcohol medium gives 2-alkoxyisobutylhalide which is then converted to 2-alkoxyisobutylamine. In the basic condition, the reaction of 2-alkoxyisobutylamine with chloroform produces 2-alkoxyisobutylisonitrile. The synthesis process contains three steps by which a higher yield is achieved. 2-Alkoxyisobutylisonitrile is labelled with technetium-99m by exchange labelling of stable tetrakis(2-alkoxyisobutylisonitrile)copper(I) complex. Tetrakis(2-alkoxyisobutylisonitrile)copper(I) complex can be prepared by the exchange of acetonitrile molecules in tetrakis(acetonitrile)copper(I) complex with isonitrile ligands.
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FIELD OF THE INVENTION
The present invention relates to a method for production of transfected cells, more particularly, a method which makes possible to transfer a foreign gene into target cells with high efficiency in the fields such as cell technology, genetic engineering, developmental engineering and the like.
BACKGROUND OF THE INVENTION
As a method for transferring a foreign gene into target cells, there are known a calcium phosphate method, a DEAE-dextran method, a liposome method, an electroporation method, a microinjection method, a particle gun method and the like. All of these methods have both advantages and disadvantages with respect to manipulation procedures, efficiency, damage on cells and the like. Among these methods, a perforation method such as an electroporation method, a microinjection method, a particle gun method and the like enables easy handling of the cells without using special reagents and provides good transfer efficiency. However, damage to cells by perforation cannot be avoided.
The object of the present invention is to provide a method for improving the transfer efficiency when a foreign gene is transferred into target cells by a perforation method to produce transfected cells.
SUMMARY OF THE INVENTION
The first aspect of the present invention relates to a method for the production of transfected cells, which is characterized by comprising a step of culturing the cells in the presence of a cell-adhesive substance, after injection of a foreign gene into target cells using a perforation method.
The second aspect of the present invention relates to transfected cells containing a foreign gene which are produced by the method of the present invention.
The third aspect of the present invention relates to a kit, which is used for a method for the production of transfected cells according to the first aspect of the present invention and is characterized by containing a cell-adhesive substance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the effect of cell-adhesive polypeptide treatment on gene transfer efficiency in the transfer of pCAT-control vector into human epidermoid cancer cell A-431.
FIG. 2 is a graph showing the effect of cell-adhesive polypeptide treatment on gene transfer efficiency in the transfer of pCAT-control vector into African green monkey kidney cell COS-7-7.
DETAILED DESCRIPTION OF THE INVENTION
The method of the present invention is characterized by culturing the cell in the presence of a substance having the cell-adhesive activity after a foreign gene is transferred into target cells using a perforation method.
As used herein, the perforation method means a method for injection of a gene by perforating a cell wall, including an electroporation method, a microinjection method, a particle gun method and the like. The electroporation method is as described in, for example, Tanpakushitsu, Kakusan, Koso, volume 31, pages 1591-1603 (1986). The microinjection method is as described in, for example, Cell, volume 22, pages 479-488 (1980). The particle gun method is as described in, for example, Technique, volume 3, pages 3-16 (1991). These methods include the known methods used for transferring a gene into cells.
As cells to be used in these perforation methods, for example, there are animal cells which are prepared according to a known method "Shin-Seikagaku Jikkenkoza 18, Saibobaiyogijyutsu", 1st edition (1990), edited by Nippon Seikagakugakkai, published by Tokyo Kagakudojin! and cultured animal cells may be used.
As used herein, a cell-adhesive substance refers to a substance having the cell-adhesive, that is, the activity to make target cells adhere to a cell, to an extracellular matrix which is a substance filling a space between cells in the tissue, or to a material such as plastic, glass and the like. In the present invention, any substances having the activity can be used as long as they give no adverse effects on transfection of target cells. Such the activity is to fix cells, for example, to culture ware covered with a cell-adhesive substance while maintaining the cell in its form, or in a spreaded form, that is, in the changed form after the cell has been spreaded in one or more directions.
Attachment between the cell-adhesive substance and the target cell can be assayed using a conventional method. The method includes, for example, a method described in Nature, 352:438-441 (1991). Briefly, the cell-adhesive substance covers a plastic dish, and a population of cells to be assayed is put into a medium and allowing it to stand for 30 minutes to 2 hours. After this incubation period, non-adhered cells are recovered, counted and assayed for viability. Cells adhered to the cell-adhesive substance are recovered using trypsin or a cell dissociation buffer (for example, Gibco), counted and assayed for viability. Then, a ratio of adhered cells is calculated and compared with a standard control such as a plastic dish covered with bovine serum albumin (BSA). A combination of cell-adhesive substance/cell can be determined by substantial adhesion of the target cell with the cell-adhesive substance assayed. In addition, the cell-spreading activity can be determined by observing a change in the form of the adhered cells under a microscope before dissociating cells using trypsin or a cell dissociation buffer, in the above procedures.
Examples of the cell-adhesive substance include, for example, a cell-adhesive polypeptide or a functional equivalent thereof and a cell-adhesive synthetic polymer.
Examples of the polypeptide to be used in the present invention, having the cell-adhering activity include a cell-adhesive polypeptide such as invasin, polylysine which is not derived from an extracellular matrix, a polypeptide showing the cell-spreading activity described in JP-A 2-311498, components of an extracellular matrix such as fibronectin, laminin, collagen, vitronectin, osteopontin, thrombospondin, tenascin and the like. The extracellular matrix components can be prepared from a natural or cultured source by a known method International Journal of Cancer, volume 20, pages 1-5 (1977); Journal of Biological Chemistry, volume 254, pages 9933-9937, (1979); "Zoku-Seikagaku Jikkenkoza", volume 6, Saibokokkaku no Kozo to Kino (Structure and Function of Cell Skeleton) (last volume), (1st edition) (1986) edited by Nippon Seikagakugakkai, published by Tokyo Kagakudojin; Cell Structure and Function, volume 13, pages 281-292 (1988); Journal of Biological Chemistry, volume 264, pages 18202-18208 (1989); and Journal of Biological Chemistry, volume 260, pages 12240-12245 (1985)!. The cell-adhesive polypeptide may be substantially purified extracellular matrices exhibiting the cell-adhering activity, substantially purified extracellular matrix fragments or a mixture thereof. More particularly, proteins and polypeptides having the cell-adhesive or the cell spreading activity, or a functional equivalent thereof, may be used.
As these cell-adhesive polypeptides, substantially purified natural polypeptides, polypeptides from enzymatical or chemical degradation of the natural polypeptides, or the similar polypeptides made by genetic engineering may be used. Further, materials obtained by modifying these polypeptides without impairing the function, that is, the cell-adhering activity or the cell-spreading activity may be used. In the present invention, even if the polypeptide has a deletion, substitution, addition and/or insertion of amino acids in the amino acid sequence of a polypeptide from natural origin, as long as the polypeptide has the desired cell-adhering activity or the cell-spreading activity, it is referred to as a functional equivalent of a polypeptide having the natural amino acid sequence. That is, it is known that naturally occurring proteins include proteins of which amino acid sequences have mutations such as deletions, insertions, additions, substitutions and the like of amino acids, which are due to a modification reaction in the living body after production or during purification, in addition to polymorphism or mutation of genes encoding those naturally occurring proteins. Regardless of these mutations, there are proteins exhibiting the physiological and biological activity substantially equivalent to that of proteins having no mutation. Like this, even when there is a structural difference between polypeptides, as long as they share the common main functions, they are called polypeptides having the functionally equivalent activity.
This is also true where the above mutations are artificially introduced into the amino acid sequence of proteins. In this case, a greater variety of mutants may be made. As long as these mutants exhibit the physiological activity substantially equivalent to that of proteins having no mutations, they are interpreted to be a polypeptide having the functionally equivalent activity.
For example, in many cases, a methionine residue which is present at a N-terminus of a protein expressed in Escherichia coli is said to be removed by action of methionine aminopeptidase, thus, generating both proteins having a methionine residue or those having no methionine residue depending upon the kind of proteins. However, whether or not a protein has a methionine residue does not affect the protein activity in many cases. In addition, it is known that a polypeptide, a certain cysteine residue of which is substituted with a serine residue in the amino acid sequence of human interleukin-2 (IL-2), retains the interleukin-2 activity Science, volume 224, page 1431 (1984)!.
Further, upon production of proteins by genetic engineering, proteins are frequently expressed as fused proteins. For example, in order to increase an amount of an expressed protein of interest, the protein is expressed by adding a N-terminal peptide chain derived from another protein to the N-terminal of the protein of interest, or adding a suitable peptide chain to the N-terminus or the C-terminus of the protein of interest to facilitate purification of the protein of interest by using a carrier having the affinity to the added peptide chain.
In this respect, the related biotechnological 10 techniques have advanced to a state in which deletion, substitution, addition or other modification of amino acids in a functional region of the polypeptide can be routinely carried out. Then, the resulting amino acid sequence may be routinely screened for the desired cell-adhering activity or the cell-spreading activity according to the above method.
Polypeptides having the cell-adhering activity may be an artificial polypeptide containing, in the molecule, the amino acid sequence necessary for the cell-adhering activity, for example, the amino acid sequence may be selected from the amino acid sequence represented by SEQ ID No:1 (RGDS), the amino acid sequence represented by SEQ ID NO:2 (CS1) and the amino acid sequence represented by SEQ ID NO:6 (central sequence of laminin, YIGSR). These polypeptides can be prepared in a large amount by a genetic engineering method or a chemical synthesis method and may be used as a purified polypeptide.
Examples of the artificial polypeptide having, in the molecule, the amino acid sequence represented by SEQ ID NO:1 include a polypeptide represented by SEQ ID NO:7 described in JP-A 1-180900. The polypeptide can be prepared using Escherichia coli HB101/pTF1409 (FERM BP-1939) according to a method described in JP-A 1-180900. In addition polypeptides represented by their respective sequence ID numbers in the sequence list shown in Table 1 below can be prepared according to a genetic engineering method described in each specification.
In addition, a plasmid pCHV90 contained in Escherichia coli HB101/pCHV90 in Table 1 can be prepared using Escherichia coli HB101/pHD101 (FERM BP-2264) and Escherichia coli JM109/pTF7021 (FERM BP-1941) according to a method described in JP-A 5-271291.
TABLE 1______________________________________Laid Open SEQ ID Living BacteriumPublication NO (Escherichia coli) Accession No.______________________________________JP-A 1-206998 8 JM109/pTF7021 FERM BP-1941JP-A 1-261398 9 HB101/pTF1801 FERM P-9948JP-A 2-97397 3 JM109/pTF7221 FERM BP-1915JP-A 2-152990 10 JM109/pTFB800 FERM BP-2126JP-A 2-311498 11 HB101/pCH101 FERM BP-2799JP-A 3-59000 12 JM109/pCF406 FERM P-10837JP-A 3-232898 13 HB101/pCE102 FERM P-11226JP-A 4-54199 14 JM109/pTF7520 + FERM P-11526 VN-IN.TAA 15 JM109/pTF7520 + FERM P-11527 Col.sup.×1JP-A 5-271291 16 HB101/pCHV179 FERM P-12183 17 HB101/pCHV90 18 HB101/pCHV89 FERM P-182JP-A 5-97698 19 JM109/pTF7520ColV FERM BP-5277JP-A 5-178897 20 JM109/pYMH-CF.A FERM BP-5278______________________________________
Alternatively, artificial polypeptides having, in the molecule, the amino acid sequence represented by SEQ ID NO:1 can be PolyRGDS described, described in JP-A 3-173828, can be synthesized and used.
Examples of artificial polypeptides having, in the molecule, the amino acid sequence represented by SEQ ID NO:2 include a polypeptide represented by SEQ ID NO:4, described in JP-A 2-311498, and the polypeptide can be prepared by genetic engineering using Escherichia coli HB101/pHD102 (FERM P-10721) according to a method described in JP-A 2-311498. In addition, a polypeptide represented by SEQ ID NO:2 may be chemically synthesized according to a method described in JP-A 3-284700.
Further, examples of artificial polypeptides having, in the molecule, the amino acid sequence represented by SEQ ID NO:2 and the amino acid sequence represented by SEQ ID NO:3 include a polypeptide represented by SEQ ID NO:21 described in JP-A 2-311498 and the polypeptide can be prepared by genetic engineering using Escherichia coli HB101/pCH102 (FERM BP-2800) according to a method described in JP-A 2-311498. In addition, a polypeptide represented by SEQ ID NO:5 described in JP-A 3-284700 is a polypeptide containing, in the molecule, the amino acid sequences of SEQ ID NOs: 1 and 2 and the polypeptide can be prepared by genetic engineering using Escherichia coli HB101/pCS25 (FERM P-11339) according to a method described in JP-A 3-284700.
As described above, examples of the polypeptides used in the present invention are cell-adhesive polypeptides containing, in the molecule, the amino acid sequence represented by SEQ ID NO:1 and/or the amino acid sequence represented by SEQ ID NO:2. As the polypeptide, a polypeptide obtained by covalently binding a polypeptide derived from a cell adhesion domain of human fibronectin "Fibronectin", pages 47-121 (1989), edited by Mosher, D. F., published by Academic Press! with a CS1 polypeptide derived from the same (ibid), a polypeptide derived from a heparin binding domain (ibid) containing a CS1 polypeptide, or a polypeptide derived from a cell adhesion domain can be used, and they can be made by genetic engineering, respectively. For example, respective necessary regions are taken out from a vector containing a DNA encoding a cell adhesion domain-derived polypeptide, a vector containing a DNA encoding a CS1 polypeptide, and a vector containing a DNA encoding a heparin binding domain-derived peptide containing a CS1 polypeptide, respectively, and they can be used alone or in combination thereof to make a vector expressing a polypeptide containing, in the molecule, the amino acid sequence represented by SEQ ID NO:1 and/or the amino acid sequence represented by SEQ ID NO:2.
When a polypeptide, where a polypeptide containing, in the molecule, the amino acid sequence represented by SEQ ID NO:1 and a polypeptide containing, in the molecule, the amino acid sequence represented by SEQ ID NO:2 are covalently bound, is made, a covalent bonding between polypeptides may be a direct bonding or an indirect bonding, for example, an indirect bonding via a spacer. A spacer is an insertion sequence for adjusting an intermolecular distance in each region. As the spacer, an arbitrary peptide chain can be used, for example, a sequence upstream of a CS1 region in the fibronectin molecule. The spacer sequence can be easily introduced therein by genetic engineering.
The cell-adhesive synthetic polymers include the known poly-N-p-vinylbenzyl-D-lactoneamide (PVLA) polymer.
In the present invention, the target cell include, but is not limited to, hematopoietic stem cell, peripheral blood stem cell, umbilical blood cell, ES cell, lymphocyte, cancer cell and the like.
Examples of the foreign gene include, but are not limited to, nucleic acid selected from nucleic acids encoding proteins, nucleic acids encoding polypeptides, antisense DNAs, antisense RNAs, ribozymes, nucleic acids encoding intracellular antibodies and pseudogenes (decoy genes). In the present invention, the foreign gene may be inserted into a vector.
Examples of the vector are retrovirus vector, adenovirus vector, vacciniavirus vector, herpesvirus vector and the like.
According to the present invention a transfected cell with a foreign gene can be obtained with high efficiency by culturing a target cell, into which a foreign gene has been transferred by a perforation method according to a conventional method, in the presence of a cell-adhesive substance. A cell culture method may be selected from the known methods depending upon the cell used. For example, when cell culturing is performed in the presence of a cell-adhesive polypeptide, 250 to 2000 μg/ml of the cell-adhesive polypeptide may be used in a culture medium to culture it according to a conventional method.
Particularly, culturing is preferably carried out using a culture ware covered with a cell-adhesive substance. The culture ware refers to any ware normally used for cell culture, for example, a culture dish, a culture ware using a microcarrier, and a culture ware using fibrous hollow fibers. The culture ware may be covered with the substance by coating or spraying. For example, the culture may be easily covered with the polypeptide by dissolving it in a suitable solution such as a phosphate buffered saline (PBS), adding the solution to the culture ware and allowing it to stand for a suitable period of time. An amount of the polypeptide with which the culture ware is covered may be selected from a range of 50 to 1000 pmol/cm 2 , suitably 150 to 600 pmol/cm 2 .
Transfected cells which have been cultured in the presence of the cell-adhesive substance can be obtained from a culture according to a conventional method. Thus, transfected cells can be produced with high efficiency.
The resulting transfected cells are useful for the production of useful substances by cells using recombinant DNA techniques, development of disease models, gene therapy and the like. Thus, transfected cells can be produced with high efficiency according to the present invention.
In addition, the present invention can be simply carried out by using a kit containing a cell-adhesive substance. The cell-adhesive substance to be contained in the kit may be in a form of solutions or lyophilized powders. The kit may contain a buffer for dissolving or diluting the cell-adhesive substance, a cell culture medium, a cell culture ware and the like. For example, a transfected cell can be simply produced by preparing a kit combining polypeptides, PBS for diluting the polypeptide, a cell culture ware and the like which are used for the method of the present invention. A reagent contained in the kit may be in liquid form or in lyophilized form.
A perforation method in the present invention can be used by appropriately selecting from an electroporation method, a microinjection method, a particle gun method and the like depending upon the purpose.
The present invention is illustrated by the non-limiting Examples below.
EXAMPLE 1
1. Coating of culture dish with cell-adhesive polypeptide.
A polypeptide represented by SEQ ID NO:3 (hereinafter referred to as "C274"), a polypeptide represented by SEQ ID NO:4 (hereinafter referred to as H296) and a polypeptide represented by SEQ ID NO:5 (hereinafter referred to as "C·CS1") were each dissolved in a phosphate buffered saline (PBS) to 1 μM, respectively, which were then sterilized using a 0.22 μm filter (Millex-GV, Millipore).
Each 1 ml/well of these solutions was added to a 24-well polystyrene culture dish (manufactured by Corning), respectively, to coat the dish at 4° C. overnight. These dishes were rinsed with a 500μl/well of a Dulbecco's modified minimum basal medium not containing bovine fetal serum prior to the addition of a transformed cell described below.
2. Transfection of cells
Two culture dishes (diameter: 100 mm) of human epidermoid cancer cell A-431 which had been cultured in a Dulbecco's modified minimum basal medium containing 10% bovine fetal serum were rinsed with 10 ml of a Dulbecco's modified minimum basal medium not containing bovine fetal serum, respectively, and 3 ml of PBS containing 0.25% bovine trypsin and 0.02% EDTA was added thereto to detach cells from the culture dish. To these, 7 ml of a Dulbecco's modified minimum basal medium not containing bovine fetal serum was added, followed by centrifugation at 800 rpm for 3 minutes to collect cells. The resulting cells were suspended in 10 ml of a Dulbecco's modified minimum basal medium containing bovine fetal serum, followed by centrifugation at 800 rpm for 3 minutes to collect cells. The resulting cells were combined, suspended in 10 ml of PBS, a 3/10 aliquot of the suspension was taken and divided into two equal aliquots, which were centrifuged at 800 rpm for 3 minutes to collect cells, respectively. The resulting cells were suspended again in 10 ml of PBS, followed by centrifugation at 800 rpm for 3 minutes to collect two batches of cells. One batch of the resulting cells were suspended in 1 ml of PBS containing 15 μg of pCAT-control vector (Promega) which had been aseptically prepared, and placed in an electroporation cuvette for Gene Pulser (BioRad), which was allowed to stand in ice for 10 minutes. The other batch of the resulting cells were suspended in 1 ml of PBS, and placed in an electroporation cuvette for Gene Pulser (BioRad), which was allowed to 15 stand in ice for 10 minutes. Each batch of cells was allowed to stand in ice for 10 minutes, and voltage was applied thereto at 250 V and 960 μF. After application, the cells were allowed to stand in a cuvette in ice for 10 minutes. Thereafter, the cells were recovered into 15 ml 20 of a Dulbecco's modified minimum basal medium containing 10% bovine fetal serum, 1 ml/well of which were added to a 24-well polystyrene culture dish covered with the above polypeptide. These cells were cultured at 37° C. in the presence of 5% CO 2 gas overnight, the medium was removed by aspiration, and 1 ml/well of a fresh Dulbecco's modified minimum basal medium containing 10% bovine fetal serum was added thereto, followed by culturing at 38° C. in the presence of 5% CO 2 gas overnight.
3. Determination of transfection efficiency (efficiency of gene transfer)
The cultured cells were rinsed three times with 1.25 ml of PBS per well, a lysed cell solution was prepared, and detection of expressed CAT was carried out using CAT-ELISA kit (manufactured by Boehringer Mannheim) according to a method for using the present kit. Since the present kit used a horseradish peroxidase-labelled secondary antibody and ABTS as a substrate, a ratio of absorbance at 405 nm/490 nm was determined. A value obtained by subtracting a blank value from a value for each group in a case of addition of pCAT-control vector, using a value for the group in a case of no addition of pCAT-control vector upon electroporation as a blank, was adopted as an amount of expressed CAT.
The results thereof are shown in FIG. 1. That is, FIG. 1 is a figure showing efficiency of gene transfer into a cell in each polypeptide-treatment group, where the ordinate shows non-treated group and each polypeptide-treatment group and the abscissa shows gene transfer efficiency expressed as a ratio of absorbance at 405 nm relative to that at 490 nm.
As shown in FIG. 1, an amount of expressed CAT in the culture dish in the C274, H296 or C·CS1-treatment group is higher as compared with that in a non-treatment group, demonstrating that efficiency of transfer of pCAT-control vector into a cell is higher.
EXAMPLE 2
1. Coating of culture dish with cell-adhesive polypeptide
A polypeptide represented by SEQ ID NO:3 (hereinafter referred to as "C274"), a polypeptide represented by SEQ ID NO:4 (hereinafter referred to as "H296") and a polypeptide represented by SEQ ID NO:5 (hereinafter referred to as "C·CS1") were each dissolved in a phosphate buffered saline (PBS) to 1 μM, respectively, which were then sterilized using a 0.22 μm filter (Millex-GV, Millipore). 1 ml/well of these solutions were added to a 24-well polystyrene culture dish (manufactured by Corning) to coat the dish at 4° C. overnight, respectively. These dishes were rinsed with 500 μl/well of a Dulbecco's modified minimum basal medium not containing bovine fetal serum prior to addition of a transformed cell described below.
2. Transfection of cell
Two culture dishes (diameter: 100 mm) of African green monkey kidney cell COS-7 which had been cultured in a Dulbecco's modified minimum basal medium containing 10% bovine fetal serum were rinsed with 10 ml of a Dulbecco's modified minimum basal medium not containing bovine fetal serum, respectively, and 3 ml of PBS containing 0.25% bovine trypsin and 0.02% EDTA was added thereto to detach cells from the culture dish. To these, 7 ml of a Dulbecco's modified minimum basal medium not containing bovine fetal serum was added, respectively, followed by centrifugation at 800 rpm for 3 minutes to collect cells. The resulting cells were suspended in 10 ml of a Dulbecco's modified minimum basal medium containing bovine fetal serum, followed by centrifugation at 800 rpm for 3 minutes to collect cells. The resulting cells were combined, suspended in 12 ml of PBS, a 5/6 aliquot of the suspension was taken and divided into two equal aliquots, which were centrifuged at 800 rpm for 3 minutes to collect cells, respectively. The resulting cells were suspended in 6 ml of PBS, followed by centrifugation at 800 rpm for 3 minutes to collect two batches of cells. One batch of the resulting cells were suspended in 1 ml of PBS containing 15 μg of pCAT-control vector (Promega) which had been aseptically prepared, and placed in an electroporation cuvette for Gene Pulser (BioRad), which was allowed to stand in ice for 10 minutes. The other batch of the resulting cells were suspended in 1 ml of PBS, and placed in an electroporation cuvette for Gene Pulser (BioRad), which was allowed to stand in ice for 10 minutes. Each batch of cells was allowed to stand in ice for 10 minutes, and voltage was applied thereto at 250 V and 960 μF. After application, the cells were allowed to stand in a cuvette in ice for 10 minutes. Thereafter, the cells were recovered into 15 ml of a Dulbeccol's modified minimum basal medium containing 10% bovine fetal serum, 1 ml/well of the cells were added to a 24-well polystyrene culture dish covered with the above polypeptide. These cells were cultured at 37° C. in the presence of 5% CO 2 gas overnight, the medium was removed by aspiration, and 1 ml/well of a fresh Dulbecco's modified minimum basal medium containing 10% bovine fetal serum was added, followed by culturing at 37° C. in the presence of 5% CO 2 gas overnight.
3. Determination of transfection efficiency (efficiency of gene transfer)
The cultured cells were rinsed three times with 1.25 ml of PBS per well, a lysed cell solution was prepared, and detection of expressed CAT was carried out using CAT-ELISA kit (manufactured by Boehringer Mannheim) according to a method for using the present kit. Since the present kit used a horseradish peroxidase-labelled secondary antibody and ABTS as a substrate, a ratio of absorbance at 405 nm/490 nm was determined. A value obtained by subtracting a blank value from a value for each group in a case of addition of pCAT-control vector, using a value for the group in a case of no addition of pCAT-control vector upon electroporation as a blank, was adopted as an amount of expressed CAT. The results thereof are shown in FIG. 2. That is, FIG. 2 is a figure showing efficiency of gene transfer into a cell in each polypeptide-treatment group, where the ordinate shows non-treated group and each polypeptide-treatment group and the abscissa shows gene transfer efficiency expressed as a ratio of absorbance at 405 nm relative to that at 490 nm.
As shown in FIG. 2, an amount of expressed CAT in the culture dish in the above C274, H296 or C·CS1-treatment group is higher as compared with that in a non-treatment group, demonstrating that efficiency of transfer of pCAT-control vector into a cell is higher.
EXAMPLE 3
Preparation of kit
A kit for production of gene-transferred cells was made from C274, H296, C·CS1, PBS and a culturing dish as shown in Table 2 below. Reagents A, B and C were prepared so that the above polypeptides were adjusted with PBS to the indicated concentrations shown in the Table. Other components used are described in Example 1. In addition, all reagents A, B and C and a diluent for the reagents were aseptically prepared by pre-filtering with a 0.22 μm sterile filter.
TABLE 2______________________________________Kit for production of transfected cell______________________________________Reagent A . . . 100 μM C274 150 μlReagent B . . . 100 μM H296 150 μlReagent C . . . 100 μM C.CS1 150 μlDiluent for reagents . . . PBS 45 ml24-well polystyrene culture dish 3______________________________________
As described above, the present invention can overcome the problems of the previous methods for gene transfer into cells and provide a method, for production of transfected cells, having improved efficiency of gene transfer into target cells. The present invention can also provide a kit, for production of transfected cells, which is used for the method.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 21(2) INFORMATION FOR SEQ ID NO: 1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 4 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:ArgGlyAspSer(2) INFORMATION FOR SEQ ID NO: 2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 25 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:AspGluLeuProGlnLeuValThrLeuProHisProAsnLeuHis151015GlyProGluIleLeuAspValProSerThr2025(2) INFORMATION FOR SEQ ID NO: 3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 274 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAsp(2) INFORMATION FOR SEQ ID NO: 4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 296 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:AlaIleProAlaProThrAspLeuLysPheThrGlnValThrPro51015ThrSerLeuSerAlaGlnTrpThrProProAsnValGlnLeuThr202530GlyTyrArgValArgValThrProLysGluLysThrGlyProMet354045LysGluIleAsnLeuAlaProAspSerSerSerValValValSer505560GlyLeuMetValAlaThrLysTyrGluValSerValTyrAlaLeu657075LysAspThrLeuThrSerArgProAlaGlnGlyValValThrThr808590LeuGluAsnValSerProProArgArgAlaArgValThrAspAla95100105ThrGluThrThrIleThrIleSerTrpArgThrLysThrGluThr110115120IleThrGlyPheGlnValAspAlaValProAlaAsnGlyGlnThr125130135ProIleGlnArgThrIleLysProAspValArgSerTyrThrIle140145150ThrGlyLeuGlnProGlyThrAspTyrLysIleTyrLeuTyrThr155160165LeuAsnAspAsnAlaArgSerSerProValValIleAspAlaSer170175180ThrAlaIleAspAlaProSerAsnLeuArgPheLeuAlaThrThr185190195ProAsnSerLeuLeuValSerTrpGlnProProArgAlaArgIle200205210ThrGlyTyrIleIleLysTyrGluLysProGlySerProProArg215220225GluValValProArgProArgProGlyValThrGluAlaThrIle230235240ThrGlyLeuGluProGlyThrGluTyrThrIleTyrValIleAla245250255LeuLysAsnAsnGlnLysSerGluProLeuIleGlyArgLysLys260265270ThrAspGluLeuProGlnLeuValThrLeuProHisProAsnLeu275280285HisGlyProGluIleLeuAspValProSerThr290295(2) INFORMATION FOR SEQ ID NO: 5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 302 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerAspGluLeuProGlnLeuValThr275280285LeuProHisProAsnLeuHisGlyProGluIleLeuAspValPro290295300SerThr(2) INFORMATION FOR SEQ ID NO: 6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 5 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:TyrIleGlySerArg15(2) INFORMATION FOR SEQ ID NO: 7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 283 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:7:AlaValProProProThrAspLeuArgPheThrAsnIleGlyPro151015AspThrMetArgValThrTrpAlaProProProSerIleAspLeu202530ThrAsnPheLeuValArgTyrSerProValLysAsnGluGluAsp354045ValAlaGluLeuSerIleSerProSerAspAsnAlaValValLeu505560ThrAsnLeuLeuProGlyThrGluTyrValValSerValSerSer657075ValTyrGluGlnHisGluSerThrProLeuArgGlyArgGlnLys808590ThrGlyLeuAspSerProThrGlyIleAspPheSerAspIleThr95100105AlaAsnSerPheThrValHisTrpIleAlaProArgAlaThrIle110115120ThrGlyTyrArgIleArgHisHisProGluHisPheSerGlyArg125130135ProArgGluAspArgValProHisSerArgAsnSerIleThrLeu140145150ThrAsnLeuThrProGlyThrGluTyrValValSerIleValAla155160165LeuAsnGlyArgGluGluSerProLeuLeuIleGlyGlnGlnSer170175180ThrValSerAspValProArgAspLeuGluValValAlaAlaThr185190195ProThrSerLeuLeuIleSerTrpAspAlaProAlaValThrVal200205210ArgTyrTyrArgIleThrTyrGlyGluThrGlyGlyAsnSerPro215220225ValGlnGluPheThrValProGlySerLysSerThrAlaThrIle230235240SerGlyLeuLysProGlyValAspTyrThrIleThrValTyrAla245250255ValThrGlyArgGlyAspSerProAlaSerSerLysProIleSer260265270IleAsnTyrArgThrGluIleAspLysProSerGlnMet275280(2) INFORMATION FOR SEQ ID NO: 8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 279 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:8:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerGlnMet275(2) INFORMATION FOR SEQ ID NO: 9:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 474 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:9:AlaValProProProThrAspLeuArgPheThrAsnIleGlyPro151015AspThrMetArgValThrTrpAlaProProProSerIleAspLeu202530ThrAsnPheLeuValArgTyrSerProValLysAsnGluGluAsp354045ValAlaGluLeuSerIleSerProSerAspAsnAlaValValLeu505560ThrAsnLeuLeuProGlyThrGluTyrValValSerValSerSer657075ValTyrGluGlnHisGluSerThrProLeuArgGlyArgGlnLys808590ThrGlyLeuAspSerProThrGlyIleAspPheSerAspIleThr95100105AlaAsnSerPheThrValHisTrpIleAlaProArgAlaThrIle110115120ThrGlyTyrArgIleArgHisHisProGluHisPheSerGlyArg125130135ProArgGluAspArgValProHisSerArgAsnSerIleThrLeu140145150ThrAsnLeuThrProGlyThrGluTyrValValSerIleValAla155160165LeuAsnGlyArgGluGluSerProLeuLeuIleGlyGlnGlnSer170175180ThrValSerAspValProArgAspLeuGluValValAlaAlaThr185190195ProThrSerLeuLeuIleSerTrpAspAlaProAlaValThrVal200205210ArgTyrTyrArgIleThrTyrGlyGluThrGlyGlyAsnSerPro215220225ValGlnGluPheThrValProGlySerLysSerThrAlaThrIle230235240SerGlyLeuLysProGlyValAspTyrThrIleThrValTyrAla245250255ValThrGlyArgGlyAspSerProAlaSerSerLysProIleSer260265270IleAsnTyrArgThrGluIleAspLysProSerGlnAsnGluGly275280285LeuAsnGlnProThrAspAspSerCysPheAspProTyrThrVal290295300SerHisTyrAlaValGlyAspGluTrpGluArgMetSerGluSer305310315GlyPheLysLeuLeuCysGlnCysLeuGlyPheGlySerGlyHis320325330PheArgCysAspSerSerArgTrpCysHisAspAsnGlyValAsn335340345TyrLysIleGlyGluLysTrpAspArgGlnGlyGluAsnGlyGln350355360MetMetSerCysThrCysLeuGlyAsnGlyLysGlyGluPheLys365370375CysAspProHisGluAlaThrCysTyrAspAspGlyLysThrTyr380385390HisValGlyGluGlnTrpGlnLysGluTyrLeuGlyAlaIleCys395400405SerCysThrCysPheGlyGlyGlnArgGlyTrpArgCysAspAsn410415420CysArgArgProGlyGlyGluProSerProGluGlyThrThrGly425430435GlnSerTyrAsnGlnTyrSerGlnArgTyrHisGlnArgThrAsn440445450ThrAsnValAsnCysProIleGluCysPheMetProLeuAspVal455460465GlnAlaAspArgGluAspSerArgGlu470(2) INFORMATION FOR SEQ ID NO:10:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 385 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:10:AlaProIleValAsnLysValValThrProLeuSerProProThr151015AsnLeuHisLeuGluAlaAsnProAspThrGlyValLeuThrVal202530SerTrpGluArgSerThrThrProAspIleThrGlyTyrArgIle354045ThrThrThrProThrAsnGlyGlnGlnGlyAsnSerLeuGluGlu505560ValValHisAlaAspGlnSerSerCysThrPheAspAsnLeuSer657075ProGlyLeuGluTyrAsnValSerValTyrThrValLysAspAsp808590LysGluSerValProIleSerAspThrIleIleProAlaValPro95100105ProProThrAspLeuArgPheThrAsnIleGlyProAspThrMet110115120ArgValThrTrpAlaProProProSerIleAspLeuThrAsnPhe125130135LeuValArgTyrSerProValLysAsnGluGluAspValAlaGlu140145150LeuSerIleSerProSerAspAsnAlaValValLeuThrAsnLeu155160165LeuProGlyThrGluTyrValValSerValSerSerValTyrGlu170175180GlnHisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeu185190195AspSerProThrGlyIleAspPheSerAspIleThrAlaAsnSer200205210PheThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyr215220225ArgIleArgHisHisProGluHisPheSerGlyArgProArgGlu230235240AspArgValProHisSerArgAsnSerIleThrLeuThrAsnLeu245250255ThrProGlyThrGluTyrValValSerIleValAlaLeuAsnGly260265270ArgGluGluSerProLeuLeuIleGlyGlnGlnSerThrValSer275280285AspValProArgAspLeuGluValValAlaAlaThrProThrSer290295300LeuLeuIleSerTrpAspAlaProAlaValThrValArgTyrTyr305310315ArgIleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGlu320325330PheThrValProGlySerLysSerThrAlaThrIleSerGlyLeu335340345LysProGlyValAspTyrThrIleThrValTyrAlaValThrGly350355360ArgGlyAspSerProAlaSerSerLysProIleSerIleAsnTyr365370375ArgThrGluIleAspLysProSerGlnMet380385(2) INFORMATION FOR SEQ ID NO:11:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 549 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:11:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerMetAlaIleProAlaProThrAsp275280285LeuLysPheThrGlnValThrProThrSerLeuSerAlaGlnTrp290295300ThrProProAsnValGlnLeuThrGlyTyrArgValArgValThr305310315ProLysGluLysThrGlyProMetLysGluIleAsnLeuAlaPro320325330AspSerSerSerValValValSerGlyLeuMetValAlaThrLys335340345TyrGluValSerValTyrAlaLeuLysAspThrLeuThrSerArg350355360ProAlaGlnGlyValValThrThrLeuGluAsnValSerProPro365370375ArgArgAlaArgValThrAspAlaThrGluThrThrIleThrIle380385390SerTrpArgThrLysThrGluThrIleThrGlyPheGlnValAsp395400405AlaValProAlaAsnGlyGlnThrProIleGlnArgThrIleLys410415420ProAspValArgSerTyrThrIleThrGlyLeuGlnProGlyThr425430435AspTyrLysIleTyrLeuTyrThrLeuAsnAspAsnAlaArgSer440445450SerProValValIleAspAlaSerThrAlaIleAspAlaProSer455460465AsnLeuArgPheLeuAlaThrThrProAsnSerLeuLeuValSer470475480TrpGlnProProArgAlaArgIleThrGlyTyrIleIleLysTyr485490495GluLysProGlySerProProArgGluValValProArgProArg500505510ProGlyValThrGluAlaThrIleThrGlyLeuGluProGlyThr515520525GluTyrThrIleTyrValIleAlaLeuLysAsnAsnGlnLysSer530535540GluProLeuIleGlyArgLysLysThr545(2) INFORMATION FOR SEQ ID NO:12:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 422 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:12:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerMetAlaAsnGluGlyLeuAsnGln275280285ProThrAspAspSerCysPheAspProTyrThrValSerHisTyr290295300AlaValGlyAspGluTrpGluArgMetSerGluSerGlyPheLys305310315LeuLeuCysGlnCysLeuGlyPheGlySerGlyHisPheArgCys320325330AspSerSerArgTrpCysHisAspAsnGlyValAsnTyrLysIle335340345GlyGluLysTrpAspArgGlnGlyGluAsnGlyGlnMetMetSer350355360CysThrCysLeuGlyAsnGlyLysGlyGluPheLysCysAspPro365370375HisGluAlaThrCysTyrAspAspGlyLysThrTyrHisValGly380385390GluGlnTrpGlnLysGluTyrLeuGlyAlaIleCysSerCysThr395400405CysPheGlyGlyGlnArgGlyTrpArgCysAspAsnCysArgArg410415420ProGly(2) INFORMATION FOR SEQ ID NO:13:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 332 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:13:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerMetAlaAsnSerAspSerGluCys275280285ProLeuSerHisAspGlyTyrCysLeuHisAspGlyValCysMet290295300TyrIleGluAlaLeuAspLysTyrAlaCysAsnCysValValGly305310315TyrIleGlyGluArgCysGlnTyrArgAspLeuLysTrpTrpGlu320325330LeuArg(2) INFORMATION FOR SEQ ID NO:14:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 341 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:14:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerMetGlyIleTyrIleSerGlyMet275280285AlaProArgProSerLeuThrLysLysGlnArgPheArgHisArg290295300AsnArgLysGlyTyrArgSerGlnArgGlyHisSerArgGlyArg305310315AsnGlnAsnSerArgArgProSerArgAlaMetTrpLeuSerLeu320325330PheSerSerLysAsnSerSerSerValProAla335340(2) INFORMATION FOR SEQ ID NO:15:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 446 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:15:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerMetValProGlyPheLysGlyAsp275280285MetGlyLeuLysGlyAspArgGlyGluValGlyGlnIleGlyPro290295300ArgGlyXaaAspGlyProGluGlyProLysGlyArgAlaGlyPro305310315ThrGlyAspProGlyProSerGlyGlnAlaGlyGluLysGlyLys320325330LeuGlyValProGlyLeuProGlyTyrProGlyArgGlnGlyPro335340345LysGlySerThrGlyPheProGlyPheProGlyAlaAsnGlyGlu350355360LysGlyAlaArgGlyValAlaGlyLysProGlyProArgGlyGln365370375ArgGlyProThrGlyProArgGlySerArgGlyAlaArgGlyPro380385390ThrGlyLysProGlyProLysGlyThrSerGlyGlyAspGlyPro395400405ProGlyProProGlyGluArgGlyProGlnGlyProGlnGlyPro410415420ValGlyPheProGlyProLysGlyProProGlyProProGlyArg425430435MetGlyCysProGlyHisProGlyGlnArgGly440445(2) INFORMATION FOR SEQ ID NO:16:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 457 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:16:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerMetAsnValSerProProArgArg275280285AlaArgValThrAspAlaThrGluThrThrIleThrIleSerTrp290295300ArgThrLysThrGluThrIleThrGlyPheGlnValAspAlaVal305310315ProAlaAsnGlyGlnThrProIleGlnArgThrIleLysProAsp320325330ValArgSerTyrThrIleThrGlyLeuGlnProGlyThrAspTyr335340345LysIleTyrLeuTyrThrLeuAsnAspAsnAlaArgSerSerPro350355360ValValIleAspAlaSerThrAlaIleAspAlaProSerAsnLeu365370375ArgPheLeuAlaThrThrProAsnSerLeuLeuValSerTrpGln380385390ProProArgAlaArgIleThrGlyTyrIleIleLysTyrGluLys395400405ProGlySerProProArgGluValValProArgProArgProGly410415420ValThrGluAlaThrIleThrGlyLeuGluProGlyThrGluTyr425430435ThrIleTyrValIleAlaLeuLysAsnAsnGlnLysSerGluPro440445450LeuIleGlyArgLysLysThr455(2) INFORMATION FOR SEQ ID NO:17:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 368 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:17:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerMetAlaIleAspAlaProSerAsn275280285LeuArgPheLeuAlaThrThrProAsnSerLeuLeuValSerTrp290295300GlnProProArgAlaArgIleThrGlyTyrIleIleLysTyrGlu305310315LysProGlySerProProArgGluValValProArgProArgPro320325330GlyValThrGluAlaThrIleThrGlyLeuGluProGlyThrGlu335340345TyrThrIleTyrValIleAlaLeuLysAsnAsnGlnLysSerGlu350355360ProLeuIleGlyArgLysLysThr365(2) INFORMATION FOR SEQ ID NO:18:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 367 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:18:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerMetAsnValSerProProArgArg275280285AlaArgValThrAspAlaThrGluThrThrIleThrIleSerTrp290295300ArgThrLysThrGluThrIleThrGlyPheGlnValAspAlaVal305310315ProAlaAsnGlyGlnThrProIleGlnArgThrIleLysProAsp320325330ValArgSerTyrThrIleThrGlyLeuGlnProGlyThrAspTyr335340345LysIleTyrLeuTyrThrLeuAsnAspAsnAlaArgSerSerPro350355360ValValIleAspAlaSerThr365(2) INFORMATION FOR SEQ ID NO:19:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 464 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:19:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerMetGlyIleArgGlyLeuLysGly275280285ThrLysGlyGluLysGlyGluAspGlyPheProGlyPheLysGly290295300AspMetGlyIleLysGlyAspArgGlyGluIleGlyProProGly305310315ProArgGlyGluAspGlyProGluGlyProLysGlyArgGlyGly320325330ProAsnGlyAspProGlyProLeuGlyProProGlyGluLysGly335340345LysLeuGlyValProGlyLeuProGlyTyrProGlyArgGlnGly350355360ProLysGlySerIleGlyPheProGlyPheProGlyAlaAsnGly365370375GluLysGlyGlyArgGlyThrProGlyLysProGlyProArgGly380385390GlnArgGlyProThrGlyProArgGlyGluArgGlyProArgGly395400405IleThrGlyLysProGlyProLysGlyAsnSerGlyGlyAspGly410415420ProAlaGlyProProGlyGluArgGlyProAsnGlyProGlnGly425430435ProThrGlyPheProGlyProLysGlyProProGlyProProGly440445450LysAspGlyLeuProGlyHisProGlyGlnArgGlyGluThr455460(2) INFORMATION FOR SEQ ID NO:20:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 432 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:20:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerMetAlaAlaGlySerIleThrThr275280285LeuProAlaLeuProGluAspGlyGlySerGlyAlaPheProPro290295300GlyHisPheLysAspProLysArgLeuTyrCysLysAsnGlyGly305310315PhePheLeuArgIleHisProAspGlyArgValAspGlyValArg320325330GluLysSerAspProHisIleLysLeuGlnLeuGlnAlaGluGlu335340345ArgGlyValValSerIleLysGlyValCysAlaAsnArgTyrLeu350355360AlaMetLysGluAspGlyArgLeuLeuAlaSerLysCysValThr365370375AspGluCysPhePhePheGluArgLeuGluSerAsnAsnTyrAsn380385390ThrTyrArgSerArgLysTyrThrSerTrpTyrValAlaLeuLys395400405ArgThrGlyGlnTyrLysLeuGlySerLysThrGlyProGlyGln410415420LysAlaIleLeuPheLeuProMetSerAlaLysSer425430(2) INFORMATION FOR SEQ ID NO:21:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 574 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:21:ProThrAspLeuArgPheThrAsnIleGlyProAspThrMetArg151015ValThrTrpAlaProProProSerIleAspLeuThrAsnPheLeu202530ValArgTyrSerProValLysAsnGluGluAspValAlaGluLeu354045SerIleSerProSerAspAsnAlaValValLeuThrAsnLeuLeu505560ProGlyThrGluTyrValValSerValSerSerValTyrGluGln657075HisGluSerThrProLeuArgGlyArgGlnLysThrGlyLeuAsp808590SerProThrGlyIleAspPheSerAspIleThrAlaAsnSerPhe95100105ThrValHisTrpIleAlaProArgAlaThrIleThrGlyTyrArg110115120IleArgHisHisProGluHisPheSerGlyArgProArgGluAsp125130135ArgValProHisSerArgAsnSerIleThrLeuThrAsnLeuThr140145150ProGlyThrGluTyrValValSerIleValAlaLeuAsnGlyArg155160165GluGluSerProLeuLeuIleGlyGlnGlnSerThrValSerAsp170175180ValProArgAspLeuGluValValAlaAlaThrProThrSerLeu185190195LeuIleSerTrpAspAlaProAlaValThrValArgTyrTyrArg200205210IleThrTyrGlyGluThrGlyGlyAsnSerProValGlnGluPhe215220225ThrValProGlySerLysSerThrAlaThrIleSerGlyLeuLys230235240ProGlyValAspTyrThrIleThrValTyrAlaValThrGlyArg245250255GlyAspSerProAlaSerSerLysProIleSerIleAsnTyrArg260265270ThrGluIleAspLysProSerMetAlaIleProAlaProThrAsp275280285LeuLysPheThrGlnValThrProThrSerLeuSerAlaGlnTrp290295300ThrProProAsnValGlnLeuThrGlyTyrArgValArgValThr305310315ProLysGluLysThrGlyProMetLysGluIleAsnLeuAlaPro320325330AspSerSerSerValValValSerGlyLeuMetValAlaThrLys335340345TyrGluValSerValTyrAlaLeuLysAspThrLeuThrSerArg350355360ProAlaGlnGlyValValThrThrLeuGluAsnValSerProPro365370375ArgArgAlaArgValThrAspAlaThrGluThrThrIleThrIle380385390SerTrpArgThrLysThrGluThrIleThrGlyPheGlnValAsp395400405AlaValProAlaAsnGlyGlnThrProIleGlnArgThrIleLys410415420ProAspValArgSerTyrThrIleThrGlyLeuGlnProGlyThr425430435AspTyrLysIleTyrLeuTyrThrLeuAsnAspAsnAlaArgSer440445450SerProValValIleAspAlaSerThrAlaIleAspAlaProSer455460465AsnLeuArgPheLeuAlaThrThrProAsnSerLeuLeuValSer470475480TrpGlnProProArgAlaArgIleThrGlyTyrIleIleLysTyr485490495GluLysProGlySerProProArgGluValValProArgProArg500505510ProGlyValThrGluAlaThrIleThrGlyLeuGluProGlyThr515520525GluTyrThrIleTyrValIleAlaLeuLysAsnAsnGlnLysSer530535540GluProLeuIleGlyArgLysLysThrAspGluLeuProGlnLeu545550555ValThrLeuProHisProAsnLeuHisGlyProGluIleLeuAsp560565570ValProSerThr__________________________________________________________________________
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A method is disclosed for the efficient production of a transfected cell which comprises a step of culturing transfected cells in the presence of a cell-adhesive substance, after injection of a foreign gene into target cells, upon production of the transfected cells by transfer of a foreign gene into the target cells through cell perforation. Also provided are transfected cells produced by the method, and a kit for the production of transfected cells that includes a cell-adhesive substance as an essential component, which kit is suitable for use with the method for the efficient production of transfected cells by cell perforation.
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FIELD
The application pertains to a water flow detector which incorporates a spring driven escapement which provides a delay function. An adjustable timing gap is established between an end of a rack for the escapement and a linearly movable stop to set overall timing delay.
BACKGROUND
Water flow detectors having a timer responsive to movement of a lever connected to a paddle are known. A known water flow detector uses an air bleed timer. U.S. Pat. No. 6,331,820, entitled Explosion Proof Water Flow Detector, issued Dec. 18, 2001, discloses a paddle type flow detector which relies on an air bleed timer. U.S. Pat. No. 4,782,333, entitled Water-flow Detector With Rapid Switching, issued Nov. 1, 1988, discloses an air bleed timer. Both of these patents are assigned to the assignee hereof and incorporated herein by reference.
In general a water flow detector using an air bleed timer has a cam. The cam, when in a first position, maintains a switch assembly in a first state. The cam when in a second position enables the switch assembly to move to a second state. The lever when moved to a second position enables the cam to move from the first position to the second position.
The time it takes the cam to move depends upon the rate at which air is set to bleed out of an air chamber formed by a diaphragm. If the air is set to bleed out quickly, the cam will move quickly from the first to the second position. If the air is set to bleed out slowly, the cam will move slowly from the first to the second position and it will take longer for the switch to move from the first to the second state.
The lever is moved from the first position to the second position by the flow of water in a riser pipe of a fire sprinkler assembly. The water causes the paddle to move from a first to a second position. If the lever is not in the second position, the cam cannot move from the first to the second position. Accordingly the switch can not move from the first state to the second state. Whether the cam moves from the first to the second position depends on the rate of air bleed and the duration of suitable water flow.
If the water flow stops before the air bleed is complete, the cam will be moved back to the first position by the lever prior to the cam moving to the second position. The switch will not move to the second state. For instance, if the bleed duration is 50 seconds then the cam will move from the first to the second position in 50 seconds so long as the lever is maintained in the 2 nd position by the water flow.
If the lever is not maintained in a second position by the water flow for 50 seconds then the cam will not be able to move to the second position. The switch will not move to the second state. Accordingly the longer the bleed time, the longer the water flow most continue for the switch to move from the first to the second state. The shorter the bleed time the shorter amount of time the water flow most continue for the switch to orient from the first state to the second state.
Another embodiment is disclosed in pending U. S. application Ser. No. 12/974,637 filed Dec. 21, 2010 and entitled, Water Flow Detector. The '637 application is assigned to the assignee hereof and incorporated by reference.
While timers of the type described above have been found to be useful in providing needed delays, it would be desirable to be able to reduce their complexity and cost while still providing an adjustable time delay.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall diagram of an embodiment hereof;
FIG. 2 illustrates a timer/brake installed on an embodiment as in FIG. 1 ;
FIG. 3 illustrates the embodiment of FIG. 2 with the timer/brake removed exposing the associated rack;
FIG. 4 illustrates the embodiment of FIG. 3 with a gap between the rack and the slide nut; and
FIG. 5 illustrates the embodiment of FIG. 3 with a delay adjusting knob installed.
DETAILED DESCRIPTION
While disclosed embodiments can take many different forms, specific embodiments thereof are shown in the drawings and will be described herein in detail with the understanding that the present disclosure is to be considered as an exemplification of the principles thereof as well as the best mode of practicing same, and is not intended to limit the application or claims to the specific embodiment illustrated.
In one aspect, a delay mechanism usable in a flow detector includes first and second mechanical elements. The first element includes an axially movable shaft which carries a switch activating cam. The initial position of the shaft is linearly adjustable to establish a free fall timing gap.
A second element comprises a spring driven escapement, a fixed timer, which limits the rate at which the shaft can move axially in response to the spring force. By adjusting the length of the free fall timing gap, the time duration that the second element operates before the cam changes position of the switch can be varied.
Embodiments hereof incorporate an adjustable nut, barrel gear and dial/knob with meshing gear teeth which can index the nut along the shaft via a thread on the shaft. The nut then forms a stop against a fixed time delay, the second element, which includes a gear rack of a verge and foliot-type escapement which provides the time delay function. Changing the length of the free fall timing gap (distance between the nut and gear rack in rest position) changes the length of time that the timer is working, prior to a switch change, and hence the time delay.
In accordance herewith, the time delay is altered by adjusting a manually rotatable dial. Rotating the dial then changes the timing gap.
Advantageously, such embodiments do not require electrical energy for the timer mechanism. All required energy is supplied by an incorporated spring.
In yet another aspect hereof, the time delay mechanism is activated by movement of a spring biased water flow sensing paddle from a no flow to a flow position. As those of skill will understand, the paddle is installed in a water supply pipe which is part of a fire suppression sprinkling system.
When the paddle moves to the flow indicating position, a second spring, part of the delay mechanism, pulls the shaft and nut, axially until the nut engages an adjacent end of the rack. This in turn causes the timer to operate for a period of time determined by the initial length of the gap, which alters the axial starting position of the rack and the delay provided thereby.
When the cam has moved a required distance, in response to the driving force of the detector's second spring, a switch closing/opening can be produced indicative of sensed flow. The resulting electrical signal can in turn be detected at a monitoring, or fire detecting station, or, system. When flow ceases, the detector can automatically reset itself.
FIG. 1 illustrates an embodiment of a water flow detector 10 in accordance herewith. The detector 10 can be carried on a mounting plate 12 .
A flow indicating lever 14 can be rotatably carried by the plate 12 , biased to a no-flow state by a spring 18 a. Lever 14 can move from the indicated no flow position to the flow indicating position, indicted in phantom, in response to water flow F in an adjacent pipe P.
Detector 10 carries first and second mechanical structures, 20 , 22 which provide a delay in responding to the movement of the lever 14 . Structure 20 includes an axially movable shaft 26 with a threaded end 26 a. The end 26 a carries a nut 26 b threaded onto the portion 26 a and rotatable therealong.
The nut 26 b also carries an interior set of threads 26 c which can be used to rotate the nut 26 b along the shaft 26 a, discussed subsequently.
The second structure, a timer/brake assembly, 22 includes a rack 22 a , with teeth 22 a - 1 , and associated escapement mechanism 22 b. The mechanism 22 b permits the rack to move freely in a slip direction 22 - 1 . Movement opposite the direction 22 - 1 , a timed direction, is regulated by operation of the escapement and rack combination which implements the timer/brake 22 .
Those of skill will appreciate that one implementation of the timer/brake 22 could be a verge and foliot-type escapement mechanism. Other types of mechanisms could be used, without limitation, without departing from the spirit and scope hereof.
The detector 10 also includes a switch and cam mechanism 30 which can produce a contact opening or closure in response to lever 14 moving to the flow position, and subsequent to a delay provided by the mechanism 20 , 22 . Cam 32 is carried on shaft 26 . The switches 34 a, b open or close in response to movement of cam 32 .
A spring 18 b which is extended when the lever 14 is biased to the no flow condition, provides a force to draw the cam 32 axially toward the switches 34 a, b once the lever 14 moves into the flow indicating position. The shaft 26 , also drawn by the spring 18 b closes a gap 10 - 1 between the nut 26 b and the rack 22 a.
When surface 26 d, see FIG. 1 , of the nut 26 b contacts the end surface 22 c of the rack 22 a, the timer mechanism 22 starts to function. This brakes motion of shaft 26 thereby delaying the time when cam 32 can trip the switches 34 a, b.
Once the switches 34 a, b are tripped by the cam 32 , and water flow ceases, the lever 14 will return to the no flow position. In this condition surface 26 e of the shaft 26 forces the rack 22 a to a no flow state by moving it in the slip direction 22 - 1 . This represents a common initial state of the apparatus prior to the lever 14 moving toward a flow indicating state.
In summary, when the gap 10 - 1 is increased, the timer/brake 22 is engaged later and there is less of a delay. When the gap 10 - 1 is decreased, the timer/brake 22 is engaged sooner and a longer delay results.
FIGS. 2-5 illustrate aspects of another embodiment hereof. Elements previously discussed have been assigned the same identification numerals and need not be discussed further.
FIG. 2 illustrates the timer 22 installed in place on an apparatus comparable to the apparatus 10 of FIG. 1 . The timer 22 is in a fixed position on the assembly. FIG. 2 illustrates the location of the spring 18 b and the direction that the spring 18 b pulls on the main shaft 26 and cam assembly 32 .
The switches 34 a, b are illustrated in a standby position. The main flow sensing pivot shaft 14 is in a no flow state, holding the shaft/cam assembly 26 / 32 to the right
In FIG. 3 , timer 22 has been removed to expose rack 22 a and related components in an initial no flow state. The gap 10 - 1 has been reduced substantially to zero in FIG. 3 . In this configuration, the timer/brake 22 will produce a maximum delay.
FIG. 4 illustrates the gap 10 - 1 produced by rotating the gear 26 c to move the nut 26 b away from the rack 22 . To produce a reduced delay. Once the surface 26 d - 1 contacts end 22 c of the rack 22 , the timer/brake 22 will start to function to provide a delay.
FIG. 5 illustrates a knob or dial 40 with teeth 42 that mesh with the teeth 27 b of pinion gear 27 a. Pinion 27 a is slidably locked to the nut 26 b by grooves 26 b - 1 in nut 26 b. The grooves 26 b - 1 slidably engage radial members 27 c of the pinion 27 a. Turning the dial 40 rotates the nut 26 b thereby sliding it along the threaded portion 26 a of timer shaft 26 . As a result the delay can be increased or decreased. In accordance with the above, the pinion gear 27 a rotates in response to movement of the knob 40 which in turn causes the nut 26 b to both rotate (due to the grooves 26 b - 1 and extending radial members 27 c ) and move axially relative to the shaft 25 as it rotates on threads 26 a.
With respect to FIG. 5 , in summary, the pinion gear 27 a rotates the nut 26 b as the knob 40 is being turned. Gear 27 a has teeth 27 b that interface with the teeth 42 on the knob 40 and also has interlock groves 27 c along which the nut 26 b slides. The pinion 27 a is stationary except for rotation when the knob 40 spins it.
In response to rotating the knob 40 , the threaded nut 26 b slides on the shaft 26 a as shown. This sliding in turn adjusts the length of the gap 10 - 1 as described above. The timer shaft 26 a, during timing stroke, is locked to the nut 26 b and pulls the nut 26 b along. As a result, nut 26 b glides axially through the pinion gear 27 a.
From the foregoing, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims. Further, logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. Other steps may be provided, or steps may be eliminated, from the described flows, and other components may be add to, or removed from the described embodiments.
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A water flow detector has a spring driven mechanical timer responsive to the movement of a lever. The lever is connected to a paddle. The paddle is responsive to the flow of water in a pipe. The detector via the spring driven timer responds to the flow of water in the pipe after a predetermined delay.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to illumination, and more particularly to support of light sources for lamps.
2. Background Information
A lamp is generally viewed as a piece of furniture holding one or more electric light bulbs. The electric light bulbs operate as an artificial source of visible illumination. Most table lamps vertically support light sources by employing a vase having a light bulb in a socket and a harp that supports a lamp shade about the light bulb. Other types of lamps such as floor lamps employ a pole or post having adjustable ball and socket light supports attached to the pole. The benefit of such table or floor lamps is that they may be quickly located and installed in one place or another. The problem with such lamps is that the vertical height of each light source on the lamp is fixed by the manufacturer.
Some light sources are supported by line-wire or cable. For example, holiday lights include a series of light bulbs coupled to a flexible wire that is horizontally strung to the eaves of a roof. This allows a user to adjust the vertical height of each light source on the lamp. For example, the string of lights may be suspended from the ceiling of a home. The benefit of flexible line-wire lamps is that the vertical position of each light source may be controlled by the consumer. However, line-wire lamps lack the locational flexibility of table and floor lamps. Thus, what is needed are light sources that include the locational flexibility of table and floor lamps as well as the vertical height adjustibility of line-wire lamps.
BRIEF SUMMARY OF THE INVENTION
The invention relates to an interleaved illumination support. The support includes a base and a wire coupled to the base. The wire includes beads attached to the wire along the length of the wire. A first leaf is coupled between the base and a bead that is the second bead above the base so as to maintain the wire in tension. A second leaf is coupled between a first bead and a fourth bead so as to maintain the wire in tension. A light source is coupled to the wire. Other features are disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of an embodiment of lamp 10 ;
FIG. 2 is a side view of lamp 10 of FIG. 1;
FIG. 3 is a plan view of light source 40 taken off of line 3 — 3 of FIG. 2;
FIG. 4 illustrates leaf 20 disposed below beads 104 ;
FIG. 5 is a detailed view of the tension of wire 60 between two leaves as taken off of line 5 of FIG. 2; and
FIG. 6 is a detailed view of vase 12 showing leaf 20 placed into cutout 16 as taken off of line 6 — 6 of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
For purposes of explanation, specific embodiments are set forth to provide a thorough understanding of the present invention. However, it will be understood by one skilled in the art from reading this disclosure that the invention may be practiced without these details. Moreover, well-known elements, devices, process steps and the like are not set forth in detail in order to avoid obscuring the invention.
Reference is now made to FIGS. 1 through 6 to illustrate the embodiments of the invention. FIG. 1 is an isometric view of an embodiment of lamp 10 . FIG. 2 is a side view of lamp 10 of FIG. 1 . Included with lamp 10 is base 12 , leaf 20 , light source 40 , wire 60 , power cord 70 , and plug 72 .
Base 12 preferably is composed of cone 14 that extends to flat bottom 16 . Base 12 includes cutout 16 and aperture 18 as best seen in FIG. 6 . However, base 12 may be any structure that permits lamp 10 to stand on its own, that serves to anchor wire 60 and leaf 20 as discussed below.
Leaf 20 preferably is an oblong shaped piece of resilient plastic into which slots 26 are cut into each end as best seen in FIG. 4 . In one embodiment, leaf 20 measures 12×4×0.125 inches and is used as a light deflector. Additional leaves, such as leaf 22 and leaf 24 may be added to lamp 10 as discussed below.
Light source 40 preferably is a light source that is clipped on to wires 60 . FIG. 3 is a plan view of light source 40 taken off of line 3 — 3 of FIG. 2 . Included with light source 40 may be bulb 42 coupled to housing 44 . So as to be able to clip light source 40 to two wires 60 , light source 40 further includes two terminals 46 . Each terminal 46 may have an opening that is narrower than the diameter of wire 60 , but is made of a resilient conductive material that works to return to its original position once wires 60 are snapped into place. Alternatively, the distance between each of the two terminals 46 is slightly greater or less than the distance between each of the two wires 60 .
Wire 60 may be any conductive material the is elongated. Preferably, wire 60 is made of flexible, twenty four gauge picture frame wire. At one end, wire 60 is coupled to a power source. This may be through power cord 70 and plug 72 as shown in FIG. 1 . Plug 72 preferably is a low voltage transformer that steps down a conventional one hundred twenty volt power supply to twelve volts. Light source 40 may be self powered such as including a battery. An insulating sleeve 74 may be placed around each wire 60 as shown in FIG. 6 . Preferably two wires 60 are provided so as to be able to use clip-on light source 40 . Where light source is coupled to power cord 70 , power is distributed to light source 40 through two wires 60 .
Attached along wire 60 is beads 100 . Beads 100 include the group of beads attached to wire 60 . Beads 100 may be solder drop welds or any other material that is fixed to wire 60 so as to retain the leaves of lamp 10 under compression. For example, beads 100 may be nuts screwed onto wire 60 or fishing weights clamped about wire 60 . As best seen in FIG. 2, leaf 24 is retained under compression by beads 106 and beads 112 . So as to be able to retain leaves 20 , 22 , and 24 against wire 60 and to maintain a vertical stacking of leaves 20 , 22 , and 24 , the spacing between beads 100 needs to be considered.
In one embodiment of the invention, such as that shown in FIG. 2, beads 100 include a multitude of beads attached to wire 60 . Beads 104 may be attached at two inches from bead 102 . Beads 106 may be attached at seven inches from bead 104 . Beads 108 may be attached at two inches from bead 106 . Beads 110 may be attached at seven inches from bead 108 . Beads 112 may be attached at two inches from bead 110 , and beads 114 may be at seven inches from bead 112 . If leaf 24 is twelve inches and is retained under compression by beads 106 and beads 112 , where the distance between beads 106 and beads 112 is nine inches, the length of leaf 24 is compressed by approximately three inches. This compression imparts a tension into wire 60 .
To assemble lamp 10 , leaf 20 is inserted into cutout 16 of base 12 as seen in FIG. 6 and FIG. 2 . Two wires 60 are placed through aperture 18 and fixed to base 12 so that leaf 20 will be placed in compression by one quarter of the length of leaf 20 . This is achieved by pre-positioning bead 104 (FIG. 2) at the distance described above. With leaf 20 in cutout 16 , leaf 20 is compressed so that slots 26 may be placed around wires 60 at a position that is below beads 104 . This is best seen in FIG. 4 .
With leaf 20 positioned around wires 60 and compressed at a position that is below beads 104 , leaf 20 pushes on beads 104 so as to maintain wire 60 in tension. With wire 60 in tension and leaf 20 in compression, lamp 10 stands erect. With wire 60 in tension, light source 40 is clipped onto wires 60 . As shown in FIG. 2, light emanating from light source 60 may be directed into leaf 20 so that leaf 20 acts as a light deflector. Light source 60 may be directed towards other directions as well.
In a second embodiment of the invention, lamp 10 may be built upon so as to increase the height of lamp 10 . To build upon lamp 10 , leaf 22 is compressed between beads 102 and beads 108 . Similar to leaf 20 , the compression of leaf 22 maintains wire 60 between beads 102 and beads 108 in tension. To insure that lamp 10 stands erect, one end of leaf 22 must be inserted around a portion of wire 60 that is in tension from leaf 20 . With leaf 22 in place, another light source 40 may be clipped to lamp 10 .
Similar to leaf 20 and leaf 22 , leaf 24 is compressed and placed into position between two sets of beads. As seen in FIG. 2, leaf 24 is placed into position between beads 106 and beads 112 . This maintains tension on wire 60 as one leaf flows into the next leaf as illustrated by the arrows in FIG. 5 .
With the addition of leaf 24 , the height of lamp 10 has now increased by the three leaves so that a third light source 40 may be placed on wire 60 . A fourth leaf may be placed between beads 110 and beads 114 . Alternatively, beads 114 may serve to prevent wire 60 from fraying. With additional lengths of wire 60 , more leaves and light sources may be stacked on top of lamp 10 . In this way, light sources may be positioned in the vertical direction at any location the user chooses.
While the present invention has been particularly described with reference to the various figures, it should be understood that the figures and detailed description, and the identification of certain preferred and alternate materials, are for illustration only and should not be taken as limiting the scope of the invention or excluding still other alternatives. Many changes and modifications may be made to the invention, by one having ordinary skill in the art, without departing from the scope of the subject matter of the claimed invention.
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The invention relates to an interleaved illumination support. The support includes a base and a wire coupled to the base. The wire includes beads attached to the wire along the length of the wire. A first leaf is coupled between the base and a bead that is the second bead above the base so as to maintain the wire in tension. A second leaf is coupled between a first bead and a fourth bead so as to maintain the wire in tension. A light source is coupled to the wire. Other features are disclosed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a multi-shaft rotary creel suitably used for a sample warper which is provided with a plurality of yarn guides for winding yarns on a warper drum and automatically exchanges yarns in preset pattern data (a preset yarn order) to wind yarns on the warper drum, a sample warper provided with the multi-shaft rotary creel and a warping method.
[0003] 2. Description of the Related Art
[0004] As a sample warper used conventionally, there has been known, for example, a structure disclosed in Japanese Patent No. 1529104, namely a structure, wherein using a fixed creel for supporting a plurality of bobbins on which different kinds (different colors or twisted differently) of yarns are to be wound, the yarns are successively wound on a warper drum by yarn guides while yarn exchanging is performed by a yarn selection device according to preset pattern data (a preset yarn order).
[0005] Further, there has been also known a sample warper for winding a plurality of yarns simultaneously, wherein using a rotary creel and omitting a yarn exchanging step, it is possible to cancel loss of time for yarn exchanging, to wind simultaneously a plurality of yarns on a warper drum, and further to reduce a warping time (refer to Japanese Patent No. 1767706, U.S. Pat. No. 4,972,662 and EP375480).
[0006] The fixed creel has a plurality of bobbins on which the same kind and/or of different kinds (mainly different kinds) of yarns are to be wound, wherein since yarns can be warped for each yarn while yarn exchanging is freely performed by the selection device, a warping operation for pattern warping can be advantageously performed, but since yarns are sequentially wound on the warper drum for each yarn, much time is disadvantageously required for a warping operation. On the other hand, the rotary creel has a plurality of bobbins on which the same kind and/or different kinds of yarns are to be wound, and it can be applied to repetition warping for an extremely limited number of patterns such as solid color warping (for example, one color of a red color yarn), one to one warping (for example, repetition of one red yarn and one white yarn, or repetition of one S-twisted yarn and one Z-twisted yarn), two to two warping (for example, repetition of two red yarns and two white yarns, or two S-twisted yarns and two Z-twisted yarns) and the like. In the rotary creel, a warping operation of pattern warping except for the extremely limited number of patterns can not be disadvantageously performed but a warping time can be advantageously reduced to a great extent because the plural yarns are wound on the warper drum simultaneously.
[0007] The present applicant has already proposed a sample warper provided with a plurality of yarn selection devices corresponding to a fixed creel and a rotary creel, which can perform jointly pattern warping and repetition warping and reduce a warping time of a warping operation requiring solid color warping and pattern warping to achieve an extremely high efficiency (refer to JP2000-136456A and EP933455A2).
[0008] Further, the present applicant has also proposed a sample warper, wherein a plurality of rotary creel are combined to freely perform the pattern warping and the repetition warping (JP2002-339183A).
[0009] In the above-described sample warper with the rotary creel, improvement has been conducted aiming at how to reduce a warping time by effectively utilizing an advantage of the rotary creel that allows feeding a plurality of yarns simultaneously.
[0010] On the other hand, there has also been proposed a sample warper without a yarn selection device, wherein yarns are wound on a warper drum by performing yarn winding and suspension thereof alternately (refer to Japanese Patent No. 3263050 and JP2002-212851A).
[0011] In the sample warper described in JP2002-339183A, wherein a plurality of rotary creels are combined on a plane to allow performing freely pattern warping and repetition warping, since there are positional differences between the warper drum and the respective rotary creels, distances or angles between the bobbins and the distal end guide portions of the yarn guides become uneven according to a rotary creel to be used. For this reason, tension of yarns that are drawn out from the bobbins and wound on the warper drum via the distal end guide portions of the yarn guides become uneven, tension fluctuations being generated.
SUMMARY OF THE INVENTION
[0012] The present inventors have reached the present invention as a result of the repeated researches for developing a rotary creel with a novel mechanism, which has solved the above-described problem.
[0013] An object of the present invention is to provide a novel multi-shaft rotary creel where the degree of freedom for warping is further improved as compared with the conventional single shaft rotary creel and generation of tension fluctuations can be prevented, a sample warper with the multi-shaft rotary creel capable of efficient warping and a warping method
[0014] A multi-shaft rotary creel according to the present invention comprises: a base body; a main shaft rotatably mounted on the base body so as to project forward; a plurality of supporting shafts rotatably mounted on a forward projecting portion of the main shaft; and a plurality of bobbins mountable on each of the supporting shafts, which is installed opposing to a sample warper with a plurality of yarn guides, and wherein, while the main shaft or each of the supporting shafts rotates in synchronism with rotation of the yarn guides, simultaneous warping of plural yarns by the main shaft or each of the supporting shafts can be performed. The multi-shaft rotary creel according to the present invention may preferably comprise further a driving unit for performing rotation and suspension of the main shaft and each of the supporting shafts and serving to keep suspended positions thereof.
[0015] One aspect of a sample warper according to the present invention comprises: a warper drum; and a plurality of yarn guides each rotatably mounted on a side surface of the warper drum for winding yarns on the warper drum, wherein yarns are wound on the warper drum according to a preset yarn order, and wherein there is installed the multi-shaft rotary creel according to the present invention having a plurality of bobbins on which different kinds and/or the same kind of yarns have been wound.
[0016] Another aspect of a sample warper according to the present invention comprises: a warper drum; and a plurality of yarn guides each rotatably mounted on a side surface of the warper drum for winding yarns on the warper drum, a yarn selection device for rotary creel provided with a plurality of yarn selection guides which are in correspondence with the yarn guides, each of the yarn selection guides being pivotally moved to a yarn exchanging position when exchanging yarns and retract to a standby position when storing yarns, wherein yarns are automatically exchanged and successively wound on the warper drum according to a preset yarn order by passing the yarns between the yarn guides and the yarn selection guides, and wherein the multi-shaft rotary creel according to the present invention having a plurality of bobbins on which different kinds and/or the same kind of yarns have been wound is installed in correspondence with the yarn selection device.
[0017] According to the above-described structure, the following warping modes (1) to (3) will be made possible.
[0018] (1) Simultaneous warping of a plurality of yarns is performed using all bobbins under the following conditions. The main shaft is rotated in synchronism with rotation of the yarn guides of the sample warper and each of the supporting shafts is rotated to positions such that the guide plates form a shape approximating to a circle shown in FIG. 3 , and then suspended at the positions, the suspended state of each of the supporting shafts being kept. All bobbins mounted on the suspended supporting shafts are used for warping.
[0019] (2) Simultaneous warping of a plurality of yarns using a plurality of bobbins mounted on one of the supporting shafts is performed under the following conditions. The only one supporting shaft is rotated in synchronism with rotation of the yarn guides for warping. The plural bobbins mounted on the rotating supporting shaft are only used for warping.
[0020] (3) Single yarn warping is performed using any one of bobbins of the multi-shaft rotary creel under the following conditions. The main shaft and each of the supporting shafts are suspended and the suspended states are kept. Any one of the bobbins mounted on the suspended supporting shafts is only used for warping.
[0021] The warping modes (1), (2) and (3) are preferably applied to a sample warper without a yarn selection device, but a sample warper with a yarn selection device mounted below the center line of the warper drum is desirably applied with the following warping modes (2′) and (3′) in addition to the above mode (1).
[0022] (2′) Simultaneous warping of a plurality of yarns is performed using a plurality of bobbins mounted on one of the supporting shafts under the following conditions. The one supporting shaft to be used for warping is moved to a close position vertically above an extension line of the center position of a front face of the warper drum by rotating the main shaft, then suspended at the position and the suspended state of the supporting shaft is kept, the supporting shaft being rotated in synchronism with rotation of the yarn guides of the sample warper, and the remaining supporting shafts are rotated to positions such that guide plates become approximately horizontal as shown in FIG. 4 , and then suspended at the positions, the suspended state of each of the remaining supporting shafts being kept.
[0023] (3′) Single yarn warping is performed using one bobbin under the following conditions. The main shaft is rotated such that a supporting shaft which supports the bobbin to be used for warping is positioned at a close position vertically above an extension line of the center position of the front face of the warper drum, then suspended at the position and the suspended state of the main shaft is kept, and next after the supporting shaft is rotated such that a bobbin to be used for warping is positioned at the highest position, the suspended state of each of all the supporting shafts is kept.
[0024] By performing warping according to the warping modes (1), (2) and (3), or (1), (2′) and (3′), warping is made possible with less tension fluctuations among the respective yarns. A warping method according to the present invention using the sample warper of the present invention is characterized in that there is performed simultaneous warping of a plurality of yarns using all the bobbins, simultaneous warping of a plurality of yarns using a plurality of bobbins mounted on one supporting shaft or a single yarn warping of one yarn using one bobbin.
[0025] According to the multi-shaft rotary creel of the present invention, such an advantage is achieved that the degree of freedom for warping can be further improved as compared with the conventional single shaft rotary creel, and occurrence of tension fluctuations can be prevented. Further, the sample warper of the present invention is capable of warping efficiently by installing the multi-shaft rotary creel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a schematic explanatory perspective view showing an embodiment of the sample warper of the present invention;
[0027] FIG. 2 is an explanatory side view showing a structural example of the multi-shaft rotary creel of the present invention;
[0028] FIG. 3 is an explanatory front view of the multi-shaft rotary creel shown in FIG. 2 ; and
[0029] FIG. 4 is an explanatory front view showing a state that yarns have been pulled out from bobbins held by respective bobbin holders of the multi-shaft rotary creel.
DETAILED DESCRIPTION OF THE INVENTION
[0030] An embodiment of the present invention will be explained below with reference to the attached drawings. The embodiment described herein is illustrative, and it may be modified variously without departing from the scope and spirit of the present invention.
[0031] In FIG. 1 , a sample warper 200 of the present invention comprises: a warper drum 202 ; and a plurality of yarn guides 6 a to 6 h (in this illustrated example, the number of the yarn guides is eight, but actually yarn guides of the same number as the total number of bobbins are used, for example, if the number of bobbins is sixteen, the number of yarn guides is sixteen) each rotatably mounted on a side surface of the warper drum 202 for winding yarns 22 on the warper drum 202 , a yarn selection device 27 for a rotary creel provided with a plurality of yarn selection guides which are in correspondence with the yarn guides, each of the yarn selection guides being pivotally moved to a yarn exchanging position when exchanging yarns and retract to a standby position when storing yarns; and a multi-shaft rotary creel 206 having a plurality of bobbins 146 on which different kinds and/or the same kind of yarns 22 have been wound and installed in correspondence with the yarn selection device 27 , wherein yarns 22 are automatically exchanged and successively wound on the warper drum 202 according to a preset yarn order by passing the yarns 22 between the yarn guides 6 a to 6 h and the yarn selection guides of the yarn selection device 27 . Incidentally, the basic structure and function of the sample warper 200 are broadly known from the above-described patent documents and the like, and detailed explanation thereof will be omitted.
[0032] Reference numeral 17 denotes a conveyor belt movably mounted on a circumferential surface of the warper drum 202 . A feed rate of the conveyor belt 17 is controlled by a conveyor belt feed unit in accordance with warping conditions (the number of warping yarns, a warping width, the winding number of warping yarns and the like). The movement of the conveyor belt 17 is synchronized with rotation of the yarn guides 6 a to 6 h . Reference numerals 18 a to 18 g denote shedding bars. Distal end portion of the shedding bars 18 a to 18 g on the yarn guide side are provided with shedding units for forming a shed of the yarns 22 .
[0033] In this connection, as the yarn selection device 27 , there can be used a conventional one, for example, one described in JP2002-339183A.
[0034] In the sample warper 200 of the present invention, the multi-shaft rotary creel with a novel structure is adopted, which will be explained below. As shown in FIG. 2 and FIG. 3 , the multi-shaft rotary creel 206 has a base body 100 , and a front frame 102 a and a rear frame 102 b are mounted opposing to each other on an upper surface of the base body 100 in a standing manner. Incidentally, in FIG. 2 , reference numeral 107 denotes a slip ring provided on a surface of a main shaft 106 .
[0035] A pair of front and rear bearings 104 a , 104 b for the main shaft 106 are provided on upper portions of the front frame 102 a and the rear frame 102 b , respectively. The main shaft 106 is rotatably mounted via the main shaft bearings 104 a and 104 b . The main shaft 106 is provided such that the front end side thereof is projected ahead of the front frame 102 .
[0036] A main shaft counter pulley 108 is provided at a rear end portion of the main shaft 106 protruding rearward from the rear main shaft bearing 104 b . Reference numeral 110 denotes a main shaft motor, which is disposed at a suitable portion of the rear frame 102 b . A main shaft motor axis 112 protrudes at a rear end portion of the main shaft motor 110 , and the main shaft motor axis 112 is provided with a main shaft motor pulley 114 . The main shaft counter pulley 108 and the main shaft motor pulley 114 are coupled with a main shaft belt 116 . Therefore, by driving the main shaft motor 110 , its driving force is transmitted to the main shaft 106 via the main shaft motor axis 112 , the main shaft motor pulley 114 , the main shaft belt 116 and the main shaft counter pulley 108 , whereby the main shaft 106 is rotated. In this connection, as the main shaft motor 110 , a servomotor may be used. Further, it is preferable that when toothed pulleys are used as the main shaft counter pulley 108 and the main shaft motor pulley 114 and a toothed belt is used as the main shaft belt 116 , the main shaft counter pulley 108 and the motor pulley 114 can be coupled in a state that no slip occurs therebetween.
[0037] A pair of front and rear supporting plates 118 a and 118 b are provided opposing to each other at a projecting portion 106 a of the main shaft 106 projecting forward from the front main shaft bearing 104 a . Plural (four in this embodiment, namely, first to fourth) supporting shafts 120 , 122 , 124 and 126 are rotatably mounted between the supporting plates 118 a and 118 b via front or rear supporting shaft bearings 128 a , 128 b , 130 a , 130 b , 132 a , 132 b , and 134 a , 134 b (only the shaft bearings 128 a , 128 b , and 130 a , 130 b are illustrated in FIG. 2 ) so as to be positioned radially about the projecting portion 106 a of the main shaft 106 . In this connection, reference numeral 127 in FIG. 2 denotes each of slip rings provided on a surface of the supporting shafts 120 , 122 , 124 and 126 .
[0038] Supporting shaft counter pulleys 136 a , 136 b , 136 c and 136 d are provided at rear end potions of the supporting shafts 120 , 122 , 124 and 126 projecting rearward from the rear bearings 128 b , 130 b , 132 b and 134 b . Reference numerals 138 a , 138 b , 138 c and 138 d denote supporting shaft motors, which are provided at suitable portions of the rear supporting plates 118 b . Supporting shaft motor axes are protruded at rear end portions of the supporting shaft motors 138 a , 138 b , 138 c and 138 d , and the supporting shaft motor axes are provided with supporting shaft motor pulleys 140 a , 140 b , 140 c and 140 d . The supporting shaft counter pulleys 136 a , 136 b , 136 c and 136 d and the supporting shaft motor pulleys 140 a , 140 b , 140 c and 140 d are coupled with supporting shaft belts 142 a , 142 b , 142 c and 142 d . Therefore, by driving the supporting shaft motors 138 a , 138 b , 138 c and 138 d , their driving forces are transmitted to the supporting shafts 120 , 122 , 124 and 126 via the supporting shaft motor axes, the supporting shaft motor pulleys 140 a , 140 b , 140 c and 140 d , the supporting shaft belts 142 a , 142 b , 142 c and 142 d , and the supporting shaft counter pulleys 136 a , 136 b , 136 c and 136 d , whereby the supporting shafts 120 , 122 , 124 and 126 are rotated. In this connection, as the supporting motors 138 a , 138 b , 138 c and 138 d , servomotors may be used. It is preferable that, when toothed pulleys are used as the counter pulleys 136 a , 136 b , 136 c and 136 d and the motor pulleys 140 a , 140 b , 140 c and 140 d , and toothed belts are used as the supporting shaft belts 142 a , 142 b , 142 c and 142 d , the counter pulleys 136 a to 136 d and the motor pulleys 140 a to 140 d are coupled in a state that no slip occurs therebetween.
[0039] Annular bobbin holders 144 a , 144 b , 144 c and 144 d are fixed to distal end portions of the supporting shafts 120 , 122 , 124 and 126 projecting forward from the front supporting shaft bearings 128 a , 130 a , 132 a and 134 a . Plural (four in this embodiment) bobbins 146 are mounted on each of the bobbin holders 144 a , 144 b , 144 c and 144 d , respectively. Different kinds and/or the same kind of yarns 22 have been wound on the bobbins 146 . Therefore, supply or suspension of the yarns 22 can be performed by suitably combining rotating or suspending state of the main shaft 106 and rotating or suspending state of the supporting shafts 120 , 122 , 124 and 126 . In FIG. 2 , such a situation is shown that yarns 22 m from the bobbins 146 held by the bobbin holder 144 a provided on the distal end portion of the first supporting shaft 120 are in a warping state, i.e., the yarns 22 m are caught by the yarn guides 6 a to 6 h to be wound on the warper drum 202 , while the yarns 22 n from the bobbins 146 held by the bobbin holder 144 b provided on the distal end portion of the second supporting shaft 122 are in a suspending state, i.e., the yarns 22 n are stored in the yarn selection device 27 .
[0040] Reference numerals 148 a , 148 b , 148 c and 148 d denote guide plates, which serve to guide the plural yarns 22 not to get tangled. The structure of each of the guide plates 148 a to 148 d is not limited to a specific one, but rod shaped one is shown in the illustrated embodiment. Incidentally, in a general structure of the rotary creel, as shown in JP2002-339183A, a yarn reserving device and a yarn returning device are disposed between the bobbins and the guide plate, but they are omitted in the embodiment shown in FIG. 2 . With such a structure, plural yarns 22 which have been wound on plural bobbins 146 respectively are guided through the yarn reserving device, the yarn returning device and guide plates 148 and the yarns 22 m to be warped are introduced to the yarn guides 6 a to 6 h , whereby the yarns 22 m are wound on the warper drum 202 . On the other hand, the suspending yarns 22 n are guided through the yarn reserving devices, the yarn returning devices and the guide plates 148 , and then the yarns 22 n are introduced to the yarn selection device 27 and stored therein.
[0041] Various warping methods can be employed using the multi-shaft rotary creel of the present invention, which will be explained below.
[0042] (1) Simultaneous warping of a plurality of yarns is performed using all bobbins (sixteen bobbins in the illustrated embodiment) 146 under the following conditions. The main shaft 106 is rotated in synchronism with rotation of the yarn guides 6 a to 6 b of the sample warper and each of the supporting shafts 120 , 122 , 124 and 126 is rotated to positions such that the guide plates 148 a to 148 d forms a shape approximating to a circle shown in FIG. 3 , then suspended at the positions and the suspended state of each of the supporting shafts 120 , 122 , 124 and 126 is kept. All bobbins 146 held by the bobbin holders 144 a , 144 b , 144 c and 144 d provided on the suspended supporting shafts 120 , 122 , 124 and 126 are used for warping. By employing such warping, the yarns 22 are pulled out smoothly, which is convenient.
[0043] (2) Simultaneous warping of a plurality of yarns using four bobbins 146 held by the bobbin holder 144 a provided on one of the supporting shafts, for example, the supporting shaft 120 is performed under the following conditions. First, the main shaft 106 is rotated such that the supporting shaft 120 to be used for warping is moved to a close position vertically above an extension line of the center position of the front face of the warper drum 202 , that is to say, the bobbin holder 144 a to be used for warping is moved to the highest position. In this state, the suspended position of the main shaft 106 is kept and the supporting shaft 120 to be used for warping is rotated in synchronism with rotation of the yarn guides 6 a to 6 h of the sample warper 200 , and the remaining supporting shafts 122 , 124 and 126 are rotated to their horizontal positions shown in FIG. 4 , then suspended at the positions and the suspended state is kept for warping. In this case, four bobbins 146 held by the bobbin holder 144 a are rotated according to rotation of the supporting shaft 120 , so that warping is performed using four yarns. Therefore, in case where various kinds of yarns are warped according to various warping conditions, if different kinds or different colors of yarns 22 are set as the yarns 22 of the bobbins 146 held by the four bobbin holders 144 a to 144 d , respectively, various kinds of yarns 22 can be warped by sequentially rotating the supporting shafts 120 , 122 , 124 and 126 to a warping position (the highest position in FIG. 4 ).
[0044] (3) Single yarn warping is performed using one bobbin 146 under the following conditions. The main shaft 106 is rotated such that the supporting shaft (indicated by reference numeral 120 in the embodiment shown in FIG. 4 ) supporting the bobbin 146 to be used for warping is positioned at a close position vertically above the extension line of the center position of the front face of the warper drum 202 , then suspended at the positions and the suspended state is kept for warping. Next, the supporting shaft 120 is rotated such that a bobbin (indicated by reference numeral 146 A in FIG. 4 ) of the four bobbins 146 on which a yarn for single yarn warping has been wound held by the bobbin holder 144 a is moved to the highest position. In this state, all the supporting shafts 120 , 122 , 124 and 126 are suspended and the suspended positions are kept. Single yarn warping is performed using the bobbin 146 A positioned at the highest position. Accordingly, when single yarn warping of different kinds or different colors is performed, such single yarn warping can be performed by sequentially moving the bobbins on which the yarns of different kinds or different colors have been wound to the highest position in the same procedure as the above one.
[0045] In the illustrated embodiment, there is shown the example where one multi-shaft rotary creel 206 is installed opposing to the sample warper 200 , but the multi-shaft rotary creel 206 may be combined with a fixed creel, as shown in JP2000-136456A and EP933455A2, and a plurality of the multi-shaft rotary creels 206 may be installed, as shown in JP2002-339183A.
[0046] Further, in the illustrated embodiment, there is shown the example where the multi-shaft rotary creel of the present invention is applied to the sample warper 200 provided with the yarn selection device 27 in which pattern warping is performed by winding yarns on the warper drum 202 while exchanging yarns. However, as a matter of course, the multi-shaft rotary creel of the present invention may be applied to a sample warper where yarns are wound on the warper drum 202 by performing winding and suspension of yarns alternately to perform pattern warping without installing the yarn selection device 27 , as shown in, for example, Japanese Patent No. 3263050 and JP2002-212851A.
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There is provided a multi-shaft rotary creel where the degree of freedom for warping can be further improved as compared with the conventional single shaft rotary creel and occurrence of tension fluctuations can be prevented. There are further provided a sample warper and a warping method where warping can be performed efficiently by installing the multi-shaft rotary creel. The multi-shaft rotary creel comprises: a base body; a main shaft rotatably mounted on the base body so as to project forward, a plurality of supporting shafts rotatably mounted on a forward projecting portion of the main shaft; and a plurality of bobbins mountable on each of the supporting shafts, which is installed opposing to a sample warper with a plurality of yarn guides, and wherein, while the main shaft or each of the supporting shafts rotates in synchronism with rotation of the yarn guides, simultaneous warping of plural yarns by the main shaft or each of the supporting shafts can be performed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. application Ser. No. 10/641,242, which was filed on Aug. 14, 2003.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to methods and compositions for treating subterranean formations, and more specifically, to improved methods and compositions for degrading filter cake deposited in a subterranean formation.
[0003] Filter cake, the residue deposited on a permeable medium when servicing fluids contact the medium under a pressure, is formed in a variety of subterranean operations such as drilling, fracturing, and gravel packing. A filter cake is often desirable, at least temporarily, in subterranean operations as it may act to stem the flow of a servicing fluid from its desired location, to the surrounding subterranean formation. For instance, where the servicing fluid is a drilling fluid, a filter cake formed on the wall of the well bore may act to keep the drilling fluid in its desired location, in the annulus between the well bore and the drill pipe, rather than allowing the drilling fluid to leach off into the surrounding formation. Loss of drilling, fracturing, gravel transport and other servicing fluids into the formation represents an increased expense and, if too much fluid is lost, the attendant increase in damage to the producing zones in the formation. Moreover, the presence of a filter cake may add strength and stability to the formation surfaces on which the filter cake forms, as in the case of soft sandstone formations.
[0004] Filter cakes may be formed during drilling and fracturing operations. Once a well bore is established, the producing zones along the well bore may be treated to increase their production rate. One such production stimulation treatment involves hydraulically fracturing the formation with a viscous treating fluid to create one or more cracks or “fractures.” As a fracture is created, a portion of the fluid contained in the viscous fracturing fluid leaks off into the formation and creates a filter cake comprising deposited viscosifying agent and fluid loss control agent on the walls of the fracture and the formation. The filter cake acts as a physical barrier to liquid travel that, as described above, helps reduce fluid loss into the producing zone. The filter cake may also present a barrier to flow of liquid from the zone, thus, after the fracturing operation has been completed, the filter cake generally needs to be removed to maximize oil and/or gas production.
[0005] Sand control operations, such as gravel packing, are also common after a well bore is drilled. One common type of gravel packing operation involves placing a gravel pack screen in the well bore and packing the surrounding annulus between the screen and the well bore with gravel of a specific size designed to prevent the passage of formation sand. The gravel pack screen is generally a filter assembly used to retain the gravel placed during gravel pack operation. A wide range of sizes and screen configurations are available to suit the characteristics of the gravel pack sand used. Similarly, a wide range of sizes of gravel is available to suit the characteristics of the unconsolidated or poorly consolidated particulates in the subterranean formation. The resulting structure presents a barrier to migrating sand from the formation while still permitting fluid flow. When installing the gravel pack, the gravel is carried to the formation in the form of a slurry by mixing the gravel with a transport fluid. Gravel packs act, inter alia, to stabilize the formation while causing minimal impairment to well productivity. The gravel, inter alia, acts to prevent the particulates from occluding the screen or migrating with the produced fluids, and the screen, inter alia, acts to prevent the gravel from entering the production tubing. Often, gravel packs are placed along a well bore having a filter cake on its walls.
[0006] While filter cakes may be beneficial, it is generally necessary to remove filter cakes from producing zones before the well is placed onto production. One known method for the removal of filter cakes from producing formations involves including an acid-soluble particulate solid bridging agent for bridging over the formation pores in the drilling, fracturing, gravel transport or other servicing fluid that forms the filter cake. Such an acid-soluble filter cake could then be removed by placing a strongly acidic acid solution in contact with the filter cake and allowing that solution to remain in contact for a period of time sufficient to dissolve the filter cake.
[0007] One consideration in removing a deposited filter cake from a subterranean well bore formation involves the timing of such removal. For instance, in situations where sand control of the formation is a concern, a filter cake offers some degree of control over unconsolidated particulates in the subterranean formation while placing the gravel pack. For example, if the filter cake is removed prior to gravel packing, the unconsolidated particulates are not controlled and well bore stability problems may arise causing the collapse of the bore hole and preventing the installation of a gravel pack. While installing the screen and placing the gravel before removing the filter cake helps control unconsolidated particulates and maintain bore hole stability, it also makes the filter cake itself more difficult to remove. This is because the screen and gravel represents a physical barrier between the filter cake on walls of the well bore and the acidic fluid used to remove the filer cake.
[0008] One conventional method that attempts to overcome that problem involves placing a breaker (e.g., an oxidizer, ester, enzyme, or the like) in the fracturing, transport or other servicing fluid that creates and/or treats the filter cake in hopes that the breaker will permeate the filter cake and break it down. However, because the breaker is dissolved in the servicing fluid and not all of the servicing fluid remains in the subterranean formation inter alia, while circulating a gravel pack, much of the breaker that is used gets circulated out of the well bore and does not interact with the filter cake as desired.
[0009] More recently, it has been found that acid-releasing degradable material may be coated onto a particulate and act at a delayed rate to produce acid such that the particulate may be placed in the subterranean formation adjacent to the filter cake before a substantial amount of acid is released. In such methods known in the art, the acid-releasing degradable material had to be coated onto the particulate in a controlled environment off-site from the well head. The material then had to be coated onto various types and sizes of gravel/proppant, stored, and transported before it could be used in a subterranean formation.
SUMMARY OF THE INVENTION
[0010] The present invention relates to methods and compositions for treating subterranean formations, and more specifically, to improved methods and compositions for degrading filter cake deposited on a subterranean formation.
[0011] One embodiment of the present invention provides a method of creating particulates coated with acid-releasing degradable material on-the-fly comprising the step of: combining an acid-releasing degradable material with a solvent or a plasticizer to create a coating solution; and, coating the coating solution onto a particulate on-the-fly to create coated particulates.
[0012] Another embodiment of the present invention provides a method of degrading filter cake in a subterranean formation comprising the steps of: combining an acid-releasing degradable material with a solvent or a plasticizer to create a coating solution; coating the coating solution onto a particulate on-the-fly to create coated particulates; placing the coated particulates into a subterranean formation so that they form a pack substantially adjacent to a filter cake; allowing the low molecular weight acid-releasing degradable material to produce acid; and allowing the acid to contact and degrade a portion of the filter cake.
[0013] Still another embodiment of the present invention provides a gravel pack comprising gravel particles coated on-the-fly with an acid-releasing degradable material.
[0014] The objects, features, and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of the preferred embodiments that follows.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0015] The present invention relates to methods and compositions for treating subterranean formations, and more specifically, to improved methods and compositions for degrading filter cake deposited on a subterranean formation.
[0016] Certain embodiments of the compositions of the present invention comprise particulates coated on-the-fly with an acid-releasing degradable material that releases acid over time. The released acid may be used to degrade an acid-degradable filter cake substantially adjacent to the coated particulates. In some embodiments the acid-releasing degradable material used to coat the particulates acts at a delayed rate to produce acid such that the particles may be placed in the subterranean formation adjacent to the filter cake before a substantial amount of acid is released. The compositions and methods of the present invention are suitable for use in removing any filter cake that degrades in the presence of an acid.
[0017] Any particulate material suitable for use in conjunction with subterranean applications is suitable for use as the particulate in the compositions and methods of the present invention. Natural sand, quartz sand, particulate garnet, glass, ground walnut hulls, nylon pellets, bauxite, ceramics, polymeric materials, or the like are all suitable. Suitable sizes range from 4 to 100 U.S. mesh, in certain preferred embodiments the sizes range from 10 to 70 US mesh. The particulate material of the present invention may be used as gravel particles used in sand control operations, as proppant particles used in fracturing operations, or as any other particulate employed in subterranean operations that may be placed substantially adjacent to a filter cake.
[0018] Acid-releasing degradable materials that may be used in conjunction with the present invention are those materials that can be coated onto a particulate on-the-fly and that are substantially water insoluble such that they degrade over time, rather than instantaneously, to produce an acid.
[0019] Moreover, in order for an acid-releasing degradable material to be suitable for on-the-fly coating onto a particulate, it must be in a substantially liquid, flowable form. Solvents can be used for this purpose. Such suitable solvents include, but are not limited to, acetone, propylene carbonate, di(propylene glycol) methyl ether, di(propylene glycol) propyl ether, di(propylene glycol) butyl ether, di(propylene glycol) methyl ether acetate, isopropyl alcohol, chloroform, dichloromethane, trichloromethane, 1,2-dichlorobenzene, tetrahydrofuran, benzene, acetonitrile, dioxane, dimethylformamide, toluene, ethyl acetate, isoamyl alcohol, N-methylpyrrolidone, xylenes, dichloroacetic acid, m-cresol, hexafluoroisopropanol, diphenyl ether, acetonitrile, methanol, ethyl benzene, naphthalene, naphtha and combinations thereof As an alternative to a solvent, a plasticizer also may be used to make the polymer more flowable for the coating process. Examples of plasticizers useful for this purpose include, but are not limited to, polyethylene glycol; polyethylene oxide; oligomeric lactic acid; citrate esters (such as tributyl citrate oligomers, triethyl citrate, acetyltributyl citrate, acetyltriethyl citrate, 25% by weight after the phase separate); glucose monoesters; partially fatty acid esters; PEG monolaurate; triacetin; poly(e-caprolactone); poly(hydroxybutyrate); glycerin-1-benzoate-2,3-dilaurate; glycerin-2-benzoate-1,3-dilaurate; starch; bis(butyl diethylene glycol)adipate; ethylphthalylethyl glycolate; glycerine diacetate monocaprylate; diacetyl monoacyl glycerol; polypropylene glycol (and epoxy derivatives thereof); poly(propylene glycol)dibenzoate, dipropylene glycol dibenzoate; glycerol; ethyl phthalyl ethyl glycolate; poly(ethylene adipate)disterate; di-iso-butyl adipate; and combinations thereof
[0020] Generally, suitable acid-releasing degradable materials include polyesters; poly(orthoesters); aliphatic polyesters; lactides, poly(lactides); glycolides; poly(glycolides); poly(ε-caprolactone); poly(hydroxybutyrate); substantially water insoluble anhydrides; poly(anhydrides); poly(amino acids); and mixtures and copolymers of the same. The acid-releasing degradable material chosen must be substantially soluble in the chosen solvent. While no particular molecular weight is required, lower molecular weight materials may be more easily soluble. By way of example, polylactides having a molecular weight of less than about 3,000 are generally soluble in propylene carbonate while polylactides having a molecular weight of 50,000 generally are not. Copolymerization may also be used to facilitate solubility in a suitable solvent. By way of example, copolymers of lactide and glycolide will be soluble in di(proplylene glycol) methyl ether at molecular weights where a polylacide material of the same molecular weight would not be soluble. Amorphous polymers are generally more soluble in solvents and this property can be considered in choosing a material for coating. It is within the ability of one skilled in the art, with the benefit of this disclosure, to select an acid-releasing degradable material suitable for use in the present invention.
[0021] Polymers suitable for use as an acid-releasing degradable material of the present invention may be considered degradable if the degradation is due, inter alia, to chemical and/or radical process such as hydrolysis, oxidation, or enzymatic decomposition. The degradability of a polymer depends at least in part on its backbone structure, type of repetitive unit, composition, sequence, length, molecular geometry, molecular weight, morphology (e.g., crystallinity, size of spherulites, and orientation), hydrophilicity, hydrophobicity, surface area, and additives. Also, the environment to which the polymer is subjected may affect how it degrades, e.g., temperature, presence of moisture, oxygen, microorganisms, enzymes, pH, and the like.
[0022] Blends of certain acid-releasing degradable materials may also be suitable. One example of a suitable blend of materials includes a blend of a poly(lactic acid) and lactide. Other materials that undergo degradation and produce acid may also be suitable, if the products of the degradation do not undesirably interfere with either the subterranean treatment being performed or the subterranean formation.
[0023] In choosing the appropriate acid-releasing degradable material, one should consider the degradation products that will result. Also, these degradation products should not adversely affect other operations or components. The conditions of the well, e.g., well bore temperature and environmental factors, must also be considered when choosing an acid-releasing degradable material. For instance, polyesters have been found to be suitable for well bore temperatures in the range of 60° F. to 400° F. Generally, smaller molecule acid-releasing degradable materials are suitable for use in lower temperature application and larger molecule acid-releasing degradable materials are suitable for use in higher-temperature applications. By way of example, lactide is suitable for temperatures below 120 F and 3,000 molecular weight polylactide for temperatures above 180 F. Copolymers of lactide and glycolide are suitable for use in the 120 F to 180 F. It is within the ability of one skilled in the art, with the benefit of this disclosure, to select a suitable acid-releasing degradable material.
[0024] When used in the present invention, a preferable result is achieved if the degradable material degrades slowly over time as opposed to instantaneously. Even more preferable results have been obtained when the degradable material does not substantially degrade until after the subterranean treatment, such as a gravel packing or fracturing operation, has been substantially completed.
[0025] The acid-releasing degradable material of the present invention may be coated onto particulate material by any means known in the art. In one embodiment, the particles may be coated with the acid-releasing degradable material “on-the-fly.” The term “on-the-fly” is used herein to mean that one flowing stream is continuously introduced into another flowing stream so that the streams are combined and mixed while continuing to flow as a single stream as part of the on-going treatment at the job site. Such mixing can also be described as “real-time” mixing. One such on-the-fly mixing method would involve continuously conveying the particles and the acid-releasing degradable material to a mixing vessel. Once inside the mixing vessel, the particles would be coated with the acid-releasing degradable material and continuously removed from the mixing vessel. In that situation, a sand screw could be used both to aid in mixing the particulates, be they gravel, proppant, or some other particulate, with the acid-releasing degradable material and to remove the acid-releasing degradable material-coated particles from the mixing tank. As is well understood by those skilled in the art, batch or partial batch mixing may also be used to accomplish such coating.
[0026] In some embodiments of the present invention the particle material, such as gravel in a gravel packing operation or proppant in a fracturing operation, is coated with from about 0.1% to about 20% acid-releasing degradable material by weight of the gravel particles, more preferably from about 0.5% to about 10% acid-releasing degradable material by weight of the gravel particles and most preferably from about 1% to about 8% acid-releasing degradable material by weight of the particulate material. In some embodiments of the present invention, all of the particles used in the subterranean operation are coated with an acid-releasing degradable material of the present invention. In other embodiments, only a portion of the particles is coated. Where the percentage of particles coated is less than 100%, it may be desirable to coat a higher percentage of the acid-releasing degradable material on the coated particles. It is within the ability of one skilled in the art to determine the amount of acid-releasing degradable material that will be necessary to sufficiently degrade the filter cake and to coat enough particles with enough acid-releasing degradable material to achieve that goal.
[0027] Where the coated particles of the present invention are used in a sand control operation such as gravel packing, the gravel pack may be formed using any technique known in the art. In one technique, gravel particles at least partially coated with an acid-releasing material are slurried into a delivery fluid and pumped into the well bore having a filter cake deposited thereon and substantially adjacent to the zone of the subterranean formation that has been fitted with a gravel pack screen. The gravel material is separated from the slurry as the delivery fluid is forced into the well bore and through the screen. The gravel particles are not able to flow through the mesh of the screen and are left behind, thus forming a gravel pack. In a gravel pack formed from such coated particles, the acid-releasing degradable material substantially degrades the adjacent filter cake.
[0028] Similarly, where the coated particles of the present invention are used in a fracturing operation, the proppant pack formed inside the fracture with the coated particles of the present invention may be formed using any technique known in the art. In one technique, proppant particles at least partially coated with an acid-releasing material are slurried into a fracturing fluid and pumped into a fractured subterranean formation. The proppant particles are then placed in the fracture and form a proppant pact substantially adjacent to walls of the fracture. Once the proppant pack is substantially formed, the acid-releasing degradable material produces a sufficient amount of acid at least to partially degrade the filter cake on the walls of the fracture.
[0029] To facilitate a better understanding of the present invention, the following example of a preferred embodiment is given. In no way should the following example be read to limit the scope of the invention.
EXAMPLE
[0030] A 6100 molecular weight copolymer of 50% lactic acid and 50% glycolic acid was synthesized. The copolymer was then dissolved in propylene carbonate to a 50/50% concentration of polymer to solvent. The polymer/solvent was coated onto 20/40 Carbolite® proppant at a 4% concentration by weight of the proppant. A filter cake was deposited on a 35 micron Aloxite core in a Fann HPHT Filtration Cell from a drill-in fluid formulated using a 10% sodium chloride base fluid with 0.2% xanthan, 1.9% starch, 6.7% 5 micron median diameter calcium carbonate, 16.7% 25 micron median diameter calcium carbonate 0.025% sodium hydroxide. Once the filter cake was formed, with 500 psi differential pressure at 150 F for 60 minutes, the excess drill-in fluid was removed from the test chamber and replaced with 141 grams of the coated proppant and 64 mL of 10% sodium chloride solution. The cell was heated to 160 F with 50 psi differential pressure and the filtrate rate was monitored. The filtrate rate averaged around 2 mL/hr for the first 9 hours indicating the filter cake was still intact. At around 9 hours, the filtrate rate began to increase and was around 300 mL/hr within about 5 minutes of the point of the increase. The increase flow rate is an indication of filter cake degradation.
[0031] Therefore, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned as well as those that are inherent therein. While numerous changes may be made by those skilled in the art, such changes are encompassed within the spirit and scope of this invention as defined by the appended claims.
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Methods of creating particulates coated with acid-releasing degradable material comprising the steps of: combining an acid-releasing degradable material with a solvent or a plasticizer to create a coating solution; providing a first flowing stream comprising the coating solution; providing a second flowing stream comprising particulates; and, combining the first and second flowing streams to create a third flowing stream comprising particulates coated with the coating solution. Wherein the acid-releasing degradable material comprises at least one acid-releasing degradable material selected from the group consisting of: poly(orthoester); a lactide, a poly(lactide); a glycolide; a poly(glycolide); a poly(ε-caprolactone); a poly(hydroxybutyrate); a substantially water insoluble anhydride; a poly(anhydride); a poly(amino acid); a copolymer of two or more of the above-listed compounds; and any combination thereof.
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RELATED APPLICATIONS
[0001] This application is a continuation of, and claims priority under 35 U.S.C. §120 on, U.S. application Ser. No. 12/824,715, filed Jun. 28, 2010, which is a continuation of U.S. application Ser. No. 11/746,973, filed May 10, 2007, now U.S. Pat. No. 7,810,714, which is a continuation of U.S. application Ser. No. 11/116,593, filed Apr. 28, 2005, now U.S. Pat. No. 7,219,831. The contents of each of these related applications are incorporated by reference herein in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method, a program medium, and an apparatus for processing checks in conjunction with using checks to complete financial transactions.
[0004] 2. Description of the Related Art
[0005] When a check is processed for payment in a bank, authorization data indicating that the check has been processed is imprinted on the back of the check. The front and back of the check imprinted with this authorization data are then scanned and the captured image data is stored so that the image data can be retrieved and used as proof or evidence of transaction if the customer, bank, or store later questions the transaction.
[0006] Check processing apparatuses such as these used in banks therefore typically have the following devices positioned along the check transportation path in order starting from the upstream end: a magnetic ink character recognition reader (MICR) for reading magnetic ink characters printed on each check, a print head for printing the authorization data, and two image scanners for scanning the front and back sides of each check.
[0007] Thus positioning scanners for scanning the front and back sides of the check downstream from the print head increases the length of the check transportation path and thus increases the size of the apparatus. Furthermore, if the magnetic ink character area of the check is also scanned in order to complement the MICR function, a third scanner must also be positioned upstream of the MICR. This obviously further increases the size and parts count of the apparatus.
[0008] If scanners for scanning the front and back of the check are positioned upstream of the print head and the back of the check with imprinted authorization data is also to be scanned, the check must be reinserted after the authorization data is printed in order to scan the back side of the check. Operation is thus more complicated and inefficient.
[0009] To avoid the foregoing problem, Japanese Unexamined Patent Application 2000-344428 discloses a check processing apparatus having a U-shaped check transportation path with a scanner, print head, and MICR positioned in sequence from the upstream side. After printing the check, this check processing apparatus changes the check transportation path and repeats the check scanning operation.
[0010] This check processing apparatus has two drive rollers positioned along the check transportation path and one transportation roller in proximity to the check exit. A reversible motor rotationally drives these other rollers by way of an intervening gear train. The gear train turns the transportation roller forward or reverse according to the direction the motor is driving, but the drive rollers always turn in the forward direction regardless of which direction the motor is turning. More specifically, the direction in which the motor turns controls whether a check is conveyed to and discharged from the check exit, or whether the transportation path is changed by a guide for changing the transportation path and the check is thus returned to the check transportation path.
[0011] The check processing apparatus thus arranged scans the front of the check, reads the magnetic ink characters, prints the check, conveys the check to near the check exit during a first pass of the check through the transportation path, and then reverses the transportation rollers to return the check to near the check insertion slot. The back of the check is then printed during a second pass of the check through the transportation path.
[0012] After then conveying the check to near the check exit again, the transportation roller is again reversed to return the check to near the check insertion opening. The printed face of the check is then scanned during a third pass through the transportation path to near the check exit, and the feed roller drives forward to discharge the check from the exit. If the back of the check is to be scanned after the back is printed, the check is again returned to near the check insertion opening after the third pass, and the back of the check is then scanned during a fourth pass.
[0013] The foregoing check processing apparatus thus reduces the size of the apparatus while enabling scanning both the front and back sides of a printed check with a single check insertion operation. However, the construction and control of this check processing apparatus are relatively complex, and check processing requires a long time. The likelihood of paper jams also increases because each check is conveyed multiple times through the transportation path.
Object of the Invention
[0014] An object of the present invention is therefore to provide a check processing method, a program, and a check processing apparatus for generating an electronic merged image in which image data captured from the back of a printed check is combined with authorization data in a single pass of the check in one direction through a transportation path of such an apparatus.
SUMMARY OF THE INVENTION
[0015] To achieve the foregoing object, a check processing method according to the present invention comprises scanning a back of a check having no authorization data printed thereon; scanning a front of the check to capture a front image of the check, the front of the check being preprinted with magnetic ink characters; generating authorization data indicating that processing payment of the check has been completed and that the check is valid based on a reading of the magnetic ink characters and a response from an external analysis source, the authorization data being generated electronically without printing the authorization data; generating an electronic merged image by electronically combining back image data captured during the scanning of the back of the check with the generated authorization data, the electronic merged image being generated without printing any data; and storing the electronic merged image with the front image.
[0016] In accordance with another aspect of the invention, a check processing apparatus configured to communicate with a host device is provided. Such apparatus comprises a transportation path for conveying a check from a check insertion opening to an exit opening; a transportation mechanism that conveys the check through the transportation path; a scanning component that captures both a back image of the check and a front image of the check conveyed through the transportation path; an authorization data component that sends a request to the host device for electronic authorization data indicating that the check is valid based on a response from an external analysis source, wherein the authorization data component receives the requested electronic authorization data from the host device if the check is determined to be valid; a merged image generating component that generates an electronic merged image by combining back image data captured during the capturing of the back image with the received electronic authorization data without printing the authorization data; and a memory that stores the electronic merged image with the front image.
[0017] The present invention is well adapted for use in a check processing apparatus that does not have print capability, thus allowing for a more simplified arrangement of the check processing apparatus. Furthermore, the invention can be employed in completely or substantially paperless systems that involve transfer of electronic data between multiple companies and/or financial institutions.
[0018] A check typically has an endorsement area where information is written or printed by a payee of the check. This information verifies that the check was used in a particular business and may include banking account information for that business, such as a store where the check is used. In generating the merged image the authorization data may be merged so that it appears outside the endorsement area. In that case, information written or printed in the endorsement area by the business is not lost or visually obscured as a result of the merging process.
[0019] In another aspect, the invention includes a medium readable by a machine embodying a program of instructions executable by the machine to execute the operations of a check processing method as described herein.
[0020] Other objects and attainments together with a fuller understanding of the invention will become apparent and appreciated by referring to the following description and claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1A is a plan view showing a typical face of check;
[0022] FIG. 1B is a plan view showing a typical back of check;
[0023] FIG. 2 is a schematic diagram showing a check processing apparatus according to a preferred embodiment of the present invention;
[0024] FIG. 3 is a schematic diagram showing the transportation path in a hybrid processing apparatus having the function of a check processing apparatus according to the present invention;
[0025] FIG. 4 is a control block diagram of a check processing apparatus according to the present invention;
[0026] FIG. 5 is a flow chart showing an operation from check scanning to printing;
[0027] FIG. 6A illustrates generating the merged image data in a preferred embodiment of the present invention;
[0028] FIG. 6B shows the printed back of check;
[0029] FIG. 7A illustrates a use of the merged image data produced in a preferred embodiment of the present invention;
[0030] FIG. 7B shows the image data of both sides of check C printed on a single page;
[0031] FIG. 8 illustrates another use of the merged image data produced in a preferred embodiment of the present invention;
[0032] FIG. 9A is a plan view showing a face of substitute check generated using a check processing apparatus according to the present invention; and
[0033] FIG. 9B is a plan view showing a back of substitute check generated using a check processing apparatus according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] A check processing method, program embodied on a medium, and check processing apparatus according to preferred embodiments of the present invention are described below with reference to the accompanying figures.
[0035] An electronic payment process using a check is described first briefly below.
[0036] As shown in FIG. 1A , a check serial number 91 and account-holder name 92 are preprinted on the face of the check C together with spaces for writing the date 93 , payee 94 , check amount 95 , 96 , and a signature line 97 . The bank identification number, account number, and check number are also printed in magnetic ink characters (MIC) 98 along the bottom on the check face. Validity of the check C is determined by reading and referencing the information printed in the magnetic ink characters 98 using a magnetic ink character reader (MICR) 13 (see FIG. 4 ).
[0037] The check user writes the date, payee, and payment amount on the face of the check C and then signs the check C before handing the check to the store clerk, for example. As shown in FIG. 1B , the clerk then writes or prints an endorsement in a specific endorsement area on the back of the check. The endorsement typically includes information proving that the check C was used, as well as deposit information. The store then delivers the check C to a bank where the store has an account. Note that there are two endorsement areas on the back of the check: endorsement area C 1 used for the store endorsement, and a bank processing area C 2 used by the bank or other financial institution for printing authorization data. The store endorsement is thus written or printed in endorsement area C 1 .
[0038] When a bank receives a check that has been processed by a store or other business, the bank may print the check amount on the face of the check C in magnetic ink characters as may be needed using a printer other than that of the hybrid processing apparatus 1 according to the present invention. The check amount may also be printed on the face of the check C using the printing unit 120 of the hybrid processing apparatus 1 according to this embodiment of the invention. The magnetic ink characters 98 preprinted on the check C are then read using an MICR 13 , and if the check is determined to be valid, authorization data d indicating that check processing has been completed by the bank is printed in the bank processing area C 2 on the back of the check C. The front and back of the check C are then scanned and saved as image data. Note that while the content of the authorization data d includes the bank name, bank tracking number, processing date, and processing number, it may include other content depending upon the bank.
[0039] The bank then transfers the specified check amount from the bank account of the checking account holder to the bank account of the store where the check C was used. If the check is drawn on an account in a bank other than the same bank where the store has an account, the check C data, including the check number and amount, is sent to that other bank, that is, the bank on which the check is drawn, for processing.
[0040] The arrangement of a check processing apparatus 10 according to the present invention is described next below. As shown in FIG. 2 , a check processing apparatus 10 according to the present invention is composed of a hybrid processing apparatus 1 for scanning, reading and printing checks C, and a host computer 50 connected to the hybrid processing apparatus 1 for controlling generating the authorization data d and the hybrid processing apparatus 1 .
[0041] The host computer 50 has an input device such as a keyboard 51 and mouse 52 for data entry, and an output device such as a display monitor 53 for displaying error messages, prompts, and check C image data. The host computer 50 communicates with the hybrid processing apparatus 1 via a wired connection such as a USB (Universal Serial Bus), parallel interface, LAN, or other cable, or via a wireless connection such as a wireless LAN or Bluetooth interface. Note that a wired connection is shown in FIG. 2 by way of example only.
[0042] The host computer 50 is also connected over a network (such as the Internet) to a transaction processing server for verifying check C validity. The host computer 50 receives check data read by the MICR 13 of the hybrid processing apparatus 1 (see FIG. 4 ) and sends the check data to the transaction processing server. Whether the check C is valid or invalid is then determined based on the response from the transaction processing server.
[0043] The arrangement of a hybrid processing apparatus 1 according to this embodiment of the invention is described next.
[0044] As shown in FIG. 2 the hybrid processing apparatus 1 has an image scanning unit 100 (also shown in FIG. 3 ) forming a U-shaped transportation path P for transporting checks C for scanning, a magnetic ink character reader (MICR) 110 (see FIG. 3 ) for reading magnetic ink characters preprinted on the check C, a printing unit 120 for printing authorization data on the check C, and a transportation mechanism 20 (see FIG. 3 ) for conveying checks C through the transportation path P.
[0045] As shown in FIG. 3 , the generally U-shaped transportation path P is a slit-shaped path formed between an outside guide 2 a and an inside guide 2 b , and has straight portions 35 a and 35 b and a U-shaped portion 34 formed between and communicating with both straight portions 35 a and 35 b.
[0046] When an operator inserts a check C from the check insertion opening 3 to the transportation path P, the transportation mechanism 20 conveys the check C through the straight portion 35 a in the direction of arrow A, through the U-shaped portion 34 into straight portion 35 b , through straight portion 35 b in the direction of arrow B, and then discharges the check C from the check exit 4 . Note that the direction of check transportation changes 180 degrees from the insertion direction indicated by arrow A as the check passes through the U-shaped portion 34 . More specifically, the transportation mechanism 20 bends the check C in a U-shape as the check C travels through the transportation path P.
[0047] Note further that this hybrid processing apparatus 1 is arranged so that the front of the check C normally faces the inside guide 2 b as the check C is conveyed through the transportation path P.
[0048] The transportation mechanism 20 has first transportation rollers 6 , second transportation rollers 7 , and discharge rollers 8 . These roller sets 6 , 7 , and 8 are gripping rollers each having a drive roller 6 a , 7 a , 8 a driven by a motor 40 shown in FIG. 4 , and a pressure roller (driven roller) 6 b , 7 b , 8 b for pressing a check C against the opposing drive roller.
[0049] The first transportation rollers 6 are positioned in a first corner part of the transportation path P. A bottom of form (BOF) detector 9 is positioned upstream of the first transportation rollers 6 , and a top of form (TOF) detector 16 is positioned downstream of the first transportation rollers 6 . The BOF detector 9 and TOF detector 16 are reflecting or transmitting type photodetectors for detecting the leading edge and trailing edge of a check C traveling through the transportation path P. Driving of the motor 40 starts when the BOF detector 9 detects the leading edge, and the first transportation rollers 6 , second transportation rollers 7 , and discharge rollers 8 thus start turning.
[0050] Two scanners 11 , 12 and the MICR 13 are positioned along the U-shaped portion 34 between the TOF detector 16 and the second transportation rollers 7 . The two scanners 11 , 12 constitute the image scanning unit 100 for scanning the back and front of the check. The MICR 13 constitutes a magnetic ink character reading unit 110 , shown in FIG. 4 .
[0051] These two scanners 11 , 12 are contact image sensor (CIS) or charge-coupled device (CCD) image sensors for scanning checks C. The back scanner 11 is positioned on the outside guide 2 a side of the transportation path P for capturing images from the back side of each check C. The front scanner 12 is likewise positioned on the inside guide 2 b side of the transportation path P for capturing images from the face of each check C. Pressure members (rollers) 11 a , 12 a opposing scanners 11 , 12 , respectively, with the transportation path P therebetween press the check C against the scanner 11 , 12 surface for imaging.
[0052] The MICR 13 is a magnetic reading detector having a magnetic head for reading magnetic ink characters printed on the surface of the check C, and is thus positioned on the inside guide 2 b side of the transportation path P so that the MICR 13 faces the front of the check C. A pressure member (pad) 13 a is positioned opposite the MICR 13 with the transportation path P therebetween for pressing the check C against the MICR 13 when reading the magnetic ink characters.
[0053] The second transportation rollers 7 are located in a second corner part of the transportation path P. The discharge rollers 8 are positioned downstream from the second transportation rollers 7 near the check exit 4 . A print head 14 , comprising the printing unit 120 shown in FIG. 4 , is positioned in the straight portion 35 b between the second transportation rollers 7 and discharge rollers 8 . The print head 14 is mounted on a carriage 15 , which can move along a guide shaft 15 a . The print head 14 can thus be moved by way of the carriage 15 to a retracted position 19 and to a printing area 18 for printing on checks C.
[0054] To print on a check C, the print head 14 is stopped at a specific position in the printing area 18 and is then driven synchronized to check C transportation to print on the check C. Though described in further detail below, if roll paper is transported through this straight portion 35 b while a check C is not in the transportation path P, the roll paper can be printed by synchronizing roll paper transportation (sub-scanning) to print head 14 movement (main scanning).
[0055] The discharge rollers 8 and check exit 4 are positioned downstream from the print head 14 . When printing is completed, the check C is thus discharged from the check exit 4 by the discharge rollers 8 . A discharge detector (not shown in the figure) comprised of a reflecting or transmitting photodetector is also positioned near the discharge rollers 8 for detecting if the printed check C has been discharged. A stacker (not shown in the figure) for collecting the discharged checks C could also be positioned downstream from the check exit 4 .
[0056] The height of the outside guide 2 a and inside guide 2 b is less than the height (short dimension) of the conveyed check C in areas outside the U-shaped portion 34 of the transportation path where the front and back scanners 11 , 12 and the MICR 13 are positioned. The check can thus be easily removed from the transportation path if a paper jam, for example, occurs while a check is being conveyed through the transportation path.
[0057] Though not shown in the figures, a hybrid processing apparatus 1 according to this embodiment of the invention also has a roll paper transportation path overlapping part of the straight portion 35 b of the transportation path P, in addition to the transportation path P for conveying checks C. This roll paper transportation path is substantially perpendicular to the check transportation path P (that is, arranged in the direction passing through the page on which FIG. 3 is printed). A roll paper compartment for storing roll paper is positioned in the space between the straight portions 35 a and 35 b of the transportation path P. One end of the roll paper is drawn from the roll paper compartment into the roll paper transportation path, and is transported along the roll paper transportation path. If a check C is not in the transportation path P, the print head 14 moves in a main scanning direction through the printing area 18 proximally opposite the print head 14 to print on the roll paper. A hybrid processing apparatus 1 according to this embodiment of the invention can thus both print on checks C and on roll paper.
[0058] The hybrid processing apparatus 1 in this embodiment of the invention also has a vertical transportation path for vertically conveying a check C inserted between the outside guide 2 a and inside guide 2 b from a top opening formed between the outside guide 2 a and inside guide 2 b near the printing area 18 . This vertical transportation path is a paper transportation path for validation printing in which a check C dropped into the transportation path from above is printed by moving the print head 14 positioned in the printing area 18 in the main scanning direction. When validation printing is completed, the check C is then discharged up and out from the transportation path.
[0059] As noted above, the print head 14 in this embodiment of the invention is mounted on a carriage 15 and can thus move horizontally along the straight portion 35 b of the transportation path P. There are thus two check C printing modes: a stationary print head mode in which the position of the print head 14 remains fixed while the check C is carried horizontally past the print head 14 for printing, and a stationary check mode in which the position of the check C remains stationary while the print head 14 is moved horizontally over the check surface for printing.
[0060] When printing on roll paper the print head 14 prints one line while being carried on the carriage 15 horizontally over the paper surface. To print multiple lines, the roll paper is advanced one line (in the sub-scanning direction) after printing one line ends, and the print head 14 is then driven horizontally again (in the main scanning direction) while printing the next line. This operation repeats for each subsequent line.
[0061] Scanning a check C, reading magnetic ink characters, and printing on a check C are described next. When a check C is inserted by the operator in the direction of arrow A from the check insertion opening 3 , the check C is nipped by the rollers and conveyed at a constant speed through the transportation path P.
[0062] More specifically, when the check C reaches the BOF detector 9 , the BOF detector 9 detects the leading edge of the check C and thus causes the drive roller 6 a of the first transportation rollers 6 to start turning. The check C is thus nipped by the first transportation rollers 6 , that is, is smoothly gripped between the drive roller 6 a and pressure roller 6 b . Rotation of the drive roller 6 a thus conveys the check C without slipping through the transportation path P guided by the outside guide 2 a of the U-shaped portion 34 .
[0063] When the leading edge of the check C conveyed by the first transportation rollers 6 reaches the TOF detector 16 , the TOF detector 16 detects the leading edge of the check C. This causes the scanners 11 , 12 and MICR 13 downstream therefrom to turn on and enter a standby mode. A hybrid processing apparatus 1 according to this embodiment of the invention is thus arranged to prevent unnecessary power consumption by supplying power only when needed to the necessary parts, including the drive rollers.
[0064] When a check C travels through the transportation path P, the back scanner 11 positioned on the outside guide 2 a side scans the back of the check C, and the front scanner 12 positioned on the inside guide 2 b side scans the face of the check C. The MICR 13 positioned on the inside guide 2 b side then reads the magnetic ink characters preprinted on the check C.
[0065] As described in further detail below, the front image data g 1 and the back image data g 2 captured from the check C are stored temporarily in the check front image data block 242 and check back image data block 243 , respectively, in the hybrid processing apparatus 1 (see FIG. 4 ). The CPU 220 later retrieves the image data from memory to generate the merged image data g 3 and other processes.
[0066] When the leading edge of the check C passes the TOF detector 16 and reaches the second transportation rollers 7 , the check C is nipped between the drive roller 7 a and pressure roller 7 b and is thus conveyed by rotation of the drive roller 7 a into the straight portion 35 b.
[0067] When the check C passes through the printing area 18 opposite the print head 14 , the print head 14 prints to the check C. The print head 14 is stopped at a predefined position in the printing area 18 at this time and is driven to print in synchronization with the movement of the check C (print medium) in the main scanning direction.
[0068] After the back of the check C is printed by the print head 14 , the check C is discharged in the direction of arrow B by the discharge rollers 8 . More specifically, the drive roller 8 a turns with the check C held between the drive roller 8 a and pressure roller 8 b to deliver the check C to the outside of the hybrid processing apparatus 1 , thus completing check processing.
[0069] The control arrangement of the hybrid processing apparatus 1 and host computer 50 constituting the check processing apparatus 10 of the present invention is described next referring next to FIG. 4 .
[0070] The hybrid processing apparatus 1 has an image scanning unit (image scanning mechanism) 100 for scanning checks C, an MICR unit (magnetic ink character reading mechanism) 110 for reading magnetic ink characters printed on the checks C, a printing unit 120 (printing mechanism) for printing on the back of the checks C, a detection unit 130 for detecting the leading edge and trailing edge of the checks C, a drive unit 140 for driving the other parts, and a control unit 200 connected to these other parts for controlling overall operation of the hybrid processing apparatus 1 .
[0071] The image scanning unit 100 includes the scanners 11 , 12 for scanning the front and back of a check, and thus captures an image of the front and back of each check C. The magnetic ink character reading unit 110 includes the MICR 13 for reading the magnetic ink characters printed on each check C. The printing unit 120 includes the print head 14 for printing primarily the authorization data d received from the host computer 50 in the bank processing area C 2 on the back of each check C.
[0072] The detection unit 130 includes the BOF detector 9 and TOF detector 16 for detecting the leading edge and trailing edge, respectively, of the check C.
[0073] The drive unit 140 includes the first transportation rollers 6 , second transportation rollers 7 , and discharge rollers 8 (transportation mechanism 20 ), and the motor 40 for rotationally driving the drive rollers 6 a , 7 a , 8 a of the roller sets 6 , 7 , 8 .
[0074] The control unit 200 includes the CPU 220 , ROM 230 , RAM 240 , and input/output control apparatus 210 (referred to below as the I/O controller) connected to each other by an internal bus 250 .
[0075] The ROM 230 has a control program block 231 and a control data block 232 . The control program block 231 stores a program for controlling scanning, reading and printing on a check C, a program for generating the merged image data g 3 by merging the back image data g 2 captured from the check C with the authorization data d received from the host computer 50 , and other programs run by the CPU 220 . The control data block 232 stores control data for generating the merged image data g 3 and other data tables.
[0076] RAM 240 is used as working memory for the control processes run by the CPU 220 , and includes a work area block 241 for temporarily storing data and flags, a check front image data block 242 for temporarily storing front image data g 1 captured from a check C, a check back image data block 243 for temporarily storing the back image data g 2 captured from the check C, a magnetic data block 244 for temporarily storing the magnetic ink character data read from the check C, an authorization data block 245 for temporarily storing the authorization data d received from the host computer 50 , and a merged image data block 246 for temporarily storing the merged image data g 3 generated by merging the back image data g 2 and the authorization data d.
[0077] The I/O controller 210 is an arrangement of gate arrays, custom IC chips, and other logic circuits for complementing the function of the CPU 220 and processing interface signals for communication with peripheral devices. The I/O controller 210 thus passes the image data captured by the scanners 11 , 12 from the front and back sides of the check C, the magnetic data captured by the MICR 13 , and the authorization data and control data received from the host computer 50 to the internal bus 250 either directly or after processing the data, and in conjunction with the CPU 220 outputs data and control signals output from the CPU 220 to the internal bus 250 to the printing unit 120 either directly or after processing the data.
[0078] Thus comprised, the CPU 220 controls the merged image data g 3 generation process and printing on a check C by controlling signal and data processing in the hybrid processing apparatus 1 according to a control program read from ROM 230 through the I/O controller 210 .
[0079] The host computer 50 , which is connected to the hybrid processing apparatus 1 for use, has memory 54 such as ROM and RAM, a CPU 55 for controlling the other parts of the host computer 50 , and a driver 56 , which is a program for controlling the hybrid processing apparatus 1 .
[0080] Memory 54 is used to store control data including data tables and control programs run by the CPU 55 in ROM, and as working memory for control processes and storing data temporarily in working memory and registers in RAM. This temporarily stored data includes information input by the operator (such as the bank name and number), the merged image data g 3 received from the hybrid processing apparatus 1 , and the front image data g 1 from the check C.
[0081] When an authorization data request command requesting transmission of the authorization data is received from the hybrid processing apparatus 1 , the host computer 50 generates the authorization data d by adding the processing date, processing number, and other information to information stored in RAM (the bank name and number), and sends the authorization data d to the hybrid processing apparatus 1 .
[0082] The check C scanning process, the magnetic ink character reading process, and check C printing process of the hybrid processing apparatus 1 are described next below with reference to the flow chart in FIG. 5 .
[0083] When a check C is fed into the hybrid processing apparatus 1 from the check insertion opening 3 (S 01 ), the check C is conveyed to a position opposite the back scanner 11 and the back scanner 11 then scans the back side of the check C (S 02 ). The CPU 220 temporarily stores the back image data g 2 captured from the check C through the I/O controller 210 to the check back image data block 243 in RAM 240 .
[0084] After the back is scanned the check C is conveyed to a position opposite the front scanner 12 and the front scanner 12 thus scans the face of the check C (S 03 ). The CPU 220 then also stores this front image data g 1 from the check C through the I/O controller 210 to the check front image data block 242 in RAM 240 .
[0085] After the front image data is captured the check C is conveyed to a position opposite the MICR 13 and the MICR 13 then reads the magnetic ink characters printed on the check C (S 04 ). The magnetic data captured by the MICR 13 is sent through the host computer 50 to the transaction processing server, and the host computer 50 then determines if the check C is valid or invalid based on the response from the transaction processing server (S 05 ). If the hybrid processing apparatus 1 receives a report from the host computer 50 indicating that the check C is valid (S 05 returns yes), the hybrid processing apparatus 1 sends an authorization data request command to the host computer 50 . The magnetic data from the check C is stored in the magnetic data block 244 .
[0086] The host computer 50 generates and sends the authorization data d to the hybrid processing apparatus 1 (S 06 ).
[0087] When the hybrid processing apparatus 1 receives the authorization data d, the hybrid processing apparatus 1 merges the back image data g 2 of the check C stored in the check back image data block 243 with the received authorization data d, and thus generates the merged image data g 3 (S 07 ). This merged image data g 3 is stored in the merged image data block 246 .
[0088] The check C is then conveyed to a position opposite the print head 14 , which is standing by in the printing area 18 (see FIG. 3 ), and the hybrid processing apparatus 1 thus prints the authorization data d on the back of the check C (S 08 ). The check C is then discharged and processing ends (S 09 ).
[0089] If the hybrid processing apparatus 1 receives a report from the host computer 50 indicating that the check C is invalid (S 05 returns no), the hybrid processing apparatus 1 stops processing the check C and discharges the check without further processing (S 09 ).
[0090] The merged image data g 3 could alternatively be generated by the host computer 50 merging the authorization data d generated by the host computer 50 with the front image data g 1 and back image data g 2 received from the hybrid processing apparatus 1 .
[0091] Furthermore, if the host computer 50 determines that the check is valid, the host computer 50 could immediately send the authorization data d to the hybrid processing apparatus 1 . This eliminates the steps of sending, receiving, and processing the authorization data request command.
[0092] Producing the merged image data g 3 is described next with reference to FIG. 6A and FIG. 6B .
[0093] The hybrid processing apparatus 1 generates the merged image data g 3 as shown in FIG. 6A by pasting the authorization data d onto the bank processing area C 2 in the back image data g 2 of the check C stored in the check back image data block 243 . The result is merged image data g 3 functionally identical to an image of the back of the check C to which the authorization data d is actually printed as shown in FIG. 6B . The back image data g 2 of the check C is stored with specific image coordinate data in the check back image data block 243 , and the authorization data d is recorded with specific coordinate data in the authorization data block 245 . The merged image data g 3 is then produced by writing the image data and coordinate data from the check back image data block 243 and the image data and coordinate data from the authorization data block 245 to specific locations in the merged image data block 246 . The coordinate data enable pasting the authorization data d in the back image data g 2 while avoiding the endorsement area C 1 used by the store to endorse the check. The coordinate data can be an address in RAM or other such data.
[0094] The merged image data g 3 thus generated is stored temporarily in the merged image data block 246 . When the merged image data g 3 is then saved as a result of a user instruction, for example, the merged image data g 3 is sent with the front image data g 1 of the check C to the host computer 50 and is stored by the host computer 50 .
[0095] The merged image data g 3 can be used by displaying the merged image data g 3 on the display 53 of the host computer 50 for confirmation by the operator (see FIG. 7A , for example), or the front image data g 1 of the check C and the merged image data g 3 representing the back of the check C after the check C is printed could be printed and output on a single page as shown in FIG. 7B . This is convenient for outputting and storing images of both sides of the check.
[0096] Furthermore, if a problem occurs the operator can enter the check serial number, account holder name, check date, or payee in the host computer 50 to search for and output the saved image data. The retrieved data can be output by displaying the data on the display 53 of the host computer 50 or using the hybrid processing apparatus 1 of the present embodiment, or by printing the data with a separate printer connected to the host computer 50 .
[0097] A scanner for reading a driver license or cash or credit card, for example, could also be incorporated in this hybrid processing apparatus 1 . This enables also capturing an image of the driver license or cash or credit card presented as personal identification when cashing or using a check C, and storing the identification image with the check C image data. Yet further, the front image data g 1 , merged image data g 3 , and the image data captured from the driver license or cash or credit card can be printed on a single page as described above or displayed on the display 53 (see FIG. 8 ). Illegal use of forged, stolen, or lost checks can thus also be prevented or reduced by also capturing an image of the user's identification.
[0098] While thus featuring a compact configuration having a scanner positioned on the upstream side of the print head, a hybrid processing apparatus 1 according to this embodiment of the present invention can acquire an image that is functionally identical to an image of the back of a check C after authorization data d is printed thereto, and can acquire this image using a simple control and a single check insertion operation.
[0099] Furthermore, image data that is functionally identical to an image of the back of a check C after authorization data d is printed thereto can even be acquired using a hybrid processing apparatus that does not have a printing function.
[0100] While electronic payment systems enabling data read from a check to be communicated over a network for transaction processing are available, not all banks have introduced such electronic payment systems. As a result, some banks can and some banks cannot process such check data as the check amount and check number read from individual checks.
[0101] Another method of processing check payments in this case is by sending a substitute check instead of the check data to banks that have not yet introduced the foregoing electronic payment system. These substitute checks have the check front image data, bank authorization data, magnetic ink character data, and check back image data printed out on a single sheet.
[0102] As described above, a check processing apparatus 10 according to the present invention can generate image data that is functionally identical to an image of the back of a check after the authorization data d has been printed. The image data acquired as described above can thus be used to output a substitute check as described above. See, for example, FIG. 9A and FIG. 9B .
[0103] The present invention has been described using a check by way of example as the imaging medium and print medium, but the invention shall not be limited to using a check as the imaging medium or print medium. A cashier's check, promissory note, or other instrument could alternatively be used as the imaging medium or print medium.
[0104] A function for selecting whether to generate the merged image data g 3 can also be rendered in the driver 56 stored on the host computer 50 . This enables even more efficient operation because the merged image data g 3 is generated only when needed. If generating the merged image data g 3 is not selected, or if the back image data is acquired after the authorization data d has been printed, the check C can be reinserted for scanning the back of the check after the authorization data d is printed and the check C is discharged.
[0105] The method of operation of the check processing apparatus 10 or check processing method of the present invention as described above can also be embodied as a program on a machine-readable or computer-readable medium.
[0106] Examples of such data recording media include but are not limited to CD-ROM, flash ROM, memory cards (such as Compact Flash (R), Smart media, and memory sticks), Compact Disc (R), magneto-optical disc, DVD media, and floppy disks.
[0107] The invention being thus described, it will be obvious that it may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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Check processing involves scanning a back of a check having no authorization data printed thereon and also scanning a front of the check having preprinted magnetic ink characters, electronically generating authorization data indicating that the check is valid based on a response from an external analysis source, generating an electronic merged image by electronically combining back image data captured during the scanning of the back of the check with generated authorization data, and storing the electronic merged image with the front image data captured during the scanning of the front of the check. Moreover, these operations may be performed in a single pass of the check in one direction through a transportation path of a check processing apparatus. No printing of any data is required. The check processing can be embodied in a method, apparatus, or instructions embodied on a machine-readable medium.
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[0001] This application claims the benefit of Provisional Application No. 61/165,818, filed Apr. 1, 2009.
FIELD OF THE INVENTION
[0002] The present invention relates to wind turbines used to convert wind energy into mechanical energy, and more particularly relates to vertical axis wind turbines. The present invention provides automated control of the wind volume felt by the working surface of turbine blades, and more particularly increases the range of wind speeds in which a vertical axis wind turbine may operate. The present invention further provides high wind protection for the turbine device, shielding the turbine from high speed damaging winds.
BACKGROUND
[0003] The present invention relates to a combination wind generator and removable shroud design used to convert wind energy into electrical energy. While best suited for use with the Savonius mode, the present invention more specifically relates to a vertical axis wind turbine employing any design of blades, that is encompassed within a removable shroud that rotates about the turbine, is square or round in shape, and is comprised of eight (8) equidistant fins or shutters, in a manner whereby each shutter is capable of pivoting from a single point of affixation from its fully closed position to a position perpendicular to the outer surface of the frame of the shroud, thereby adjusting and redirecting the volume of air flow to the turbine based on the velocity of the wind. The present invention is designed to employ air flow resulting from a full range of wind conditions with the ability to withstand severe weather conditions and avoid damage. In addition, the present invention is capable of being manufactured in various sizes. Overall, the present invention is intended for use as an efficient, cost effective source of electrical energy.
[0004] Since ancient times, man has sought to harness the wind as a source of energy. The resulting evolution of devices to capture the energy of the wind has resulted in the development of devices ranging from sails for boats, to windmills used for grinding grain and pumping water, and to modern-day wind turbines used to convert the power of wind into mechanical energy and electrical energy.
[0005] Perhaps the most ubiquitous means of capturing wind energy today utilizes a wind turbine. Wind turbines are utilized to convert wind energy into electrical energy. Modern wind turbines utilize two common design groups: the horizontal axis wind turbines (HAWTs) and vertical axis wind turbines (VAWTs). HAWT designs, perhaps the most popular between the two types of turbines, employ blades that rotate perpendicular to the ground. It is this design that is most commonly associated with windmills and, according to one source, at some point after the 12 th century, such windmills were being widely used in Holland, England, France, and Germany. Since that time, improvements were made upon the basic windmill designs. Most notably, during the 1390's, the Dutch made significant improvements to the HAWT design by integrating the concept of lift into the design of the windmill blades. Today, according to one source, Denmark obtains nearly 25% of its electricity from the wind, while the U.S. currently obtains less than 1% from the wind.
[0006] VAWTs, according to historical accounts, have been utilized beginning as long ago as 500-900 A.D. in Persia. These ancient windmill systems converted wind energy for grinding grain and pumping water. The first use of a large windmill to generate electricity in 1888 is credited to Charles F. Brush. The first electrical output wind machine that employed aerodynamic design features was developed in 1891 by Dane Poul La Cour. With the subsequent emergence of cheaper, larger fossil-fuel steam plants, however, further development of wind energy technology was somewhat stalled until recently, with the prospects of fossil-fuel shortages creating a renewed interest in non-fossil fuel energy sources such as wind.
[0007] Thus, with the increasing demand for alternative energy sources, prompted, in part, by eminent fossil-fuel shortages and growing global concerns as to the detrimental impact of the extraction, processing, and consumption of fossil-fuels on the environment, there is re-invigorated interest in further developing efficient means to harness wind energy to create electrical power.
DESCRIPTION OF PRIOR ART
[0008] There are many U.S. patents that relate to wind turbine designs, including those that employ protective shrouds, such as U.S. Pat. No. 372,300; U.S. Pat. No. 537,494; U.S. Pat. No. 1,460,114; U.S. Pat. No. 1,677,745; U.S. Pat. No. 1,812,400; U.S. Pat. No. 1,974,008; U.S. Pat. No. 2,059,356; U.S. Pat. No. 3,942,909; U.S. Pat. No. 4,031,405; U.S. Pat. No. 4,237,384; U.S. Pat. No. 4,350,900; U.S. Pat. No. 4,474,529; U.S. Pat. No. 4,818,181; U.S. Pat. No. 5,332,354; U.S. Pat. No. 5,391,926; U.S. Pat. No. 6,638,005 B2; U.S. Pat. No. 6,740,989; U.S. Pat. No. 6,911,745; and U.S. Pat. No. 7,400,057.
[0009] None of the prior art, however, including those noted herein, disclose or suggest the present invention. The prior art is limited by a host of problems that to date have prevented commercial viability. In this regard, U.S. Pat. No. 3,942,909 and U.S. Pat. No. 4,818,181 relate to wind turbines that are designed to pivot to an open position and/or fold in variable wind conditions to protect the structural integrity of the device. Due to the nature of the design, however, these apparatuses decrease the ability to generate power. Prior art such as U.S. Pat. No. 4,474,529 employ various moving parts such as pivoting shields and vanes. However, such designs detract from the devices' overall efficiency.
[0010] And, there is a recognized need in the field for designs that incorporate feedback mechanisms that react to changing wind conditions. For example, U.S. Pat. App. No. 2007/0257494 incorporates turbine blades that adjust the angular position of the blades in response to changing wind and speed conditions. However, that design requires complicated mechanical linkages and controls on the blade surfaces themselves. In addition, during extremely high wind conditions, the wind force is still expressed against the surface of the blades. And, finally, that design requires a completely new construction of wind turbine.
[0011] In contrast, the present invention is designed such that it may be utilized as a retrofit for an existing VAWT, as the shroud encompassing the present invention may be installed over an existing VAWT. In addition, the present invention provides high wind protection for turbine blades with a separate structure, protecting the VAWT from all force resulting from extreme weather conditions. Finally, the present invention provides a range of wind force control based upon feedback from the turbine, without the need to change the configuration or design of existing blades; the present invention controllably reduces or increases the wind force available to a turbine without any physical changes to the turbine mechanism itself. In a preferred embodiment, the present invention further provides control of the wind force available to a turbine through an electromechanical feedback mechanism
[0012] The present invention relates, in particular, to VAWTs. And, more specifically, to an improved means of enhancing and controlling the airflow available to the blades of a vertical wind turbine.
[0013] Problems with current inventions include high cost of fabrication, compromised efficiency, high maintenance costs, constant repairs, dangerous designs, and complications due to variable wind velocity and wind direction. These concerns have not been adequately addressed in the prior art. The present invention addresses prominent disadvantages and issues relating to the prior art. One object of the present invention is to provide a wind turbine means that offers low manufacturing costs, high efficiency of power production by way of its ability to increase the volume of air flow to the turbine, low maintenance, accommodation of wind reception from 360 degrees (any direction). While certain features of the invention are known, the present invention offers a novel configuration of old and new elements to achieve a highly efficient, cost effective source of electrical power. Much of the prior art seeks to increase the wind velocity as a means of increasing the efficiency of the turbine system to produce power. The design of the current invention, however, increases the swept area, thereby significantly increasing the efficiency of the turbine and ultimately increasing the power output in a cost efficient manner.
[0014] The shroud design is an economic effective and efficient way to regulate incoming wind of a velocity range more broad than that accommodated by the prior art, the regulation of which results in a much higher energy/power output. The present invention provides significant advantages over existing designs in: low maintenance, increased efficiency, low cost to manufacture, flexibility of blade design, and the ability to efficiently protect the turbine from adverse weather.
SUMMARY OF THE INVENTION
[0015] The present invention provides a shroud and feedback mechanism for vertical axis wind turbines. The shroud is positioned around the rotational circumference of the turbine blades. The shroud is constructed with a frame within which moveable vanes are mounted. A mechanical linkage mechanism operates the vanes, causing them to open and close in response to an electrical signal generated by the rotation of the vertical axis of the wind turbine. The vanes direct airflow into the interior space created by the shroud and occupied by the wind turbine blades. An electrical generator mechanically connected to the vertical shaft of the turbine generates a control voltage; because the voltage generated increases and decreases with increases and decreases in rotational velocity of the turbine, the electrical generator produces a feedback signal that is utilized to control the volume of air redirected by the vanes. As external wind speed decreases and the rotation of the turbine blades slows as a result, the control voltage decreases, causing the mechanical linkage controlling the vanes to actuate and open the vanes. As external wind speed increases and the rotation of the turbine blades speeds up as a result, the control voltage increases, causing the mechanical linkage controlling the vanes to actuate and close the vanes. The number of vanes may be varied, but experimental results have shown the optimal number of vanes to be eight. Further, as opposed to the fixed vane design such as that shown in U.S. Pat. No. 5,391,926 to Staley, et al., because the vanes in the present invention are moved in relation to the wind speed, the invention will rarely, except in the highest wind speed conditions when the shroud is completely closed to external air in order to protect the turbine, feel wind forces arrayed perpendicular to the surface of the vanes. The present design, therefore, reduces the force imparted on the stationary structure of the shroud.
[0016] Vertical axis windmills are generally designed such that the turbine blades expose a concave surface to incoming wind, causing resistance by “capturing” the force of the wind and thereby causing the blades to be pushed in front of, and in the direction of, the incoming wind. In order to reduce the resistance of a blade that is rotating into position to receive the force of the incoming wind, most modern vertical axis windmills incorporate some means to reduce the wind force acting against the direction of rotation. This is generally accomplished by designing the blades such that the reverse side (i.e., the non-working surface) of each blade has a convex non-working surface in order to redirect airflow away from the blade, thereby reducing the force imparted on the windmill against the direction of rotation.
[0017] The present invention, however, negates the problem of that negative force against the non-working surface by directing the wind force only to the working surface of the windmill blades. The vanes are oriented such that incoming wind flow is directed to one side of the shroud, that side being the portion of the shroud where, relative to the direction of the wind, the effective sides of the windmill blades rotate into the wind with the working surface exposed to the force of the wind. Not only does this reduce in part or in whole the force against the direction of rotation of the windmill, but the invention also redirects the force that would otherwise have pushed against the rotation into the working faces of the windmill blades. In this manner, generally, the present invention allows for a vertical axis wind turbine to operate effectively at lower wind velocities than those without the shroud described herein, and to safely operate at higher wind velocities that are beyond the safe operational range of a wind turbine. The invention disclosed herein further allows for the wind turbine to be isolated completely from high wind conditions as needed.
[0018] The present invention further allows for automated control of the rotation of the vanes about their individual axes of movement, with the vanes being moveable from a fully closed position to a maximum open position. The maximum open position varies according to the specific design and geometry of both the windmill and the shroud. Regardless of the design and geometry particulars, however, the vanes of the shroud preferentially will not open in such a manner as to allow a wind force to be imparted against the non-working surfaces of the windmill blades. The individual vanes are mechanically linked to a common mechanism that opens and closes the vanes in unison. That mechanism, in turn, is controlled by the electrical signal generated by the electrical generator described above.
[0019] Yet a further advantage of the present invention is that it provides a device that may readily be adapted for and added to any existing vertical axis wind turbine.
[0020] The present invention, in its various embodiments, provides a significant improvement over existing means to control the wind flow to wind energy devices. And, although the invention as described herein relates to wind turbines for the generation of electrical power, the advantages provided by this invention apply regardless of the end recipient of the power or motive force generated by a vertical wind turbine that utilizes the present invention. It will be further understood that, although the present invention is described herein as controlling the flow of air to a turbine, the invention may as well be utilized with other fluids and/or gases, e.g., water.
[0021] It is therefore an object of the present invention to provide a design for a shroud to control the air flow directed to the working surfaces of the blades of a vertical axis wind turbine.
[0022] It is a further object of the present invention to provide a design for a shroud to increase the volume of wind available to drive a windmill.
[0023] It is a further object of the present invention to provide a design for a shroud to redirect air flow away from the non-working surfaces of the turbine blades of a vertical axis wind turbine.
[0024] It is yet a further object of the present invention to provide a shroud for controlling air flow to a vertical axis wind turbine,
DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a top view of the present invention with the vanes open to the outside air.
[0026] FIG. 2 is a top view of the present invention showing the vanes closed to the outside air.
[0027] FIG. 3 shows air flow into the present invention.
[0028] FIG. 4 is another embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Referring to FIG. 1 , the present invention comprises a housing 101 positioned around a central vertical windmill 102 . Standard modern vertical windmill designs are configured to capture wind energy with blades 103 , that wind energy being converted to rotational energy imparted on a vertical shaft 104 . The housing 101 consists of a frame 105 in which are situated a plurality of vanes 106 . Although any number of vanes 106 may be utilized, experimental use has shown that an optimal number of vanes 106 is eight, with the housing 101 being generally octagonal. It will be understood by those skilled in the art that, although the embodiment shown herein comprises a generally octagonal shape, other shapes may be used without deviating from the spirit and scope of the present invention. Although other housing 101 shapes may be used, it is preferred that the numbers of sides of the housing 101 correspond to the number of vanes 106 . In this manner, the amount of material necessary to construct the present invention is reduced, thus reducing the cost as well as the wind profile of the housing 101 .
[0030] The plurality of vanes 106 are pivotally mounted to the housing 101 . Although the pivot points 107 may be located at any point along the axis of the vanes 106 , the pivot points 107 are preferentially located at the midpoint of the vanes 106 . Referring now to FIG. 4 , the invention further comprises means for moving the vanes 106 about the pivot points 107 , the means comprising mechanical linkages 108 .
[0031] Although the mechanical linkages 108 may be operated by numerous means, in a preferred embodiment the linkage is operated utilizing an electromechanical impetus. An electric generator (not shown) is mechanically attached to or associated with the vertical shaft 104 by commonly utilized means, such as a wheel or gear. A means for attaching and/or connecting to an electric generator to generate parasitic power is well known in the art. The electric generator creates an increase or decrease in voltage in response to increases or decreases in rotational velocity of the vertical shaft 104 . In this manner, the present invention may have pre-set operating limits so that the effective wind velocity seen by the working surfaces 109 of the blades 103 is maintained within a range that provides the maximum possible force to the blades 103 without exceeding operating parameters of the vertical axis wind turbine. In particular, as the wind speed increases and the rotational velocity of the vertical axis 104 increases, the electric generator increases the output voltage, causing an electric drive or servo 110 to activate in such a manner as to move the mechanical linkages 108 to decrease the openings into the shroud by closing the vanes 106 . As the wind speed decreases and the rotational velocity of the vertical axis 104 decreases, the electric generator decreases the output voltage, causing an electric drive or servo 110 to activate in such a manner as to move the mechanical linkages 108 to increase the openings into the shroud by closing the vanes 106 . It will be understood by those skilled in the art that the voltage range corresponding to the wind speed range will vary depending upon the application, design, desired operating parameters, and operating limits of a particular vertical axis wind turbine.
[0032] It will further be understood by those skilled in the art that the plurality of vanes 106 may be varied without deviating from the spirit and the scope of the present invention. The preferred embodiment, however, comprises eight (8) vanes 106 , as shown in FIGS. 1-4 . In that particular configuration, the greatest wind controlling advantage is obtained as described above, while comprising a small circumference in relation to the blades 103 , thereby reducing both manufacturing costs, by constructing the present invention with as few materials as possible, while most importantly reducing to a minimum the dead air space within the housing and simultaneously eliminating any unwanted back force on the non-working side of the blades 103 .
[0033] Referring now to FIG. 3 , an embodiment of the present invention is shown with representative airflow into the housing 101 and redirected by the vanes 106 . As shown, the airflow 201 is directed by the vanes 106 to the working surface 109 of the turbine blades 103 . That portion of the wind 202 that would, without the invention herein, impact the non-working surface of the blades 103 and cause force to be imparted against the desired direction of rotation.
[0034] It will be understood that the blades may be of any design, the embodiment described herein is the most advantageous.
[0035] It will further be understood that the shroud may be open or closed at the top and/or bottom, or some variant thereof depending upon the application. Generally, the device as preferred has less material and an open top, which does not impact performance.
[0036] The invention has been described in detail with particular reference to the preferred embodiment thereof, but it is understood that modifications and variations of the invention can be made without deviating from the spirit and scope of the invention.
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A shroud for vertical axis wind turbines. The shroud contains vanes that direct airflow to the turbine blades to increase efficiency. The vanes in the shroud further provide a means to close entirely the turbine from adverse weather conditions. The vanes are operated utilizing electrical feedback from the rotational speed of the turbine.
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[0001] This application is a continuation of U.S. patent application Ser. Nos. 10/146,516 and 10/749,783, entitled “Delivery of Drug Esters Through an Inhalation Route,” filed May 13, 2002 and Dec. 30, 2003, respectively, Rabinowitz and Zaffaroni, which claim priority to U.S. provisional application Ser. No. 60/294,203 entitled “Thermal Vapor Delivery of Drugs,” filed May 24, 2001 and to U.S. provisional application Ser. No. 60/317,479 entitled “Aerosol Drug Delivery,” filed Sep. 5, 2001, all of which are hereby incorporated by reference for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates to the delivery of drug esters through an inhalation route. Specifically, it relates to aerosols containing drug esters that are used in inhalation therapy.
BACKGROUND OF THE INVENTION
[0003] There are a number of compounds containing acids and alcohols that are currently marketed as drugs. In certain circumstances, the presence of such functionality prevents effective drug delivery. This phenomenon could be due to a range of effects, including poor solubility and inadequate transcellular transport.
[0004] It is desirable to provide a new route of administration for drug acids and alcohols that rapidly produces peak plasma concentrations of the compounds. The provision of such a route is an object of the present invention.
SUMMARY OF THE INVENTION
[0005] The present invention relates to the delivery of drug esters through an inhalation route. Specifically, it relates to aerosols containing drug esters that are used in inhalation therapy.
[0006] In a composition aspect of the present invention, the aerosol comprises particles comprising at least 5 percent by weight of drug ester. Preferably, the drug ester has a decomposition index less than 0. 15. More preferably, it has a decomposition index less than 0.10 or 0.05. Preferably, the particles comprise at least 10 percent by weight of drug ester. More preferably, the particles comprise at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent or 99.97 percent by weight of drug ester.
[0007] Typically, the drug ester is an ester of a drug from one of the following classes: antibiotics, anticonvulsants, antidepressants, antihistamines, antiparkisonian drugs, drugs for migraine headaches, drugs for the treatment of alcoholism, muscle relaxants, anxiolytics, nonsteroidal anti-inflammatories, other analgesics and steroids.
[0008] Typically, where the drug ester is an ester of an antibiotic, it is selected from an ester of one of the following compounds: cefmetazole; cefazolin; cephalexin; cefoxitin; cephacetrile; cephaloglycin; cephaloridine; cephalosporins, such as cephalosporin c; cephalotin; cephamycins, such as cephamycin a, cephamycin b, and cephamycin c; cepharin; cephradine; ampicillin; amoxicillin; hetacillin; carfecillin; carindacillin; carbenicillin; amylpenicillin; azidocillin; benzylpenicillin; clometocillin; cloxacillin; cyclacillin; methicillin; nafcillin; 2-pentenylpenicillin; penicillins, such as penicillin n, penicillin o, penicillin s, and penicillin v; chlorobutin penicillin; dicloxacillin; diphenicillin; heptylpenicillin; and metampicillin.
[0009] Typically, where the drug ester is an ester of an anticonvulsant, it is selected from an ester of one of the following compounds: 4-amino-3-hydroxybutyric acid, ethanedisulfonate, gabapentin, and vigabatrin.
[0010] Typically, where the drug ester is an ester of an antidepressant, it is selected from an ester of one of the following compounds: tianeptine and S-adenosylmethionine.
[0011] Typically, where the drug ester is an ester of an antihistamine, it is an ester of fexofenadine.
[0012] Typically, where the drug ester is an ester of an antiparkinsonian drug, it is selected from an ester of one of the following compounds: apomorphine, baclofen, levodopa, carbidopa, and thioctate.
[0013] Typically, where the drug ester is an ester of a drug for migraine headaches, it is selected from an ester of one of the following compounds: aspirin, diclofenac, naproxen, tolfenamic acid, and valproate.
[0014] Typically, where the drug ester is an ester of a drug for the treatment of alcoholism, it is an ester of acamprosate.
[0015] Typically, where the drug ester is an ester of a muscle relaxant, it is an ester of baclofen.
[0016] Typically, where the drug ester is an ester of an anxiolytic, it is selected from an ester of one of the following compounds: chlorazepate, calcium N-carboamoylaspartate and chloral betaine.
[0017] Typically, where the drug ester is an ester of a nonsteroidal anti-inflammatory, it is selected from an ester of one of the following compounds: aceclofenac, alclofenac, alminoprofen, amfenac, aspirin, benoxaprofen, bermoprofen, bromfenac, bufexamac, butibufen, bucloxate, carprofen, cinchophen, cinmetacin, clidanac, clopriac, clometacin, diclofenac, diflunisal, etodolac, fenclozate, fenoprofen, flutiazin, flurbiprofen, ibuprofen, ibufenac, indomethacin, indoprofen, ketoprofen, ketorolac, loxoprofen, meclofenamate, naproxen, oxaprozin, pirprofen, prodolic acid, salsalate, sulindac, tofenamate, and tolmetin.
[0018] Typically, where the drug ester is an ester of an other analgesic, it is selected from an ester of one of the following compounds: bumadizon, clometacin, and clonixin.
[0019] Typically, where the drug ester is an ester of a steroid, it is selected from an ester of one of the following compounds: betamethasone, chloroprednisone, clocortolone, cortisone, desonide, dexamethasone, desoximetasone, difluprednate, estradiol, fludrocortisone, flumethasone, flunisolide, fluocortolone, fluprednisolone, hydrocortisone, meprednisone, methylprednisolone, paramethasone, prednisolone, prednisone, pregnan-3-alpha-ol-20-one, testosterone, and triamcinolone.
[0020] Typically, where the drug ester is an ester of a drug acid, the ester is selected from an ester of the following type: C 1 -C 6 straight chain substituted or unsubstituted alkyl ester, C 1 -C 6 branched chain substituted or unsubstituted alkyl ester, C 3 -C 6 substituted or unsubstituted cyclic alkyl ester, C 1 -C 6 substituted or unsubstituted alkenyl ester, C 1 -C 6 substituted or unsubstituted alkynyl ester, and substituted or unsubstituted aromatic ester.
[0021] Typically, where the drug ester is an ester of a drug alcohol, the ester is selected from an ester of the following type: C 1 -C 6 substituted or unsubstituted straight chain alkanoate, C 1 -C 6 substituted or unsubstituted branched chain alkanoate, C 1 -C 6 substituted or unsubstituted alkenoate, and C 1 -C 6 substituted or unsubstituted alkynoate.
[0022] Typically, the drug ester is selected from one of the following: ketoprofen methyl ester, ketoprofen ethyl ester, ketoprofen norcholine ester, ketorolac methyl ester, ketorolac ethyl ester, ketorolac norcholine ester, indomethacin methyl ester, indomethacin ethyl ester, indomethacine norcholine ester, and apomorphine diacetate.
[0023] Typically, the aerosol has a mass of at least 0.01 mg. Preferably, the aerosol has a mass of at least 0.05 mg. More preferably, the aerosol has a mass of at least 0.10 mg, 0.15 mg, 0.2 g or 0.25 mg.
[0024] Typically, the particles comprise less than 10 percent by weight of drug ester degradation products. Preferably, the particles comprise less than 5 percent by weight of drug ester degradation products. More preferably, the particles comprise less than 2.5, 1, 0.5, 0.1 or 0.03 percent by weight of drug ester degradation products.
[0025] Typically, the particles comprise less than 90 percent by weight of water. Preferably, the particles comprise less than 80 percent by weight of water. More preferably, the particles comprise less than 70 percent, 60 percent, 50 percent, 40 percent, 30 percent, 20 percent, 10 percent, or 5 percent by weight of water.
[0026] Typically, the aerosol has an inhalable aerosol drug ester mass density of between 0.1 mg/L and 100 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 0.1 mg/L and 75 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 0.1 mg/L and 50 mg/L.
[0027] Typically, the aerosol has an inhalable aerosol particle density greater than 10 6 particles/mL. Preferably, the aerosol has an inhalable aerosol particle density greater than 10 7 particles/mL or 10 8 particles/mL.
[0028] Typically, the aerosol particles have a mass median aerodynamic diameter of less than 5 microns. Preferably, the particles have a mass median aerodynamic diameter of less than 3 microns. More preferably, the particles have a mass median aerodynamic diameter of less than 2 or 1 micron(s).
[0029] Typically, the geometric standard deviation around the mass median aerodynamic diameter of the aerosol particles is less than 2. Preferably, the geometric standard deviation is less than 1.9. More preferably, the geometric standard deviation is less than 1.8, 1.7, 1.6 or 1.5.
[0030] Typically, the aerosol is formed by heating a composition containing drug ester to form a vapor and subsequently allowing the vapor to condense into an aerosol.
[0031] In a method aspect of the present invention, a drug ester is delivered to a mammal through an inhalation route. The method comprises: a) heating a composition, wherein the composition comprises at least 5 percent by weight of drug ester, to form a vapor; and, b) allowing the vapor to cool, thereby forming a condensation aerosol comprising particles, which is inhaled by the mammal. Preferably, the drug ester has a decomposition index less than 0.15. More preferably, it has a decomposition index less than 0.10 or 0.05. Preferably, the composition that is heated comprises at least 10 percent by weight of drug ester. More preferably, the composition comprises at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of drug ester.
[0032] Typically, the drug ester is an ester of a drug from one of the following classes: antibiotics, anticonvulsants, antidepressants, antihistamines, antiparkisonian drugs, drugs for migraine headaches, drugs for the treatment of alcoholism, muscle relaxants, anxiolytics, nonsteroidal anti-inflammatories, other analgesics and steroids.
[0033] Typically, where the drug ester is an ester of an antibiotic, it is selected from an ester of one of the following compounds: cefmetazole; cefazolin; cephalexin; cefoxitin; cephacetrile; cephaloglycin; cephaloridine; cephalosporins, such as cephalosporin c; cephalotin; cephamycins, such as cephamycin a, cephamycin b, and cephamycin c; cepharin; cephradine; ampicillin; amoxicillin; hetacillin; carfecillin; carindacillin; carbenicillin; amylpenicillin; azidocillin; benzylpenicillin; clometocillin; cloxacillin; cyclacillin; methicillin; nafcillin; 2-pentenylpenicillin; penicillins, such as penicillin n, penicillin o, penicillin s, and penicillin v; chlorobutin penicillin; dicloxacillin; diphenicillin; heptylpenicillin; and metampicillin.
[0034] Typically, where the drug ester is an ester of an anticonvulsant, it is selected from an ester of one of the following compounds: 4-amino-3-hydroxybutyric acid, ethanedisulfonate, gabapentin, and vigabatrin.
[0035] Typically, where the drug ester is an ester of an antidepressant, it is selected from an ester of one of the following compounds: tianeptine and S-adenosylmethionine.
[0036] Typically, where the drug ester is an ester of an antihistamine, it is an ester of fexofenadine.
[0037] Typically, where the drug ester is an ester of an antiparkinsonian drug, it is selected from an ester of one of the following compounds: apomorphine, baclofen, levodopa, carbidopa, and thioctate.
[0038] Typically, where the drug ester is an ester of a drug for migraine headaches, it is selected from an ester of one of the following compounds: aspirin, diclofenac, naproxen, tolfenamic acid, and valproate.
[0039] Typically, where the drug ester is an ester of a drug for the treatment of alcoholism, it is an ester of acamprosate.
[0040] Typically, where the drug ester is an ester of a muscle relaxant, it is an ester of baclofen.
[0041] Typically, where the drug ester is an ester of an anxiolytic, it is selected from an ester of one of the following compounds: chlorazepate, calcium N-carboamoylaspartate and chloral betaine.
[0042] Typically, where the drug ester is an ester of a nonsteroidal anti-inflammatory, it is selected from an ester of one of the following compounds: aceclofenac, alclofenac, alminoprofen, amfenac, aspirin, benoxaprofen, bermoprofen, bromfenac, bufexamac, butibufen, bucloxate, carprofen, cinchophen, cinmetacin, clidanac, clopriac, clometacin, diclofenac, diflunisal, etodolac, fenclozate, fenoprofen, flutiazin, flurbiprofen, ibuprofen, ibufenac, indomethacin, indoprofen, ketoprofen, ketorolac, loxoprofen, meclofenamate, naproxen, oxaprozin, pirprofen, prodolic acid, salsalate, sulindac, tofenamate, and tolmetin.
[0043] Typically, where the drug ester is an ester of an other analgesic, it is selected from an ester of one of the following compounds: bumadizon, clometacin, and clonixin.
[0044] Typically, where the drug ester is an ester of a steroid, it is selected from an ester of one of the following compounds: betamethasone, chloroprednisone, clocortolone, cortisone, desonide, dexamethasone, desoximetasone, difluprednate, estradiol, fludrocortisone, flumethasone, flunisolide, fluocortolone, fluprednisolone, hydrocortisone, meprednisone, methylprednisolone, paramethasone, prednisolone, prednisone, pregnan-3-alpha-ol-20-one, testosterone, and triamcinolone.
[0045] Typically, where the drug ester is an ester of a drug acid, the ester is selected from an ester of the following type: C 1 -C 6 straight chain substituted or unsubstituted alkyl ester, C 1 -C 6 branched chain substituted or unsubstituted alkyl ester, C 3 -C 6 substituted or unsubstituted cyclic alkyl ester, C 1 -C 6 substituted or unsubstituted alkenyl ester, C 1 -C 6 substituted or unsubstituted alkynyl ester, and substituted or unsubstituted aromatic ester.
[0046] Typically, where the drug ester is an ester of a drug alcohol, the ester is selected from an ester of the following type: C 1 -C 6 substituted or unsubstituted straight chain alkanoate, C 1 -C 6 substituted or unsubstituted branched chain alkanoate, C 1 -C 6 substituted or unsubstituted alkenoate, and C 1 -C 6 substituted or unsubstituted alkynoate.
[0047] Typically, the drug ester is selected from one of the following: ketoprofen methyl ester, ketoprofen ethyl ester, ketoprofen norcholine ester, ketorolac methyl ester, ketorolac ethyl ester, ketorolac norcholine ester, indomethacin methyl ester, indomethacin ethyl ester, indomethacine norcholine ester, and apomorphine diacetate.
[0048] Typically, the particles comprise at least 5 percent by weight of drug ester. Preferably, the particles comprise at least 10 percent by weight of drug ester. More preferably, the particles comprise at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of drug ester.
[0049] Typically, the condensation aerosol has a mass of at least 0.01 mg. Preferably, the aerosol has a mass of at least 0.05 mg. More preferably, the aerosol has a mass of at least 0.10 mg, 0.15 mg, 0.2 g or 0.25 mg.
[0050] Typically, the particles comprise less than 10 percent by weight of drug ester degradation products. Preferably, the particles comprise less than 5 percent by weight of drug ester degradation products. More preferably, the particles comprise 2.5, 1, 0.5, 0.1 or 0.03 percent by weight of drug ester degradation products.
[0051] Typically, the particles comprise less than 90 percent by weight of water. Preferably, the particles comprise less than 80 percent by weight of water. More preferably, the particles comprise less than 70 percent, 60 percent, 50 percent, 40 percent, 30 percent, 20 percent, 10 percent, or 5 percent by weight of water.
[0052] Typically, the particles of the delivered condensation aerosol have a mass median aerodynamic diameter of less than 5 microns. Preferably, the particles have a mass median aerodynamic diameter of less than 3 microns. More preferably, the particles have a mass median aerodynamic diameter of less than 2 or 1 micron(s).
[0053] Typically, the geometric standard deviation around the mass median aerodynamic diameter of the aerosol particles is less than 2. Preferably, the geometric standard deviation is less than 1.9. More preferably, the geometric standard deviation is less than 1.8, 1.7, 1.6 or 1.5.
[0054] Typically, the delivered aerosol has an inhalable aerosol drug ester mass density of between 0.1 mg/L and 100 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 0.1 mg/L and 75 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 0.1 mg/L and 50 mg/L.
[0055] Typically, the delivered aerosol has an inhalable aerosol particle density greater than 10 6 particles/mL. Preferably, the aerosol has an inhalable aerosol particle density greater than 10 7 particles/mL or 10 8 particles/mL.
[0056] Typically, the rate of inhalable aerosol particle formation of the delivered condensation aerosol is greater than 10 8 particles per second. Preferably, the aerosol is formed at a rate greater than 10 9 inhalable particles per second. More preferably, the aerosol is formed at a rate greater than 10 10 inhalable particles per second.
[0057] Typically, the delivered condensation aerosol is formed at a rate greater than 0.5 mg/second. Preferably, the aerosol is formed at a rate greater than 0.75 mg/second. More preferably, the aerosol is formed at a rate greater than 1 mg/second, 1.5 mg/second or 2 mg/second.
[0058] Typically, between 0.1 mg and 100 mg of drug ester are delivered to the mammal in a single inspiration. Preferably, between 0.1 mg and 75 mg of drug ester are delivered to the mammal in a single inspiration. More preferably, between 0.1 mg and 50 mg of drug ester are delivered in a single inspiration.
[0059] Typically, the delivered condensation aerosol results in a peak plasma concentration of drug acid or drug alcohol in the mammal in less than 1 h. Preferably, the peak plasma concentration is reached in less than 0.5 h. More preferably, the peak plasma concentration is reached in less than 0.2, 0.1, 0.05, 0.02 or 0.01 h.
[0060] In a kit aspect of the present invention, a kit for delivering a drug ester through an inhalation route to a mammal is provided which comprises: a) a composition comprising at least 5 percent by weight of drug ester; and, b) a device that forms a drug ester aerosol from the composition, for inhalation by the mammal. Preferably, the composition comprises at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of drug ester.
[0061] Typically the drug ester has a decomposition index less than 0. 15. More preferably, it has a decomposition index less than 0.10 or 0.05.
[0062] Typically, the device contained in the kit comprises: a) an element for heating the drug ester composition to form a vapor; b) an element allowing the vapor to cool to form an aerosol; and, c) an element permitting the mammal to inhale the aerosol.
BRIEF DESCRIPTION OF THE FIGURE
[0063] [0063]FIG. 1 shows a cross-sectional view of a device used to deliver drug ester aerosols to a mammal through an inhalation route.
DETAILED DESCRIPTION OF THE INVENTION
[0064] Definitions
[0065] “Aerodynamic diameter” of a given particle refers to the diameter of a spherical droplet with a density of 1 g/mL (the density of water) that has the same settling velocity as the given particle.
[0066] “Aerosol” refers to a suspension of solid or liquid particles in a gas.
[0067] “Aerosol drug ester mass density” refers to the mass of drug ester per unit volume of aerosol.
[0068] “Aerosol mass density” refers to the mass of particulate matter per unit volume of aerosol.
[0069] “Aerosol particle density” refers to the number of particles per unit volume of aerosol.
[0070] “Condensation aerosol” refers to an aerosol formed by vaporization of a substance followed by condensation of the substance into an aerosol.
[0071] “Decomposition index” refers to a number derived from an assay described in Example 8. The number is determined by substracting the percent purity of the generated aerosol from 1.
[0072] “Drug” refers to any chemical compound that is used in the prevention, diagnosis, treatment, or cure of disease, for the relief of pain, or to control or improve any physiological or pathological disorder in humans or animals. Such compounds are oftentimes listed in the Physician's Desk Reference (Medical Economics Company, Inc. at Montvale, N.J., 56 th edition, 2002), which is herein incorporated by reference.
[0073] “Drug acid” refers to a drug containing a carboxylic acid moiety.
[0074] “Drug alcohol” refers to a drug containing a hydroxyl moiety.
[0075] “Drug Ester” refers to a drug acid or drug alcohol, where the carboxylic acid group or hydroxyl group has been chemically modified to form an ester. The drug acids and alcohols from which the esters are formed come from a variety of drug classes, including, without limitation, antibiotics, anticonvulsants, antidepressants, antihistamines, antiparkinsonian drugs, drugs for migraine headaches, drugs for the treatment of alcoholism, muscle relaxants, anxiolytics, nonsteroidal anti-inflammatories, other analgesics, and steroids.
[0076] Examples of antibiotics from which drug esters are formed include cefmetazole; cefazolin; cephalexin; cefoxitin; cephacetrile; cephaloglycin; cephaloridine; cephalosporins, such as cephalosporin c; cephalotin; cephamycins, such as cephamycin a, cephamycin b, and cephamycin c; cepharin; cephradine; ampicillin; amoxicillin; hetacillin; carfecillin; carindacillin; carbenicillin; amylpenicillin; azidocillin; benzylpenicillin; clometocillin; cloxacillin; cyclacillin; methicillin; nafcillin; 2-pentenylpenicillin; penicillins, such as penicillin n, penicillin o, penicillin s, and penicillin v; chlorobutin penicillin; dicloxacillin; diphenicillin; heptylpenicillin; and metampicillin.
[0077] Examples of anticonvulsants from which drug esters are formed include 4-amino-3-hydroxybutyric acid, ethanedisulfonate, gabapentin, and vigabatrin.
[0078] Examples of antidepressants from which drug esters are formed include tianeptine and S-adenosylmethionine.
[0079] Examples of antihistamines from which drug esters are formed include fexofenadine.
[0080] Examples of antiparkinsonian drugs from which drug esters are formed include apomorphine, baclofen, levodopa, carbidopa, and thioctate.
[0081] Examples of anxiolytics from which drug esters are formed include chlorazepate, calcium N-carboamoylaspartate and chloral betaine.
[0082] Examples of drugs for migraine headache from which drug esters are formed include aspirin, diclofenac, naproxen, tolfenamic acid, and valproate.
[0083] Examples of drugs for the treatment of alcoholism from which drug esters are formed include acamprosate.
[0084] Examples of muscle relaxants from which drug esters are formed include baclofen.
[0085] Examples of nonsteroidal anti-inflammatories from which drug esters are formed include aceclofenac, alclofenac, alminoprofen, amfenac, aspirin, benoxaprofen, bermoprofen, bromfenac, bufexamac, butibufen, bucloxate, carprofen, cinchophen, cinmetacin, clidanac, clopriac, clometacin, diclofenac, diflunisal, etodolac, fenclozate, fenoprofen, flutiazin, flurbiprofen, ibuprofen, ibufenac, indomethacin, indoprofen, ketoprofen, ketorolac, loxoprofen, meclofenamate, naproxen, oxaprozin, pirprofen, prodolic acid, salsalate, sulindac, tofenamate, and tolmetin.
[0086] Examples of other analgesics from which drug esters are formed include bumadizon, clometacin, and clonixin.
[0087] Examples of steroids from which drug esters are formed include betamethasone, chloroprednisone, clocortolone, cortisone, desonide, dexamethasone, desoximetasone, difluprednate, estradiol, fludrocortisone, flumethasone, flunisolide, fluocortolone, fluprednisolone, hydrocortisone, meprednisone, methylprednisolone, paramethasone, prednisolone, prednisone, pregnan-3-alpha-ol-20-one, testosterone, and triamcinolone.
[0088] Examples of drug esters formed from drug acids include C 1 -C 6 straight chain substituted or unsubstituted alkyl esters, C 1 -C 6 branched chain substituted or unsubstituted alkyl esters, C 3 -C 6 substituted or unsubstituted cyclic alkyl esters, C 1 -C 6 substituted or unsubstituted alkenyl esters, C 1 -C 6 substituted or unsubstituted alkynyl esters, and substituted or unsubstituted aromatic esters. C 1 -C 6 straight chain unsubstituted alkyl esters include, for example, methyl ester, ethyl ester and propyl ester. C 1 -C 6 straight chain substituted alkyl esters include, for example, 2-(dimethylamino)-ethyl ester (—CH 2 CH 2 N(CH 3 ) 2 ). C 1 -C 6 branched chain unsubstituted alkyl esters include, for example, isopropyl ester and isobutyl ester. C 1 -C 6 branched chain substituted alkyl esters include, for example, 2-(dimethylamino)-isopropyl ester (—CH(CH 3 )CH 2 N(CH 3 ) 2 ). C 3 -C 6 unsubstituted cyclic alkyl esters include, for example, cyclopropyl and cyclohexyl ester. C 3 -C 6 substituted cyclic alkyl esters include, for example, 2-(dimethylamino)-cyclopropyl ester. C 1 -C 6 unsubstituted alkenyl esters include, for example, 2-butenyl ester (—CH 2 CHCHCH 3 ). C 1 -C 6 substituted alkenyl esters include, for example, 4-(dimethylamino)-2-butenyl ester (—CH 2 CHCHCH 2 N(CH 3 ) 2 ). C 1 -C 6 unsubstituted alkynyl esters include, for example, 2-butynyl ester (—CH 2 CCCH 3 ). C1-C6 substituted alkynyl esters include, for example, 4-(dimethylamino)-2-butynyl ester (—CH 2 CCCH 2 N(CH 3 ) 2 ). Unsubstituted aromatic esters include, for example, phenyl ester and naphthyl ester. Substituted aromatic esters include, for example, 4-(dimethylamino)phenyl ester.
[0089] Examples of drug esters formed from drug alcohols include C 1 -C 6 substituted or unsubstituted straight chain alkanoates, C 1 -C 6 substituted or unsubstituted branched chain alkanoates, C 1 -C 6 substituted or unsubstituted alkenoates, and C 1 -C 6 substituted or unsubstituted alkynoates. C 1 -C 6 unsubstituted straight chain alkanoates include, for example, methanoate (—C(O)H), ethanoate (—C(O)CH 3 ) and propanoate (—C(O)CH 2 CH 3 ). C 1 -C 6 substituted straight chain alkanoates include, for example, 2-(phenyl)-ethanoate (—C(O)CH 2 Ph). C 1 -C 6 unsubstituted branched chain alkanoates include, for example, isobutanoate (—C(O)CH(CH 3 ) 2 ). C 1 -C 6 substituted branched chain alkanoates include, for example, 3-(phenyl)-isobutanoate (—C(O)CH(CH 3 )CH 2 Ph). C 1 -C 6 unsubstituted alkenoates include, for example, 2-butenoate (—C(O)CHCHCH 3 ). C 1 -C 6 substituted alkenoates include, for example, 4-(phenyl)-2-butenoate (—C(O)CHCHCH 2 Ph). C 1 -C 6 unsubstituted alkynoates include, for example, 2-butynoate (—C(O)CCCH 3 ). C 1 -C 6 substituted alkynoates include, for example, 4-(phenyl)-2-butynoate.
[0090] Examples of other drug esters are found in U.S. Pat. No. 5,607,691 to Hale et al. and U.S. Pat. No. 5,622,944 to Hale et al. These patents are herein incorporated by reference.
[0091] “Drug ester degradation product” refers to a compound resulting from a chemical modification of the drug ester. The modification, for example, can be the result of a thermally or photochemically induced reaction. Such reactions include, without limitation, oxidation and hydrolysis.
[0092] “Inhalable aerosol drug ester mass density” refers to the aerosol drug ester mass density produced by an inhalation device and delivered into a typical patient tidal volume.
[0093] “Inhalable aerosol mass density” refers to the aerosol mass density produced by an inhalation device and delivered into a typical patient tidal volume.
[0094] “Inhalable aerosol particle density” refers to the aerosol particle density of particles of size between 100 nm and 5 microns produced by an inhalation device and delivered into a typical patient tidal volume.
[0095] “Mass median aerodynamic diameter” or “MMAD” of an aerosol refers to the aerodynamic diameter for which half the particulate mass of the aerosol is contributed by particles with an aerodynamic diameter larger than the MMAD and half by particles with an aerodynamic diameter smaller than the MMAD.
[0096] “Norcholine ester” refers to an ester where the portion attached to the ester oxygen is —CH 2 CH 2 N(CH 3 ) 2 .
[0097] “Rate of aerosol formation” refers to the mass of aerosolized particulate matter produced by an inhalation device per unit time.
[0098] “Rate of inhalable aerosol particle formation” refers to the number of particles of size between 100 nm and 5 microns produced by an inhalation device per unit time.
[0099] “Rate of drug ester aerosol formation” refers to the mass of aerosolized, drug ester produced by an inhalation device per unit time.
[0100] “Settling velocity” refers to the terminal velocity of an aerosol particle undergoing gravitational settling in air.
[0101] “Substituted” alkyl, alkenyl, alkynyl or aryl refers to the replacement of one or more hydrogen atoms on the moiety (e.g., alkyl) with another group. Such groups include, without limitation, the following: halo, amino, alkylamino, dialkylamino, hydroxyl, cyano, nitro and phenyl.
[0102] “Typical patient tidal volume” refers to 1 L for an adult patient and 15 mL/kg for a pediatric patient.
[0103] “Vapor” refers to a gas, and “vapor phase” refers to a gas phase. The term “thermal vapor” refers to a vapor phase, aerosol, or mixture of aerosol-vapor phases, formed preferably by heating.
[0104] Formation of Drug Esters from Drug Acids or Drug Alcohols
[0105] Formation of drug esters from drug acids is typically accomplished by reacting the acid, or an activated derivative (e.g., acid chloride or mixed anhydride) with an appropriate alcohol under conditions well known to those of skill in the art. See, for example, Streitweiser, A., Jr. and Heathcock, C. H. (1981) Introduction to Organic Chemistry , Macmillan Publishing Col., Inc., New York. Conversely, formation of drug esters from drug alcohols is typically accomplished by reacting the alcohol with an appropriate activated acid derivative (e.g., ClC(O)CH 3 ). See Id.
[0106] Formation of Drug Ester Containing Aerosols
[0107] Any suitable method is used to form the aerosols of the present invention. A preferred method, however, involves heating a composition comprising a drug ester to form a vapor, followed by cooling of the vapor such that it condenses to provide a drug ester comprising aerosol (condensation aerosol). The composition is heated in one of two forms: as pure active compound (i.e., pure drug ester); or, as a mixture of active compound and a pharmaceutically acceptable excipient.
[0108] Pharmaceutically acceptable excipients may be volatile or nonvolatile. Volatile excipients, when heated, are concurrently volatilized, aerosolized and inhaled with drug ester. Classes of such excipients are known in the art and include, without limitation, gaseous, supercritical fluid, liquid and solid solvents. The following is a list of exemplary carriers within the classes: water; terpenes, such as menthol; alcohols, such as ethanol, propylene glycol, glycerol and other similar alcohols; dimethylformamide; dimethylacetamide; wax; supercritical carbon dioxide; dry ice; and mixtures thereof.
[0109] Solid supports on which the composition is heated are of a variety of shapes. Examples of such shapes include, without limitation, cylinders of less than 1.0 mm in diameter, boxes of less than 1.0 mm thickness and virtually any shape permeated by small (e.g., less than 1.0 mm-sized) pores. Preferably, solid supports provide a large surface to volume ratio (e.g., greater than 100 per meter) and a large surface to mass ratio (e.g., greater than 1 cm 2 per gram).
[0110] A solid support of one shape can also be transformed into another shape with different properties. For example, a flat sheet of 0.25 mm thickness has a surface to volume ratio of approximately 8,000 per meter. Rolling the sheet into a hollow cylinder of 1 cm diameter produces a support that retains the high surface to mass ratio of the original sheet but has a lower surface to volume ratio (about 400 per meter).
[0111] A number of different materials are used to construct the solid supports. Classes of such materials include, without limitation, metals, inorganic materials, carbonaceous materials and polymers. The following are examples of the material classes: aluminum, silver, gold, stainless steel, copper and tungsten; silica, glass, silicon and alumina; graphite, porous carbons, carbon yams and carbon felts; polytetrafluoroethylene and polyethylene glycol. Combinations of materials and coated variants of materials are used as well.
[0112] Where aluminum is used as a solid support, aluminum foil is a suitable material. Examples of silica, alumina and silicon based materials include amphorous silica S-5631 (Sigma, St. Louis, Mo.), BCR171 (an alumina of defined surface area greater than 2 m 2 /g from Aldrich, St. Louis, Mo.) and a silicon wafer as used in the semiconductor industry. Carbon yams and felts are available from American Kynol, Inc., New York, N.Y. Chromatography resins such as octadecycl silane chemically bonded to porous silica are exemplary coated variants of silica.
[0113] The heating of the drug ester compositions is performed using any suitable method. Examples of methods by which heat can be generated include the following: passage of current through an electrical resistance element; absorption of electromagnetic radiation, such as microwave or laser light; and, exothermic chemical reactions, such as exothermic salvation, hydration of pyrophoric materials and oxidation of combustible materials.
[0114] Delivery of Drug Ester Containing Aerosols
[0115] Drug ester containing aerosols of the present invention are delivered to a mammal using an inhalation device. Where the aerosol is a condensation aerosol, the device has at least three elements: an element for heating a drug ester containing composition to form a vapor; an element allowing the vapor to cool, thereby providing a condensation aerosol; and, an element permitting the mammal to inhale the aerosol. Various suitable heating methods are described above. The element that allows cooling is, in it simplest form, an inert passageway linking the heating means to the inhalation means. The element permitting inhalation is an aerosol exit portal that forms a connection between the cooling element and the mammal's respiratory system.
[0116] One device used to deliver the drug ester containing aerosol is described in reference to FIG. 1. Delivery device 100 has a proximal end 102 and a distal end 104 , a heating module 106 , a power source 108 , and a mouthpiece 110 . A drug ester composition is deposited on a surface 112 of heating module 106 . Upon activation of a user activated switch 114 , power source 108 initiates heating of heating module 106 (e.g, through ignition of combustible fuel or passage of current through a resistive heating element). The drug ester composition volatilizes due to the heating of heating module 106 and condenses to form a condensation aerosol prior to reaching the mouthpiece 110 at the proximal end of the device 102 . Air flow traveling from the device distal end 104 to the mouthpiece 110 carries the condensation aerosol to the mouthpiece 110 , where it is inhaled by the mammal.
[0117] Devices, if desired, contain a variety of components to facilitate the delivery of drug ester containing aerosols. For instance, the device may include any component known in the art to control the timing of drug aerosolization relative to inhalation (e.g., breath-actuation), to provide feedback to patients on the rate and/or volume of inhalation, to prevent excessive use (i.e., “lock-out” feature), to prevent use by unauthorized individuals, and/or to record dosing histories.
[0118] In Vivo Hydrolysis of Drug Esters
[0119] After delivery of a drug ester aerosol to the lung of an animal, the ester moiety is typically hydrolyzed to provide the corresponding drug acid or drug alcohol, which produces a desired therapeutic effect. Where the ester reacts with water at ˜pH 7.4 at an appreciable rate, hydrolysis is chemically mediated. For other esters, hydrolysis is enzymatically mediated through the action of enzymes endogenous to the animal.
[0120] Dosage of Drug Ester Containing Aerosols
[0121] A typical dosage of a drug ester aerosol is either administered as a single inhalation or as a series of inhalations taken within an hour or less (dosage equals sum of inhaled amounts). Where the drug ester is administered as a series of inhalations, a different amount may be delivered in each inhalation. The dosage amount of drug ester in aerosol form is generally no greater than twice the standard dose of the drug acid or drug alcohol given orally.
[0122] One can determine the appropriate dose of drug ester containing aerosols to treat a particular condition using methods such as animal experiments and a dose-finding (Phase I/II) clinical trial. One animal experiment involves measuring plasma concentrations of drug acid or drug alcohol in an animal after its exposure to the aerosol. Mammals such as dogs or primates are typically used in such studies, since their respiratory systems are similar to that of a human. Initial dose levels for testing in humans is generally less than or equal to the dose in the mammal model that resulted in plasma drug levels associated with a therapeutic effect in humans. Dose escalation in humans is then performed, until either an optimal therapeutic response is obtained or a dose-limiting toxicity is encountered.
[0123] Analysis of Drug Ester Containing Aerosols
[0124] Purity of a drug ester containing aerosol is determined using a number of methods, examples of which are described in Sekine et al., Journal of Forensic Science 32:1271-1280 (1987) and Martin et al., Journal of Analytic Toxicology 13:158-162 (1989). One method involves forming the aerosol in a device through which a gas flow (e.g., air flow) is maintained, generally at a rate between 0.4 and 60 L/min. The gas flow carries the aerosol into one or more traps. After isolation from the trap, the aerosol is subjected to an analytical technique, such as gas or liquid chromatography, that permits a determination of composition purity.
[0125] A variety of different traps are used for aerosol collection. The following list contains examples of such traps: filters; glass wool; impingers; solvent traps, such as dry ice-cooled ethanol, methanol, acetone and dichloromethane traps at various pH values; syringes that sample the aerosol; empty, low-pressure (e.g., vacuum) containers into which the aerosol is drawn; and, empty containers that fully surround and enclose the aerosol generating device. Where a solid such as glass wool is used, it is typically extracted with a solvent such as ethanol. The solvent extract is subjected to analysis rather than the solid (i.e., glass wool) itself. Where a syringe or container is used, the container is similarly extracted with a solvent.
[0126] The gas or liquid chromatograph discussed above contains a detection system (i.e., detector). Such detection systems are well known in the art and include, for example, flame ionization, photon absorption and mass spectrometry detectors. An advantage of a mass spectrometry detector is that it can be used to determine the structure of drug ester degradation products.
[0127] Particle size distribution of a drug ester containing aerosol is determined using any suitable method in the art (e.g., cascade impaction). An Andersen Eight Stage Non-viable Cascade Impactor (Andersen Instruments, Smyrna, Ga.) linked to a furnace tube by a mock throat (USP throat, Andersen Instruments, Smyrna, Ga.) is one system used for cascade impaction studies.
[0128] Inhalable aerosol mass density is determined, for example, by delivering a drug-containing aerosol into a confined chamber via an inhalation device and measuring the mass collected in the chamber. Typically, the aerosol is drawn into the chamber by having a pressure gradient between the device and the chamber, wherein the chamber is at lower pressure than the device. The volume of the chamber should approximate the tidal volume of an inhaling patient.
[0129] Inhalable aerosol drug ester mass density is determined, for example, by delivering a drug ester-containing aerosol into a confined chamber via an inhalation device and measuring the amount of non-degraded drug ester collected in the chamber. Typically, the aerosol is drawn into the chamber by having a pressure gradient between the device and the chamber, wherein the chamber is at lower pressure than the device. The volume of the chamber should approximate the tidal volume of an inhaling patient. The amount of non-degraded drug ester collected in the chamber is determined by extracting the chamber, conducting chromatographic analysis of the extract and comparing the results of the chromatographic analysis to those of a standard containing known amounts of drug ester.
[0130] Inhalable aerosol particle density is determined, for example, by delivering aerosol phase drug ester into a confined chamber via an inhalation device and measuring the number of particles of given size collected in the chamber. The number of particles of a given size may be directly measured based on the light-scattering properties of the particles. Alternatively, the number of particles of a given size is determined by measuring the mass of particles within the given size range and calculating the number of particles based on the mass as follows: Total number of particles=Sum (from size range 1 to size range N) of number of particles in each size range. Number of particles in a given size range=Mass in the size range/Mass of a typical particle in the size range. Mass of a typical particle in a given size range=π*D 3 *Φ/6, where D is a typical particle diameter in the size range (generally, the mean boundary MMADs defining the size range) in microns, Φ is the particle density (in g/mL) and mass is given in units of picograms (g −12 ).
[0131] Rate of inhalable aerosol particle formation is determined, for example, by delivering aerosol phase drug ester into a confined chamber via an inhalation device. The delivery is for a set period of time (e.g., 3 s), and the number of particles of a given size collected in the chamber is determined as outlined above. The rate of particle formation is equal to the number of 100 nm to 5 micron particles collected divided by the duration of the collection time.
[0132] Rate of aerosol formation is determined, for example, by delivering aerosol phase drug ester into a confined chamber via an inhalation device. The delivery is for a set period of time (e.g., 3 s), and the mass of particulate matter collected is determined by weighing the confined chamber before and after the delivery of the particulate matter. The rate of aerosol formation is equal to the increase in mass in the chamber divided by the duration of the collection time. Alternatively, where a change in mass of the delivery device or component thereof can only occur through release of the aerosol phase particulate matter, the mass of particulate matter may be equated with the mass lost from the device or component during the delivery of the aerosol. In this case, the rate of aerosol formation is equal to the decrease in mass of the device or component during the delivery event divided by the duration of the delivery event.
[0133] Rate of drug ester aerosol formation is determined, for example, by delivering a drug ester containing aerosol into a confined chamber via an inhalation device over a set period of time (e.g., 3 s). Where the aerosol is pure drug ester, the amount of drug collected in the chamber is measured as described above. The rate of drug ester aerosol formation is equal to the amount of drug ester aerosol collected in the chamber divided by the duration of the collection time. Where the drug ester containing aerosol comprises a pharmaceutically acceptable excipient, multiplying the rate of aerosol formation by the percentage of drug ester in the aerosol provides the rate of drug aerosol formation.
[0134] Utility of Drug Ester Containing Aerosols
[0135] The drug ester containing aerosols of the present invention are typically used for the same indication as the corresponding drug acid or drug alcohol. For instance, a drug ester of baclofen would be used to treat parkinsons disease and a drug ester of fexofenadine would be used to treat allergy symptoms.
[0136] The following examples are meant to illustrate, rather than limit, the present invention.
[0137] Drug acids or drug alcohols are typically commercially available from Simga (www.sigma-aldrich.com), obtained in tablet form from a pharmacy and extracted, or synthesized using well known methods in the art.
EXAMPLE 1
General Procedures for Esterifying a Drug Acid
[0138] Drug acid (10 mmol) is dissolved in 90 mL of dichloromethane. To the solution is added 1 drop of dimethylformamide and 13 mmol of oxalyl chloride. The resulting mixture is allowed to stir 30 min. The mixture is concentrated to dryness on a rotary evaporator to provide a residue, to which 50 mL of an alcohol (e.g., methanol) is added. The alcoholic solution is concentrated to dryness to afford the desired drug ester.
[0139] Drug acid (6 mmol) is dissolved in 60 mL of dichloromethane. To the solution is added 1 drop of dimethylformamide and 9 mmol of oxalyl chloride. The resulting mixture is allowed to stir 1 h. The mixture is concentrated to dryness on a rotary evaporator to provide a residue, to which 47 mmol of an alcohol (e.g., HOCH 2 CH 2 N(CH 3 ) 2 ) in 20 mL dichloromethane is added. The reaction mixture is diluted with 60 mL dichloromethane and subjected to a series of washings: 50 mL saturated aqueous NaCl followed by 50 mL saturated aqueous NaHCO 3 and 2×50 mL saturated aqueous NaCl. The dichloromethane extract is dried over Na 2 SO 4 , filtered, and concentrated on a rotary evaporator to provide the desired drug ester.
EXAMPLE 2
General Procedure for Esterifying a Drug Alcohol
[0140] Drug alcohol (5 mmol) is dissolved in 50 mL of dichloromethane. To the solution is added 5.5 mmol Hünig's base and 10 mmol acetyl chloride. The reaction mixture is allowed to stir at room temperature for 1 hour. The mixture is washed with 50 mL saturated aqueous NaHCO 3 followed by 50 mL saturated aqueous NaCl. The dichloromethane extract is dried over Na 2 SO 4 , filtered, and concentrated on a rotary evaporator to provide the desired drug ester.
EXAMPLE 3
Procedure for Diesterifying Apomorphine
[0141] Apomorphine HCl.½H 2 O (300 mg) was suspended in 600 μL of acetic acid. The suspension was heated to 100° C. and then cooled to 50° C. Acetyl chloride (1 mL) was added to the suspension, which was heated at 40° C. for 3 h. The reaction mixture was allowed to cool to room temperature. Dichloromethane (1-2 mL) was added and the mixture was allowed to stir overnight. The reaction mixture was diluted with dichloromethane, and the solvent was removed on a rotary evaporator. Toluene (10 mL) was added to the residue and subsequently removed on a rotary evaporator. The toluene addition/removal was repeated. The resulting solid residue was triturated with ether, providing 430 mg of a solid (mp 158-160° C.).
[0142] A portion of the solid (230 mg) was suspended in 50 mL of dichloromethane. The suspension was washed with saturated aqueous NaHCO 3 . The dichloromethane layer was dried over Na 2 SO 4 , filtered and concentrated on a rotary evaporator to provide 190 mg of the desired free base (mp˜110° C.).
EXAMPLE 4
Procedure for Synthesis of 2-(N,N-Dimethylamino)Ethyl Ester of Ketorolac
[0143] Ketorolac (255 mg), triethylamine (101 mg) and 2-(dimethylamino)ethanol (HOCH 2 CH 2 N(CH 3 ) 2 , 380 mg) were added to 2 mL dichloromethane. The mixture was cooled to −25° C. to −20° C. for 15 min. BOP (464 mg) was added, and the reaction mixture was gradually allowed to warm to room temperature. See Kim, M. H. and Patel, D. V. (1994) Tet. Lett . 35: 5603-5606. The reaction mixture was diluted with 60 mL of dichloromethane and washed sequentially with saturated aqueous NaCl, saturated aquesous NaHCO 3 and then saturated aqueous NaCl. The dichloromethane extract was dried over Na 2 SO 4 , filtered, and concentrated on a rotary evaporator to provide 390 mg of the desired material.
EXAMPLE 5
General Procedure for Volatilizing Compounds from Halogen Bulb
[0144] A solution of drug in approximately 120 μL dichloromethane is coated on a 3.5 cm×7.5 cm piece of aluminum foil (precleaned with acetone). The dichloromethane is allowed to evaporate. The coated foil is wrapped around a 300 watt halogen tube (Feit Electric Company, Pico Rivera, Calif.), which is inserted into a glass tube sealed at one end with a rubber stopper. Running 60 V of alternating current (driven by line power controlled by a variac) through the bulb for 5-12 s or 90 V for 2.5-3.5 s affords thermal vapor (including aerosol), which is collected on the glass tube walls. (When desired, the system is flushed through with argon prior to volatilization.) Reverse-phase HPLC analysis with detection by absorption of 225 nm light is used to determine the purity of the aerosol.
[0145] Table 1, which follows, provides data from drugs volatilized using the above-recited general procedure.
TABLE 1 AEROSOL AEROSOL COMPOUND PURITY MASS Indomethacin Methyl Ester 99% 1.44 mg Indomethacin Ethyl Ester >99% 3.09 mg Indomethacin Norcholine Ester 100% 2.94 mg Ketoprofen Methyl Ester 99% 4.4 mg Ketoprofen Ethyl Ester 99.65% 4.11 mg Ketoprofen Norcholine Ester 100% 2.6 mg Ketorolac Methyl Ester 100% 3.17 mg Ketorolac Ethyl Ester >99% 5.19 mg Ketorolac Norcholine Ester 100% 1.64 mg Apomorphine Diacetate-HCl 94% 1.65 mg Apomorphine Diacetate 96.9% 2.03 mg
EXAMPLE 6
General Procedure for Hydrolysis Studies of Drug Esters
[0146] Drug ester (20 μL, 10 mM acetonitrile) is added to 1 mL PBS solution (pH 7.5) at room temperature. At intermittent time points, an aliquot of the resulting mixture is injected into an HPLC to obtain the ratio of drug ester to drug acid or drug alcohol. An Arrhenius plot of the data provides a t 1/2 for hydrolysis. Table 2 below provides t 1/2 values for a variety of compounds.
TABLE 2 COMPOUND t 1/2 Ketoprofen Methyl Ester >48 h Ketoprofen Ethyl Ester >48 h Ketoprofen Norcholine Ester 315 min. Ketorolac Methyl Ester >48 h Ketorolac Ethyl Ester >48 h Ketorolac Norcholine Ester 14 min Indomethacin Methyl Ester >48 h Indomethacin Ethyl Ester >48 h Indomethacin Norcholine Ester 315 min. Apomorphine Diacetate >48 h
EXAMPLE 7
General Procedure for Human Serum Hydrolysis Studies of Drug Esters
[0147] Human serum (2.34 mL) is placed in a test tube. To the serum is added 260 μL of a 10 mM solution of drug ester in acetonitrile. The tube is placed in a 37° C. incubator, and at various time points a 500 μL aliquot is removed. The aliquot is mixed with 500 μL methanol, and the mixture is vortex mixed and centrifuged. A sample of the supernatant is analyzed by HPLC obtain the ratio of drug ester to drug acid or drug alcohol. An Arrhenius plot of the data provides a t 1/2 for hydrolysis. Table 3 below provides t 1/2 values for a variety of compounds.
TABLE 3 COMPOUND t 1/2 Ketoprofen Methyl Ester 144 min Ketoprofen Ethyl Ester 224 min Ketoprofen Norcholine 37 s Ester Ketorolac Ethyl Ester 90 min Ketorolac Norcholine Ester 13 s Indomethacin Methyl Ester >48 h Indomethacin Ethyl Ester >48 h Indomethacin Norcholine 23 min Ester Apomorphine Diacetate 76.2 s
EXAMPLE 8
General Procedure for Screening Drug Esters for Aerosolization Preferability
[0148] Drug ester (1 mg) is dissolved or suspended in a minimal amount of a suitable solvent (e.g., dichloromethane or methanol). The solution or suspension is pipeted onto the middle portion of a 3 cm by 3 cm piece of aluminum foil. The coated foil is wrapped around the end of a 1½ cm diameter vial and secured with parafilm. A hot plate is preheated to approximately 300° C., and the vial is placed on it foil side down. The vial is left on the hotplate for 10 s after volatilization or decomposition has begun. After removal from the hotplate, the vial is allowed to cool to room temperature. The foil is removed, and the vial is extracted with dichloromethane followed by saturated aqueous NaHCO 3 . The organic and aqueous extracts are shaken together, separated, and the organic extract is dried over Na 2 SO 4 . An aliquot of the organic solution is removed and injected into a reverse-phase HPLC with detection by absorption of 225 nm light. A drug ester is preferred for aerosolization where the purity of the drug ester aerosol isolated by this method is greater than 85%. Such a drug ester has a decomposition index less than 0.15. The decomposition index is arrived at by subtracting the percent purity (i.e., 0.85) from 1.
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The present invention relates to the delivery of drug esters through an inhalation route. Specifically, it relates to aerosols containing drug esters that are used in inhalation therapy. In a method aspect of the present invention, a drug ester is delivered to a patient through an inhalation route. The method comprises: a) heating a coating of a drug ester, on a solid support, to form a vapor; and, b) passing air through the heated vapor to produce aerosol particles having less than 5% drug ester degradation product. In a kit aspect of the present invention, a kit for delivering a drug ester through an inhalation route is provided which comprises: a) a thin coating of a drug ester composition and b) a device for dispensing said thin coating as a condensation aerosol.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to resistance welding apparatus of a kind in which contact pressure, between a pair of metal surfaces joined, is imposed through the medium of an intermediate electrode wire guided by an electrode wheel on each side of the metal surfaces.
This kind of welding apparatus is particularly useful for welding steel sheet materials that have a metallic coating such as zinc, tin or chromium bearing layers (TFS) because the intermediate wire electrode is progressed around the electrode wheels to present a clean contact surface during welding and then take away any contaminating oxides or fused coating.
2. Description of the Invention
Particularly successful machines are sold by SOUDRONIC AG of Switzerland and described in British Pat. Nos. 910,216, 1,124,885 and 1,426,356 to which the reader is directed for further details. This kind of apparatus is widely used in the can making industry in which rectangular blanks of tinplate of TFS are roll formed to a cylinder having an overlapped side seam which is mash welded to make a can body.
European patent application No. 0041893 considers the problem arising when relatively small can bodies are being welded, namely the fact that the space inside the can body can only accommodate an electrode wheel that is smaller than the outside electrode wheel so that the difference in amplitude between the ridges and hollows along the weld, as created by each weld pulse, is accentuated on the interior surface of the weld. An internal electrode comprising support means to support an internal welding wheel which preferably rotates and a support roll is so arranged that the electrode wire passes across the welding wheel at which welding takes place, and continues its passage to the support roll while remaining in contact with the weld to improve the geometry of the weld and therefore its homogeneity.
French Patent published application No. 2553320 considers the distribution of energy arising in a lap welding process when the external electrode wheel is bigger than the internal welding wheel. The Applicants have surmised that the asymmetry of the contact surfaces may lead to problems with the quality of the spot welds, because energy released at the interface between the electrode with a smaller radius of curvature and the edge which it contacts is greater than the energy released at the interface between the second edge of the body and the electrode with a greater radius of curvature. As the material thickness t of each metal margin overlapped is reduced in the finished weld to a total wall thickness of about 1.5 t, this model is reasonable and leads to the conclusion that the maximum heating effect will be off-centre from the can metal to can metal contact at which it is needed. Accordingly, it is proposed in French Patent application No. 8316357 that the resistance of the coatings on the sheet metal to be welded should be selected to compensate for the difference between the internal and external contact areas.
The prior art apparatus uses costly mercury contacts to deliver electricity to the rotating electrode wheels. As one of the wheels is inside the can bodies being made there is a risk that any leakage of mercury will seriously contaminate a can interior.
SUMMARY OF THE INVENTION
The present invention sets out firstly to avoid use of a mercury contact; to permit reduction of the bulk of the internal electrode so that can bodies of smaller diameters such as say 45 or even 35 mm may be welded; and to balance the weld geometry.
Accordingly, the present invention provides apparatus for resistance welding an elongate seam in a tubular article, said apparatus comprising a first electrode wheel outside the article, a second electrode inside the article and an electrode wire arranged to pass over the electrodes to provide surfaces of contact between the electrodes and the seam material characterised in that the second electrode includes a stationary block having a guide surface of like curvature to that of the electrode wheel so that the contact area of a wire passing over the guide surface with the seam material is substantially equal to the contact area of wire passing over the external wheel with the exterior of the seam material. The benefits arising are that mercury bearings are not used inside the tubular article, and because the internal and external contact areas are substantially equalised a symmetrical distribution of welding energy is established about the metal to metal contact.
If desired, a preferably horizontal or gradually sloping portion may follow the curved guide surface of the solid block in a tangential direction so that the weld is smoothed.
In one embodiment of the apparatus the block is mounted in a holding means which also supports a freely rotating roller round which the electrode wire turns to return under the block for re-use or disposal.
The block or the supporting means or both, may be cooled by cooling means.
The stationary block may comprise a wear plate profiled to the desired curvature and to each side thereof a side plate to give lateral restraint to the wire as it passes along the profiled surface. The separable wear plate is cheap and convenient to replace when worn because it is accessible.
After use at the welding position on the block the wire may be returned under the block to pass through a guiding groove in the underside of the electrode for re-reeling or re-use.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the apparatus will now be described by way of example and with reference to the accompanying drawings in which:
FIG. 1 is a cut-away side view of an internal electrode similar to that described in European Patent Publication No. 0041893A1;
FIG. 2 is a similar view of an internal electrode according to this invention;
FIG. 3 is a perspective view of a first embodiment of a guide block;
FIG. 4 is a perspective view of a second embodiment of a guide block;
FIG. 5 is a sectioned side view of the guide blocks of FIGS. 3 and 4;
FIG. 6 is a plan view of the internal electrode of FIG. 2 but slightly modified by addition of an end cap;
FIG. 7 is a side view of the internal electrode of FIG. 6;
FIG. 8 is a fragmentary section on line EE in FIG. 2;
FIG. 9 is a fragmentary section on line DD in FIG. 2; and
FIGS. 10a and 10b are diagrammatic views permitting comparison of the weld geometry of prior art and the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 10a shows an upper welding wheel 1 which typically has a diameter of 85 mm, a lower welding roll 2 which typically has a diameter of 62 mm. A continous electrode wire 3 is wound round each roll so that the lap joint layers of metal 4, 5 are pinched between the wire on upper and lower rolls to create a mash weld. Before welding, each layer 4, 5 of metal has a thickness "t" commonly in the range 0.15 mm to 0.35 mm for ferrous based sheet metals such as tinplate or chrome/chrome oxide coated steels called TFS. After welding the finished weld thickness is typically about 1.5 t.
In FIG. 10a it will be seen that the portion of wire 3 on the upper or larger roll 1 makes a greater arc of contact than the portion of wire on the lower or smaller roll 2 so the current density at R1 between metal 4 and wire on upper roll 1 is less than the current density at R2 between the metal 5 and the wire on the lower roll 2. Furthermore the current path "I", as drawn is asymetric so the heat generated is not centred on the metal 4 to metal 5 contact R3 as is desirable.
One remedy would be to make both rolls 1 and 2 the same size but it is desirable to keep upper roll 1 large in diameter so that it is able to dissipate heat. This requirement limits the choice of the size of the lower roll. Current practice uses a lower roll of about 62 mm diameter so that the minimum internal diameter of can bodies that may be welded is just a bit bigger than 62 mm, say 65 mm, so that each body clears the underside of the lower or inner roll 2, as can be seen in FIG. 1 which will be discussed later.
In FIG. 10b the rotating lower roll 2 of FIG. 10a has been replaced by a stationary electrode 6 having an arcuate surface over which the electrode wire 3 slides to make contact during welding. The arcuate surface substantially replicates the curvature of the upper roll 1 so that the metal to wire contact resistances R are equalised. The curvatures of upper roll 1 and stationary electrode 6 being substantially equal, the contact areas are also equal so that the current path I2 is symmetrical so the heating effect is centred on the metal 4 to metal 5 contact R3 as is desirable.
FIG. 1 shows prior art apparatus during welding of the side seam of a can body 7. Components corresponding to like components in FIG. 10a are denoted by the same part numbers. A first electrode wheel 1 is supported in a frame (not shown) above the line of travel of the can body 7, from left to right as shown in FIG. 1. The external or first electrode wheel 1 cooperates with an internal or second electrode wheel 2 which is supported for rotation in an internal electrode frame 8 mounted on a mandrel 9 shown in part only. The frame 8 also supports a guide roll 10 from the underside of which wire 3 is fed to the topside of roll 2 and onwards across a support rail 11 to a turn roll 12 which returns the wire across the underside of roll 2 for re-reeling or re-use. As was apparent in FIG. 10a the outer electrode wheel 1 is larger in diameter than the inner roll 2. Both the inner electrode wheel 2 and outer electrode wheel 1 not only rotate to deliver electrode wire 3 to the roll pinch zone at which welding takes place but also delivers electrical power for resistance welding. The inner roll 2 is mounted on a stationary shaft and mercury contact bearings deliver current from the stationary shaft to the rotating wheel so it will be seen from FIG. 1 that any leakage of mercury from the inner bearing will contaminate the interior of the can body.
The apparatus shown in FIG. 2 is similar to that shown in FIG. 1 so like functioning components are denoted by the same part numbers, namely an external electrode wheel 1 moving an electrode wire 3 and an internal electrode comprising the frame 8 in which a guide roll 10 guides the wire 3 up over a support rail 11 to a turn wheel 12 which returns the wire.
However, the apparatus of FIG. 2 uses a stationary contact block 6 instead of a roll so that no mercury contact is required. A similar grooved block 13 is mounted on the underside of the frame 8 to guide returned wire from the turn roll 12 to the re-reeling position.
FIG. 3 shows a block 6 machined from a single piece of metal to have a body 14, a guide surface 15 and side flanges 16, 17 to restrain lateral movement as the wire 3 passes along the guide surface 15. FIG. 4 shows an alternative construction of the block 6 which comprises a guide plate portion 15a typically 1.9 mm wide and fixed between a pair of side plates 16a, 17a of similar thickness by means of countersunk screws. Whilst pre-assembly by means of the screws 18 may be convenient, the final fitting of cap screws through holes 19, to fix the block to the support 34, may be all that is necessary. The side plates 16a may, if desired, have passages formed in them to permit delivery of inert gas to shroud the weld.
FIG. 5 shows the profile of the guide surface 15 to have a curvature of radius R which is substantially equal to the radius of the outer electrode wheel 1. Therefore the contact areas of wire guided in block 6 and wire on the wheel 1 with the material to be welded are substantially equalised as discussed with reference to FIG. 10b.
It is necessary for any material chosen for manufacture of block 6 to (a) resist wear caused by the copper wire sliding over it; (b) have a low coefficient of friction, preferably about 0.1; and (c) to have a low contact resistance with respect to copper wire, preferably less than 250 micro ohms. One suitable material for the block 6 or the guide portion 15a is cemented tungsten carbide in a matrix of cobalt or preferably nickel which has a lower electrical resistance. However, other materials may be suitable.
The plan view FIG. 6 and side view FIG. 7 serve to show the internal electrode in sufficient detail to permit understanding of the relative positions of the guide roll 10, block 6 and turn roll 12.
It is desirable to incline the guide surface 15 and groove in external wheel 1 at opposed angles of about 0.5° to the line of travel of the can 7 so that the overlapped material of the can body is pulled into correct alignment to ensure that the weld is formed with a consistent overlap to make a true cylindrical body. This angle of inclination may be achieved on mounting or may be machined into the groove of the block 6 of FIG. 3 or alternatively machined into the side plate 16 of the composite block of FIG. 4.
In FIG. 7 it can be seen that the frame 8 comprises four parts. At the left hand end as shown in FIG. 7 a first part 20 houses a bearing 21 and is adapted for fixing to a welding arm portion not shown. A second frame part 22 is fixed by studs 23 to the first part 20 at approximately the centre of a support 34 which supports the block 6. This location joint is chosen to facilitate assembly of the support 34 to the frame 8 and connection of water cooling and inert gas supply lines (not shown). The support 34 has round stems 24 which fit in the frame part 20, 22 in like manner to the prior art roll and axle which it replaces. In order to prevent rotation of the support 34 a side block 32 is fixed to the support 34 by means of cap screws 33 which also fix the block 6 to the support 34. The side block 32 may abut the frame members or, as shown in FIGS. 6 and 7, abut the support rail 11 to prevent rotation.
In FIG. 9 the lateral relationship of the side block 32 to the block 6 is clearly shown. Also shown in FIG. 9 are passages 26 for water or other coolant. Passages 27 for nitrogen or other inert gas used to shroud the weld to minimise oxidation may be provided in block 6 as is best seen in FIG. 4 but may, if desired, extend into the rail 11 as shown in FIG. 8.
A third frame part 25 connects the second part to a fourth part or end cap 28, the joint between the third and fourth parts being centred on the bearing of the turn roll 12. The third frame part 25 also provides fixing points for fixing the support rail 11.
In FIG. 8 the support rail 11 can be seen to comprise a substantially flat surface 30 alongside which there extends a flange 31 which delivers shrouding gas through passages 27.
Referring again to FIG. 10b it will be noticed that the "inside" stationary electrode 6 has a periphery made up of four distinct arcs of differing curvature A1 A2 A3 A4. Arc A1 is that of the support surface 15a in FIGS. 3/4 and of a radius approximate by half the diameter of upper roll 1 (e.g. 42.5 mm radius). Arcs A2 and A3 are so arranged that the wire is always at a tangent to each arc. In FIG. 10b this static electrode is symmetrical so arcs A1 and A3 are identical and arcs A2 and A4 are also identical.
Clearly the static inner electrode, devoid of wheels as shown in FIG. 10b is commercially attractive because it has no moving parts and so should be cheaper to make than the moving rolls of other embodiments. However, arcs A1, A2 and part of A3 and A4 all create a frictional drag on the progress of the wire. In order to minimise frictional effects one or several rolls may be introduced if desired, for example at the start of each arc or alternatively a single fairly large turn roll close spaced to block 6 of arc A1.
Arc A1 may, if desired, include a curved portion followed by a substantially horizontal or slightly sloping ramp to maintain wire contact after welding as shown by dashed lines in FIG. 5. Ideally any support rail surface provided should extend in a direction tangential to the curvature of the block 6.
While the presently preferred embodiment of the present invention has been illustrated and described, modifications and variations thereof will be apparent to those skilled in the art given the teachings herein, and it is intended that all such modifications and variations be encompassed within the scope of the appended claims.
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Apparatus for resistance welding an elongate seam in a tubular article, comprises a first electrode wheel outside the article, a second electrode inside the article and a continuous electrode wire arranged to pass over the electrodes to provide surfaces of contact between the electrodes and seam material. The second electrode has a stationary block having a guide surface of like curvature to that of the outer electrode wheel so that the contact arcs of wire passing over the guide surface with the seam material is substantially equal to the contact area of wire passing over the external wheel. The use of this stationary inner electrode improves the weld of geometry and permits welding of can bodies of relatively smaller diameter without use of mercury contact bearings.
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BACKGROUND OF DISCLOSURE
[0001] 1. Field of the Disclosure
[0002] Embodiments disclosed herein relate generally to thrusters that apply a force to a drill bit during the drilling of an underground formation. In another aspect, embodiments disclosed herein relate to control of a thrust force applied to a drill bit by a thruster. More specifically, embodiments disclosed herein relate to controlling a pressure or differential pressure across a thrust piston, thereby limiting the maximum applied thrust force.
[0003] 2. Background
[0004] Hydraulic thrusters are used for applying a force to an earth boring drill bit, independent of the drill string weight. Although thrusters may be used during vertical or inclined drilling, hydraulic thrusters are generally advantageous in horizontal or near-horizontal drilling. During horizontal drilling, especially in long horizontal sections, a significant portion of the weight of the drill stem is directed toward the low side of the hole, detracting from the weight available for bit thrust. Hydraulic thrusters allow for extended reach drilling, the drilling of multiple horizontal wells from a single platform, decreasing the drilling costs associated with producing reservoirs that are offshore, in arctic regions, mountains, or near large cities.
[0005] The thruster is a telescoping tube arrangement that allows the drill bit to advance while the tubing string is supported in a rather stationary position at the surface. When the thruster has advanced its full stroke, or a notable portion thereof, the drill string is lowered from the surface, causing the upper end of the thruster to slide down and reset the thruster for the next stroke. When the drilling kelly or the stand being drilled down by the top drive reaches the drill rig floor, circulation is interrupted and another piece of tubing is added to the string at the surface or the coiled tubing is further unspooled into the wellbore. This drilling procedure also causes the thruster to reset.
[0006] Hydraulic thrusters are described in, for example, U.S. Pat. No. 4,615,401 and patents referenced therein (U.S. Pat. Nos. 3,298,449, 3,399,738, 3,797,589, 3,799,277, 4,040,494, and 4,040,495), each of which is assigned to the assignee of the present invention, and each of which is incorporated herein by reference. In the '401 patent, the hydraulic thruster includes a mandrel and sleeve forming two expandable chambers with wall anchors annularly disposed about the sleeve responsive to a pressure differential between a chamber and the bore hole pressure. Valves and actuators are provided to extend and retract a piston between two extremes of relative axial motion between the mandrel and sleeve.
[0007] Hydraulic thrusters are also described in U.S. Pat. No. 5,205,364. In the '364 patent, the hydraulic thruster includes a telescoping assembly for transmitting hydraulic force to the drill bit at the bottom of the tool. The internal hydraulic characteristics of the tool may be varied to vary the force exerted during extension and retraction of the telescoping assembly. The hydraulic characteristics are varied by varying the surface area within the drill tool on which the flow of drilling mud may act when producing the hydraulic force.
[0008] Other patents describing thrusters or equipment for controlling force or weight on the bit, for example, may include U.S. Pat. Nos. 5,316,094, 6,601,652, 7,156,181, 5,476,148, 5,884,716, 5,806,611, 6003,606, 6,230,813, and 6,286,592, and U.S. Patent Application Publication No. 20010045300.
[0009] Referring now to FIG. 1 , a simplified cross-sectional view of a prior art thruster 1 is illustrated. Thruster 1 , shown in the retracted position, may include an inner mandrel assembly 2 , which may include one or more tubular components. Threads 3 may connect inner mandrel assembly 2 to the lower drill stem (not shown) toward the bit (not shown). Threads 4 may connect inner mandrel assembly 2 to the upper drill stem (not shown). Inner mandrel assembly 2 is disposed in and is axially movable with respect to outer tubular assembly 5 . One or more anchor pistons 6 may be provided to anchor thruster 1 with respect to the hole wall (not shown). Drilling fluid supplied to the bore 2 A of inner mandrel 2 and to the drill bit (not shown) defines a high pressure area, and drilling fluid returning from the bit in the annulus 7 formed between the outer tubular assembly 6 and the hole wall defines a low pressure area. During thrusting, thrust mechanism 8 may be used to allow the high pressure drilling fluid into chamber A, allowing fluid in chamber B to escape to annulus 7 , thus creating a pressure differential across thrust mechanism 8 , causing the inner mandrel 2 to advance in direction 9 , and putting weight on the bit corresponding to the thrust force generated by the pressure differential.
[0010] A cross-sectional view of a simplified thrust mechanism 8 , which may be used in the thruster of FIG. 1 , is illustrated in FIG. 2 . Thrust mechanism 8 may include an inner tubular member 12 and an outer tubular member 14 . Drilling mud flowing through the bore 16 of inner tubular member 12 flows to the drill bit (not shown), and returns to the surface via annulus 18 , such as between outer tubular member 14 and a drill casing (not shown). When mud is flowing through thruster 1 ( FIG. 1 ), bore 16 is at a higher pressure than fluid returning through annulus 18 . A piston 20 , separating a first fluid chamber 22 and a second fluid chamber 24 , may transmit an axial force 26 to inner tubular member 12 . During thrusting, high pressure drilling mud flows from the bore 16 of the thruster 1 through inlet 28 into first fluid chamber 22 , displacing fluid in second fluid chamber 24 through outlet 30 and causing the inner tubular member 12 to advance in the direction of axial force 26 . The axial force 26 that is generated, for example, may be a function of the differential pressure between the fluid in bore 16 and annulus 18 .
[0011] Many of the patents cited above use such a differential pressure to control the force applied to the drill bit. Although not shown in FIG. 2 , thrust mechanism 8 may typically include ball valves, springs, and other mechanisms to control the flow of fluid into and from the high and low pressure chambers, respectively, during thrusting and retraction. One problem associated with this type of thruster technology includes the need to estimate the pressure and required thrust force prior to drilling. The thruster and the associated internal parts are generally selected and fabricated at the surface prior to installation on a drill string, and many of the parts used to control fluid flow, such as springs, check valves, flow orifices, and others, are sized and selected based on an expected downhole pressure.
[0012] Often, an actual downhole pressure differs from the expected downhole pressure. The difference between actual and expected downhole pressure, even by as little as 25 or 50 psi, may result in ineffective control of the force applied to the drill bit by the thruster, often as a result of the thrust mechanism fully opening or fully closing. Additionally, fluctuations in pressure drop across the bit and changes in the weight of the drilling fluid used (and hence bore pressure) may also result in ineffective control of the force applied to the drill bit by the thruster. Ineffective thruster control may lead to stalls, motor wear, stuck bits, and inefficient rate of penetration, among other problems known to those skilled in the art.
[0013] Various methods and apparatus have been proposed to compensate for a change in downhole conditions and to minimize the effect such changes have on the operation of the thruster and the force applied to the drill bit. For example, a pressure-modulation valve assembly is disclosed in U.S. Pat. No. 6,102,138. Such methods and apparatus unnecessarily increase the total number of drilling components of a drill string, where the additional apparatus may be prone to failure or malfunction due to various conditions encountered during drilling.
[0014] Accordingly, there exists a need for a thruster that may control the force applied to a drill bit independent of the downhole pressure or the pressure drop across the motor and bit. Additionally, there exists a need for a thruster that may control the force applied to the bit independent of the pressure of the supplied drilling fluid.
SUMMARY OF THE DISCLOSURE
[0015] In one aspect, embodiments disclosed herein relate to a drilling system, including: a drill bit; and a thruster to apply a force to the drill bit. The thruster may include: an inner tubular member disposed within and configured to axially move within an outer tubular member; a thrust piston to transmit a hydraulic force to the inner tubular member, the thrust piston separating an upstream fluid chamber and a downstream fluid chamber between the inner and outer tubular members; at least one pressure switch fluidly connected to the downstream fluid chamber to control flow of a fluid to and from the downstream fluid chamber via at least one fluid inlet and at least one fluid outlet.
[0016] In another aspect, embodiments disclosed herein relate to a thruster, including: an inner tubular member disposed within and configured to axially move within an outer tubular member; a thrust piston to transmit a hydraulic force to the inner tubular member, the thrust piston separating an upstream fluid chamber and a downstream fluid chamber between the inner and outer tubular members; a downstream valve member mechanically coupled to a downstream magneto-actuator and disposed in the downstream fluid chamber; and at least one pressure switch fluidly coupled to the downstream fluid chamber to control a position of the downstream valve member via the magneto-actuator; wherein the position of the downstream valve member affects a flow of a fluid to and from the downstream fluid chamber via at least one fluid inlet and at least one fluid outlet.
[0017] In another aspect, embodiments disclosed herein relate to a process to drill an underground formation. The process may include: supplying a fluid to a thruster, wherein the thruster includes: an inner tubular member disposed within and configured to axially move within an outer tubular member; a thrust piston to transmit a hydraulic force to the inner tubular member, the piston separating an upstream fluid chamber and a downstream fluid chamber between the inner tubular member and the outer tubular member; at least one pressure switch fluidly connected to the downstream fluid chamber; and regulating a flow of the fluid to and from the downstream fluid chamber in response to a signal from the at least one downstream pressure switch to maintain the hydraulic force applied to the inner tubular member proximate a hydraulic force set point.
[0018] Other aspects and advantages will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a simplified schematic drawing of a prior art thruster.
[0020] FIG. 2 is a schematic drawing of a simplified thrust mechanism that may be used in the prior art thruster of FIG. 1 .
[0021] FIG. 3 is a simplified schematic drawing of a thruster according to embodiments disclosed herein.
[0022] FIG. 3A is a simplified schematic drawing of an actuator useful in embodiments of the thrusters described herein.
[0023] FIG. 3B is a simplified schematic drawing of an actuator useful in embodiments of the thrusters described herein.
[0024] FIG. 3C is a simplified schematic drawing of an actuator useful in embodiments of the thrusters described herein.
[0025] FIG. 4 is a simplified schematic drawing of a thruster according to embodiments disclosed herein.
[0026] FIG. 5 is a simplified schematic drawing of a thruster according to embodiments disclosed herein.
[0027] FIG. 6 is a simplified schematic drawing of a thruster according to embodiments disclosed herein.
DETAILED DESCRIPTION
[0028] In one aspect, embodiments disclosed herein relate to control of a thrust force applied to a drill bit by a thruster. More specifically, embodiments disclosed herein relate to controlling a pressure or differential pressure across a thrust piston, thereby limiting the maximum applied thrust force. Other embodiments disclosed herein relate to a method of drilling a formation using a thruster that may limit the thrust force applied to the bit independent of bore and annulus fluid pressures.
[0029] As described above, prior art thrusters generate an axial force based upon a difference in bore and annulus pressures. In contrast, thrusters disclosed herein include mechanisms to regulate the pressure in one or both of the upstream and downstream fluid chambers. The axial force generated according to embodiments disclosed herein, for example, may be a function of the differential pressure between the fluid in the upstream and downstream fluid chambers.
[0030] Referring now to FIG. 3 , a simplified schematic drawing of a thruster 50 according to embodiments disclosed herein is illustrated. Thruster 50 may include an inner tubular member 52 and an outer tubular member 54 . Drilling mud flowing through the bore 56 of inner tubular member 52 flows to the drill bit (not shown), and returns to the surface via annulus 58 , such as between outer tubular member 54 and a drill casing (not shown). When mud is flowing through thruster 50 , bore 56 is at a higher pressure than fluid returning through annulus 58 . A thrust piston 60 , separating an upstream fluid chamber 62 and a downstream fluid chamber 64 , may transmit an axial force 66 to inner tubular member 52 . During thrusting, high pressure drilling mud flows from the bore 56 of the thruster 50 through inlet 68 into upstream fluid chamber 62 , displacing low pressure fluid in downstream fluid chamber 64 through outlet 70 and causing the inner tubular member 52 to advance in the direction of axial force 66 .
[0031] To regulate thrust force, or differential pressure between the upstream chamber 62 and the downstream chamber 64 , for example, thruster 50 may include a pressure switch 72 , which may be in fluid communication with the downstream fluid chamber 64 . Pressure switch 72 , in some embodiments, may be a pressure limit switch, activating at a pressure set point. When the fluid in chamber 64 reaches a predetermined set point pressure, the pressure switch 72 may actuate. Upon actuation, pressure switch 72 may send an electronic signal to a control mechanism (not shown) for regulating the flow of fluid into or out of downstream fluid chamber 64 through downstream inlet 74 and outlet 70 .
[0032] By sending a signal to regulate the flow of fluid into and out of downstream fluid chamber 64 , pressure switch 72 may limit the thrust force applied to the drill bit, thus avoiding the full on or full off scenarios often encountered with prior art thrusters. For example, by limiting the flow of fluid through outlet 70 , pressure will build in downstream fluid chamber 64 , limiting the applied thrust force. As another example, by allowing fluid to flow in through inlet 74 , pressure will also increase in downstream fluid chamber 64 , due to high pressure fluid in bore 56 , limiting the applied thrust force.
[0033] The control mechanism may in turn send a signal or a current to a valve member 76 to regulate the flow of fluid into and out of downstream fluid chamber 64 . Valve member 76 may include, for example, an actuator 78 , a drive rod 80 , and a gate member 82 . The signal or current transmitted to valve member 76 may cause actuator 78 to extend or contract, as illustrated by the arrows, causing a similar displacement in drive rod 80 , causing gate 82 to open and/or close fluid inlet 74 and/or fluid outlet 70 . Other means of regulating fluid flow using a signal from a pressure switch are also contemplated herein.
[0034] Actuator 78 may include any one of several types of actuators responsive to electronic signals or currents. For example, actuator 78 may include magnetostrictive actuators, shape memory alloy actuators, and linear motor actuators. Examples of each of these are illustrated in FIGS. 3A-3C .
[0035] As illustrated in FIG. 3A , actuator 78 may include a magnetostrictive actuator, including permanent magnets 84 , drive rod 85 , coil 86 , preload springs 87 , and output rod 88 . Upon application of a current through coil 86 , drive rod 85 may expand or contract in response to the magnetic field generated, thereby displacing output rod 88 to control the position of the gate member 82 and thus control the flow of fluid to and from the downstream cavity 64 .
[0036] As illustrated in FIG. 3B , actuator 78 may include a shape memory alloy actuator, including shape memory alloy spring 90 , piston 92 , and drive rod 94 . Upon application of an electrical current, shape memory alloy spring may expand or contract, thereby displacing piston 92 and drive rod 94 to control the position of the gate member 82 , and thus control the flow of fluid to and from the downstream cavity 64 .
[0037] As illustrated in FIG. 3C , actuator 78 may include a linear motor actuator, including a stationary member 96 , a motive member 97 , and a drive rod 98 . Linear motor actuators may include flat linear motor actuators and, as illustrated, tubular linear motor actuators. In some embodiments, a signal sent from the control mechanism to the linear motor actuator may control the position of the motive member 97 , and thus drive rod 98 , with respect to stationary member 96 . In other embodiments, a signal sent from the control mechanism to the linear motor actuator may control an output force exerted on drive rod 98 . In this manner, the linear motor actuator may control the position of gate member 82 , and thus control the flow of fluid to and from the downstream cavity 64 .
[0038] Referring now to FIG. 4 , a simplified schematic drawing of a thruster 100 according to embodiments disclosed herein is illustrated. Thruster 100 may include an inner tubular member 102 and an outer tubular member 104 . Drilling mud flowing through the bore 106 of inner tubular member 102 flows to the drill bit (not shown), and returns to the surface via annulus 108 , such as between outer tubular member 104 and a drill casing (not shown). When mud is flowing through thruster 100 , bore 106 is at a higher pressure than fluid returning through annulus 108 . A thrust piston 110 , separating an upstream fluid chamber 112 and a downstream fluid chamber 114 , may transmit an axial force 116 to inner tubular member 102 . During thrusting, high pressure drilling mud flows from the bore 106 of the thruster 100 through inlet 118 into upstream fluid chamber 112 , displacing low pressure fluid in downstream fluid chamber 114 through outlet 120 and causing the inner tubular member 102 to advance in the direction of axial force 116 .
[0039] To regulate thrust force, or differential pressure between the upstream chamber 112 and the downstream chamber 114 , for example, thruster 100 may include a pressure switch 122 , which may be in fluid communication with each of the upstream fluid chamber 112 and the downstream fluid chamber 114 . Pressure switch 122 , in some embodiments, may be a differential pressure limit switch, activating at a differential pressure set point. When the differential pressure of the fluid in upstream and downstream chambers 112 , 114 reaches a pre-determined differential pressure set point, the pressure switch 122 may actuate. Upon actuation, pressure switch 122 may send an electronic signal to a control mechanism (not shown) for regulating the flow of fluid into or out of downstream fluid chamber 114 through downstream inlet 124 and outlet 120 .
[0040] By sending a signal to regulate the flow of fluid into and out of downstream fluid chamber 114 , pressure switch 122 may regulate the thrust force applied to the drill bit, as described above.
[0041] The control mechanism may in turn send a signal or a current to a valve member 126 to regulate the flow of fluid into and out of downstream fluid chamber 114 . Valve member 126 may include, for example, an actuator 128 , a drive rod 130 , and a gate member 132 . The signal or current transmitted to valve member 126 may cause actuator 128 to extend or contract, as illustrated by the arrows, causing a similar displacement in drive rod 130 , causing gate 132 to open and/or close fluid inlet 124 and/or fluid outlet 120 .
[0042] Referring now to FIG. 5 , a simplified schematic drawing of a thruster 150 according to embodiments disclosed herein is illustrated. Thruster 150 may include an inner tubular member 152 and an outer tubular member 154 . Drilling mud flowing through the bore 156 of inner tubular member 152 flows to the drill bit (not shown), and returns to the surface via annulus 158 , such as between outer tubular member 154 and a drill casing (not shown). When mud is flowing through thruster 150 , bore 156 is at a higher pressure than fluid returning through annulus 158 . A thrust piston 160 , separating an upstream fluid chamber 162 and a downstream fluid chamber 164 , may transmit an axial force 166 to inner tubular member 152 . During thrusting, high pressure drilling mud flows from the bore 156 of the thruster 150 through inlet 168 into upstream fluid chamber 162 , displacing low pressure fluid in downstream fluid chamber 164 through outlet 170 and causing the inner tubular member 152 to advance in the direction of axial force 166 .
[0043] To regulate thrust force, or differential pressure between the upstream chamber 162 and the downstream chamber 164 , for example, thruster 150 may include a pressure switch 172 , which may be in fluid communication with the downstream fluid chamber 164 . Pressure switch 172 , in some embodiments, may be a pressure limit switch, activating at a pressure set point. When the fluid in chamber 164 reaches a pre-determined set point pressure, the pressure switch 172 may actuate. Upon actuation, pressure switch 172 may send an electronic signal to a control mechanism (not shown) for regulating the flow of fluid into or out of downstream fluid chamber 164 through downstream inlet 174 and outlet 170 . Thruster 150 may also include a pressure switch 173 , which may be in fluid communication with the upstream fluid chamber 162 . When the fluid in chamber 162 reaches a pre-determined set point pressure, the pressure switch 173 may actuate, sending an electronic signal to a control mechanism (not shown) for regulating the flow of fluid into or out of upstream fluid chamber 162 through upstream inlet 168 and upstream outlet 175 . By sending a signal to regulate the flow of fluid into and out of upstream fluid chamber 162 and downstream fluid chamber 164 , pressure switches 173 , 172 may each, separately or collectively, limit the thrust force applied to the drill bit.
[0044] The control mechanism may in turn send a signal(s) or a current(s) to valve members 176 , 177 to regulate the flow of fluid into and out of one or both of upstream and downstream fluid chambers 162 , 164 . Valve members 176 , 177 may include, respectively, for example, actuators 178 , 179 , drive rods 180 , 181 , and gate members 182 , 183 . The signal(s) or current(s) transmitted to valve members 176 , 177 may cause actuators 178 , 179 to extend or contract, as illustrated by the arrows, causing a similar displacement in drive rods 180 , 181 , causing gates 182 , 183 to open and/or close fluid inlets 174 , 175 and/or fluid outlets 170 , 171 . In some embodiments, valve action on both sides of the thrust piston 160 is required in order to have hydraulic volume flow in the upstream and downstream chambers 162 , 164 .
[0045] Referring now to FIG. 6 , a simplified schematic drawing of a thruster 200 according to embodiments disclosed herein is illustrated. Thruster 200 may include an inner tubular member 202 and an outer tubular member 204 . Drilling mud flowing through the bore 206 of inner tubular member 202 flows to the drill bit (not shown), and returns to the surface via annulus 208 , such as between outer tubular member 204 and a drill casing (not shown). When mud is flowing through thruster 200 , bore 206 is at a higher pressure than fluid returning through annulus 208 . A thrust piston 210 , separating an upstream fluid chamber 212 and a downstream fluid chamber 214 , may transmit an axial force 216 to inner tubular member 202 . During thrusting, high pressure drilling mud flows from the bore 206 of the thruster 200 through inlet 218 into upstream fluid chamber 212 , displacing low pressure fluid in downstream fluid chamber 214 through outlet 220 and causing the inner tubular member 202 to advance in the direction of axial force 216 .
[0046] To regulate thrust force, or differential pressure between the upstream chamber 212 and the downstream chamber 214 , for example, thruster 200 may include a differential pressure switch 222 , which may be in fluid communication with each of the upstream fluid chamber 212 and the downstream fluid chamber 214 . When the differential pressure of the fluid in upstream and downstream chambers 212 , 214 reaches a pre-determined differential pressure set point, the pressure switch 222 may actuate, sending an electronic signal to a control mechanism (not shown) for regulating the flow of fluid into or out of one or both of upstream and downstream fluid chambers 212 , 214 , thereby limiting the thrust force applied to the drill bit.
[0047] The control mechanism may in turn send a signal(s) or a current(s) to valve members 226 , 227 to regulate the flow of fluid into and out of one or both of upstream and downstream fluid chambers 212 , 214 . Valve members 226 , 227 may include, respectively, for example, actuators 228 , 229 , drive rods 230 , 231 , and gate members 222 , 223 . The signal(s) or current(s) transmitted to valve members 226 , 227 may cause actuators 228 , 229 to extend or contract, as illustrated by the arrows, causing a similar displacement in drive rods 230 , 231 , causing gates 232 , 233 to open and/or close fluid inlets 224 , 225 and/or fluid outlets 220 , 221 . In some embodiments, valve action on both sides of the thrust piston 210 is required in order to have hydraulic volume flow in the upstream and downstream chambers 212 , 214 .
[0048] As described above, operation and control of the thrusters described herein may be affected by remote signals, such as by actuating valves and other thruster components. In some embodiments, the control settings for the valves, actuators, and pressure switches may be adjusted using remote signals.
[0049] In other embodiments, the operation and control of the thrusters described herein may be affected by down-linking a signal from the surface. For example, a signal from the surface may be used to communicate with the thruster control mechanism, such as to influence the forward movement of the thruster to initiate a change in drilling rate, a change in drilling direction, or other drilling parameters, for example. Down-linking signals, in some embodiments, may include a change in pump pressure at the surface held for a given period of time. In other embodiments, down-linking signals may include a positive and/or negative pressure pulses, such as may be actuated by a change in standpipe pressure, for example. In this manner, down-linking may be used to accurately position a well and improve drilling performance.
[0050] Embodiments disclosed herein may include one or more pressure switches and/or differential pressure switches to result in the desired thrust control. In some embodiments, the pressure switches may actuate upon increasing pressure or pressure differential. In other embodiments, the pressure switches may actuate upon decreasing pressure or pressure differential. In yet other embodiments, combinations of pressure switches actuating upon increasing and decreasing pressure differential may be used, such as where a valve member opens upon increasing pressure differential in response to a signal from a first pressure switch, and the valve member closes upon decreasing pressure differential in response to a signal from a second pressure switch. Additionally, embodiments may include pressure switches and differential pressure switches in fluid communication with one or more of the upstream chamber, the downstream chamber, the inner tubular member bore, and the annulus between the outer tubular member and the hole wall, with the pressure switch actuating upon a give pressure or pressure differential so as to regulate thrust force.
[0051] As described above, use of pressure switches and actuators may provide for passive thrust force control. For example, a pressure switch may actuate at a minimum or maximum desired thrust force, sensing a fully opened or fully closed condition, and thereafter adjusting the pressures in the upstream and downstream chambers.
[0052] Embodiments disclosed herein may include one or more actuators to result in active thrust force control. In some embodiments, two or more actuators, of the same or different type, may be used in parallel, such as operating two or more gate members, or in series, such as to achieve a longer stroke length. Additionally, intermediate components may be used intermediate drive rod and gate member, such as lever arms and bell cranks, among others, so as to result in the desired valve action or stroke length.
[0053] Embodiments disclosed herein may include two or more actuators and pressure switches in parallel to control fluid flow into and from a fluid chamber. In some embodiments, the two or more pressure switches may include different pressure set points, such that a valve member may reset prior to a subsequent cycle, for example. Pressure set points may be varied minimally so as to maintain a similar maximum thrust force upon actuation of the various switch/actuator/valve combinations.
[0054] As described above, use of pressure switches and actuators in parallel or series may provide for active thrust force control. For example, when approaching a fully opened or fully closed condition, the pressure switches may actuate, adjusting the pressures in the upstream and downstream chambers and thereby operating the thruster within a desired range of thrust force.
[0055] In other embodiments, two or more actuators and pressure switches may be used in series to control fluid flow into and from a fluid chamber. For example, two or more pressure switches may include different set points, such that actuators extend or contract at different pressure set points. Upon actuation of a first pressure switch/actuator pair, a minimal flow opening may be provided to limit thrust force. If differential pressure continues to increase following actuation of the first pressure switch/actuator pair, a second and subsequent pressure switch/actuator pairs may provide additional flow area to limit the thrust force applied to the bit. In this manner, thrust force may vary less significantly than an on/off type actuator/valve member.
[0056] Although described with reference to the pressure chambers, one skilled in the art will recognize that embodiments of thrusters disclosed herein may include components that may be typically included in thrusters, such as the thrusters described in U.S. Pat. No. 4,615,401 and others mentioned above. For example, thrusters disclosed herein may include anchor assemblies, ball valves, seals, springs and spring assemblies, threaded connections, spacers, snap rings, bearings, pins, valve seats, and rods, among others. Components used to regulate fluid flow during resetting of the thruster may also be included.
[0057] In some embodiments, additional measurement and control devices may also be used to limit or control the thrust force. For example, a sensor measuring rate of penetration may be used to actuate the valve members, thereby controlling the flow of fluid into and from the upstream and downstream fluid chambers. In this manner, rate of penetration may be maintained within a desired range, such as within an optimal range for a particular drill bit. Stroke measurement devices or position sensors may also be used to indicate the thruster position, thereby allowing an operator to slow the rate of thrust toward the end of a stroke.
[0058] In some embodiments, power and currents supplied to the control mechanisms, pressure switches, and actuators may include electrical currents supplied from batteries. In other embodiments, power and currents may be supplied to the control mechanisms, pressure switches, and actuators may include electrical currents supplied from downhole generators, such as turbine generators and the like.
[0059] Advantageously, embodiments disclosed herein may provide for improved thrust force control, or improved control of the weight on bit. Actuators, pressure switches and valve members described herein may advantageously limit the pressure differential between upstream and downstream chambers, thus limiting the thrust force transmitted by the thrust piston to the inner tubular member. Additionally, for embodiments limiting the pressure or pressure differential within each fluid chamber, the maximum thrust force applied may be controlled independent of fluid pressure in the inner bore and the annulus. Embodiments disclosed herein, through limiting applied thrust force, may advantageously maintain weight on bit within a desired range, improving rates of penetration, and decreasing motor wear and the occurrence of stuck bits and stalls, among other common problems known in the art.
[0060] While the disclosure includes a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the present disclosure. Accordingly, the scope should be limited only by the attached claims.
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A drilling system, including: a drill bit; and a thruster to apply a force to the drill bit. The thruster may include: an inner tubular member disposed within and configured to axially move within an outer tubular member; a thrust piston to transmit a hydraulic force to the inner tubular member, the thrust piston separating an upstream fluid chamber and a downstream fluid chamber between the inner and outer tubular members; at least one pressure switch fluidly connected to the downstream fluid chamber to control flow of a fluid to and from the downstream fluid chamber via at least one fluid inlet and at least one fluid outlet.
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BACKGROUND
[0001] The present invention relates generally to smart cards, to a communication device, methods for selecting a communication network to be used by a communication device and a computer program product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] In the drawings, like reference characters generally refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the invention are described with reference to the following drawings, in which:
[0003] FIG. 1 shows a communication device in accordance with an embodiment of the invention;
[0004] FIG. 2 shows a communication system in accordance with an embodiment of the invention;
[0005] FIG. 3 shows a message flow diagram in accordance with an embodiment of the invention; and
[0006] FIG. 4 shows a message flow diagram in accordance with another embodiment of the invention.
DESCRIPTION
[0007] In a radio communication system such as a mobile radio communication system, e.g. in a 3GPP (Third Generation Partnership Project) compliant communication system, a mobile communication device (also referred to as a mobile station in the following) usually performs a communication network selection upon certain events. The communication network to be selected may be a public land mobile communication network (PLMN), for example. It should be mentioned that, although the following described embodiments refer to a 3GPP compliant communication system (e.g. a UMTS communication system), any other kind of radio communication system, e.g. any other kind of mobile radio communication system may be used in an alternative embodiment of the invention. In one embodiment of the invention, the communication system is a wireless local area communication network (WLAN) interworking communication system. In another embodiment of the invention, the communication system is a GSM communication system (global system for mobile communications). In yet another embodiment of the invention, the communication system is a code division multiple access (CDMA) communication system or a CDMA 2000 communication system. In yet another embodiment of the invention, the communication system is a long-term evolution (LTE) communication system or a GSM/EDGE Radio Access communication network (GERAN) communication system.
[0008] As will be described in more detail below, in one embodiment of the invention, besides other rules, a selection priority of the PLMNs is given by two communication network priority lists, a first communication network priority list, also referred to as communication network operator controlled communication network priority list, and a second communication network priority list, also referred to as user controlled communication network priority list. The communication network priority lists are usually stored in a memory of a smart card of the communication device, in one embodiment of the invention, in the subscriber identity module (SIM) or UMTS subscriber identity module (USIM) of the respective user.
[0009] Usually, the PLMN selection process is implemented or resides in the protocol stack of the communication device outside the smart card.
[0010] This leads to the following problems:
[0011] a) The size of the communication network priority lists is continuously growing due to communication network operator requests. As the access to SIM data or USIM data is usually too slow, the SIM data or USIM data is usually mirrored to the random access memory (RAM) of the communication device such as the user mobile equipment. Especially for low end mobile communication devices such as low end mobile phones, RAM is a limited resource and thus the number of communication network priority list entries supported by an implementation is limited. If a communication network operator issues (U)SIMs with larger communication network priority lists, the communication device usually will only check a subset of the communication network priority list entries.
[0012] b) The possibilities for the communication network operator to control/influence the PLMN selection are limited, since, e.g in accordance with 3GPP, the process is conventionally standardized, and only the communication network operator controlled communication network priority list, which has a lower priority than the user controlled communication network priority preferred list, reflects the communication network operator preferences. Due to different roaming contracts (where the contracts could vary from month to month), communication network operators have dynamically changing preferences for the roaming communication networks.
[0013] Conventionally, the only possibility for the communication network operator to influence the PLMN selection is the “communication network operator controlled communication network priority list” stored on the SIM/USIM, more accurate, on the smart card of the communication device. The communication network operator controlled communication network priority list could be updated remotely via so called SIM-Toolkit functions. The support of the SIM-Toolkit features, however, is optional for the mobile communication devices in accordance with 3GPP.
[0014] A mobile communication device usually only supports a (implementation specific) number of PLMN entries in the communication network operator controlled communication network priority list. Thus, if a communication network operator issues a SIM/USIM with more entries, those will be ignored.
[0015] As will be described in more detail below, in accordance with one embodiment of the invention, the process for selecting the communication network, e.g. the communication network, which will be used by the communication device for further communication connections, e.g. the process for the ranking (prioritizing) of the communication networks to be used, e.g. of the PLMNs to be used, is located and thus implemented in the smart card, e.g. in the SIM or USIM of a user, the smart card being inserted in the communication device, as will be described in more detail below. The smart card may be addressed or accessed via a smart card interface, which may be standardized in a communication standard. In one embodiment of the invention, the entire or complete communication network selection process (e.g. including the final selection of the communication network to be used) is located and thus implemented in the smart card, e.g. in the SIM or USIM of a user, the smart card being inserted in the communication device, as will be described in more detail below.
[0016] Referring now to FIG. 1 , a communication device 100 such as a mobile radio communication device, e.g. being configured in accordance with one of the above-mentioned communication standards, is shown. In one embodiment of the invention, the mobile radio communication device 100 may be implemented in a computing device such as e.g. a notebook computer, a personal digital assistant, and the like. In one embodiment of the invention, the mobile radio communication device 100 is a user equipment (UE) according to UMTS (Universal Mobile Telecommunications System). In one embodiment of the invention, the mobile radio communication device 100 includes a mobile radio phone 102 (e.g. a mobile equipment (ME) in accordance with 3GPP) and a smart card 104 , e.g. a UICC (Universal Integrated Circuit Card). In another embodiment of the invention, the mobile radio communication device 100 may also be configured according to another radio communication standard like GSM or CDMA 2000 and the smart card 104 (also referred to as chip card) may be a corresponding smart card, for example a SIM (Subscriber Identity module) card in case of GSM or an R-UIM in case of CDMA 2000.
[0017] The ME 102 includes an antenna 106 , a mobile equipment input/output interface 108 and the following components, which are connected to each other via a mobile radio phone bus connection 110 : a transmitter/receiver 112 , a programmable processor 114 (in an alternative embodiment of the invention, the programmable processor 114 may be replaced by a hard-wired logic), e.g. a microprocessor, at least one read only memory (ROM) 116 storing e.g. the computer program code that is executed by the programmable processor 114 for controlling the ME 102 , and at least one random access memory (RAM) 118 storing e.g. data that is processed by the programmable processor 114 . In an alternative embodiment of the invention, more or less components may be provided which are used for mobile radio communication. However, the other conventional components of the ME 102 will not be described in detail for clarity reasons.
[0018] As shown in FIG. 1 , the smart card 104 is detachably inserted into the case of the ME 102 and includes a smart card input/output interface 120 , the smart card input/output interface 120 being connected with the mobile radio phone bus connection 110 via corresponding electrical contacts, for example. The smart card 104 further includes a smart card transmitter/receiver 122 controlling the data exchange between the ME 102 and the smart card 104 , a processing logic 124 such as a programmable processing logic such as e.g. a programmable microprocessor (in an alternative embodiment of the invention, the processing logic 124 may be hard-wired), a smart card read only memory (ROM) 126 storing e.g. the computer program(s) used for controlling the smart card 104 . In other words, the smart card read only memory (ROM) 126 stores the computer program(s) providing the conventional smart card functionality, e.g. implementing the SIM or USIM functionality.
[0019] In one embodiment of the invention, at least a part of the communication network selection process which will be described in more detail below, is implemented as a computer program stored in the smart card ROM 126 . It should be mentioned that in an alternative embodiment of the invention, the smart card ROM 126 may be replaced by a random access memory (RAM) such as e.g. a non-volatile RAM such as a Flash memory (e.g. a floating gate memory or a charge trapping memory). Furthermore, the smart card 104 includes a smart card random access memory (RAM) 128 (volatile or non-volatile). In one embodiment of the invention, data used during the operation of the smart card 104 are stored in the smart card RAM 128 . In addition to the conventionally used data which will not be described in detail due to clarity reasons, the communication network operator controlled communication network priority list 130 and the user controlled communication network priority list 132 are stored in the smart card RAM 128 . In alternative embodiments of the invention, the communication network operator controlled communication network priority list 130 and the user controlled communication network priority list 132 are provided or only one of the two priority lists 130 , 132 , i.e. only the communication network operator controlled communication network priority list 130 or only the user controlled communication network priority list 132 , is provided.
[0020] In one embodiment of the invention, the communication between the ME 102 and the smart card 104 may be provided using a so called CAT command, a SAT (SIM application toolkit) command, a USAT (USIM application toolkit; USIM: UMTS subscriber identity module) command, or a CCAT (CDMA application toolkit) command.
[0021] In one embodiment of the invention, the USIM represents a logical functionality and is implemented on the smart card 104 , which is e.g. configured as a UICC (Universal Integrated Circuit Card). The USIM (or SIM in an alternative embodiment of the invention), allows the usage of the ME 102 within a UMTS mobile communication network (or in a GSM communication network). By means of the USIM (or SIM), data are stored (e.g. in the smart card RAM 128 and/or in the smart card ROM 126 ) which serve for the identification of the user of the mobile radio communication device 100 when the mobile radio communication device 100 is used in a mobile communication system and which are used to verify the authorisation of the user to use a mobile communication service. Further, data are stored on the USIM which allow encryption and decryption of data sent and received by means of the mobile radio communication device 100 .
[0022] Applications can be run on the smart card 104 . These applications may be defined by the communication network operator of the mobile communication system that the mobile radio communication device 100 is used with. The applications can make use of the smart card input/output interface 120 between the ME 102 and the smart card 104 , which in case of UMTS is provided by the so-called USAT (USIM application toolkit). By using the smart card input/output interface 120 , the applications running on the smart card 104 can make use of functionalities of the ME 102 , e.g. send text messages (like an SMS (Short Message Service) message), displaying a graphical icon on the display of the ME 102 or playing a tone using the loudspeaker of the ME 102 . In an alternative embodiment of the invention, conventional SIM/USIM messages for communication between the ME 102 and the smart card 104 may be provided.
[0023] Referring now to FIG. 2 , a mobile radio communication system 200 is illustrated. The mobile radio communication system 200 includes an arbitrary number of communication devices such as the mobile radio communication device 100 and a plurality of communication networks 202 , 204 , 206 , 208 , which provide communication services for the communication devices. In one embodiment of the invention, some communication networks or all communication networks of the plurality of communication networks 202 , 204 , 206 , and 208 are PLMNs.
[0024] In accordance with one embodiment of the invention, the communication device 100 selects one or a plurality of communication networks 202 , 204 , 206 , and 208 for requesting communication services. The communication network selection may be provided e.g. for roaming purposes or in response to the occurrence of a predetermined event (which may be communicated to the smart card 104 from the ME 102 via the smart card input/output interface 120 or which may be generated by the smart card 104 itself, e.g. by using a smart card 104 internal timer (not shown), thereby starting the communication network selection process after a predetermined time represented by the timer setting), e.g. in case that a loss of mobile radio cell coverage occurs (i.e. the communication device 100 has lost the communication connection to the base station of the mobile radio communication network, for example).
[0025] The above described structure and configuration of the communication device 100 is the same for all embodiments described in the following, wherein the computer programs controlling the smart card is respectively configured in accordance with the respectively described functionalities and processes.
[0026] In one embodiment of the invention, the PLMN selection process is performed as an integrated functionality on the smart card 104 implementing the SIM/USIM.
[0027] In accordance with this embodiment of the invention, whenever a PLMN selection needs to be performed, the ME 102 determines a list of PLMNs, which are currently available for the communication device 100 (e.g. the list of PLMNs from which the communication device 100 has found mobile radio cells to communicate with).
[0028] The determined list of available PLMNs is transmitted to the smart card 104 (see message flow diagram 300 in FIG. 3 ) in a PLMN sorting request message 302 via the smart card input/output interface 120 . Illustratively, the ME 102 requests the prioritization of the available PLMNs from the smart card 104 using the communication network selection processes, in this embodiment of the invention implemented as a PLMN ranking process, implemented in the smart card 104 . The PLMN sorting request message 302 may further include some parameters to configure the special flavour of PLMN ranking that is requested. In one embodiment of the invention, the parameters may include radio signal quality information including information about the radio signal quality with regard to a respective available PLMN or other parameters which may be taken into consideration by the smart card 104 when ranking the PLMNs. In one embodiment of the invention, the parameters may include the information that the smart card is requested to regularly start a new communication network selection process on its own without an external trigger, e.g. after the expiration of a predetermined time period, which also may be included in the transmitted parameters.
[0029] After the smart card 104 has received the PLMN sorting request message 302 , it operates the smart card processing logic 124 selecting a communication network 304 to be used by a communication device using the smart card. In one particular embodiment of the invention, the smart card processing logic 124 carries out a communication network ranking process using the received available communication networks. The communication network ranking process may be implemented by using the preferences according to the priority lists 130 , 132 , for example, and comparing the received available communication networks with the communication networks included in the priority lists 130 , 132 . In one embodiment of the invention, the result of the communication network ranking process is a sorted list of those received available communication networks, which are containeed in the priority lists 130 , 132 , wherein the received available communication networks are sorted in accordance with the preferences (priorities) indicated in the priority lists 130 , 132 .
[0030] In another embodiment of the invention, any other suitable and even more complex process for ranking the received available communication networks may be provided, e.g. taking into account further ranking criterions like the parameters mentioned above.
[0031] The determined sorted list is transmitted from the smart card 104 to the ME 102 in a PLMN sorting response message 306 , again using a USAT command, for example. The PLMN sorting response message 306 is transmitted to the ME 102 via the smart card input/output interface 120 . As described above, in an alternative embodiment of the invention, conventional SIM/USIM messages may be provided for communication between the ME 102 and the smart card 104 .
[0032] After having received the PLMN sorting response message 306 , the ME 102 , more particularly, e.g. the processor 112 selects the communication network the communication device 100 will subsequently use, at 308 . The selection may be provided fully automatic by the ME 102 , in which case the processor 112 may select the PLMN in accordance with the sorted list. In one embodiment of the invention, the processor 112 may select the PLMN that is ranked at the top of the sorted list, i.e. the available PLMN having the highest priority in accordance with the sorted list. In one embodiment of the invention, illustratively, the SIM/USIM activates its internal PLMN ranking process and returns a sorted list of these available PLMNs back to the ME 102 .
[0033] In accordance with another embodiment of the invention, the ME 102 selects the PLMN in a partially automized manner partly with the assistance of the user of the communiation device 100 . In this embodiment, the ME 102 may display the sorted list to the user via the display of the communication device (not shown in the figures) for manual selection. The user may then manually select one PLMN out of the offered plurality of PLMNs as he desires.
[0034] After the selection of the communication network to be used, e.g. the PLMN to be used, has been completed, the communication device 100 then, at 310 , sets up a communication connection to the selected communication network, e.g. the selected PLMN, e.g. to a base station of the selected communication network.
[0035] A description of the smart card input/output interface 120 for the above described embodiment in accordance with FIG. 3 will be provided in the following:
[0036] Interface ME 102 Towards SIM/USIM to Perform the PLMN Selection:
[0000]
Rank_available_PLMNs_request( PLMN_list, PLMN_selection_type)
Parameters:
PLMN_list:
{ Number_of_PLMNs;
PLMN_entry [PLMN_entry_1,....,
PLMN_entry_n] };
PLMN_entry:
{ PLMN_code, Radio_Access_Technology,
Signal_strength };
PLMN_selection_type:
{ normal, user re-selection, in-VPLMN };
Description:
Request to sort/rank the list of available PLMNs (“PLMN_list”) according
to the requirements for the indicated “PLMN_selection_type”.
[0037] In other words, the ME 102 requests the sorted list using the parameters “PLMN_list”, “PLMN_entry”, and “PLMN_selection_type”, wherein
the parameter “PLMN_list” includes the subparameters “Number_of_PLMNs” (describing the number of currently available PLMNs) and “PLMN_entry”, which is a list of the currently n available PLMNs [PLMN_entry_ 1 , . . . , PLMN_entry_n], the parameter “PLMN_entry” includes the subparameters “PLMN_code” (being a unique identifier of the respective PLMN), “Radio_Access_Technology” (describing the radion access technology used in the respective PLMN), and “Signal_strength” (describing the signal strength of a signal sent by the respective PLMN and received by the communication device 100 ), and the parameter “PLMN_selection_type” includes the subparameters “normal” (denoting a normal selection type selecting the offered PLMN having the highest ranking), “user re-selection” (denoting a selection type according to which the user has the option to re-select the PLMN to be used), and “in-VPLMN” (denoting a selection type according to which the ME automatically (possibly event-driven, e.g. timer-driven) searches for a PLMN having a higher priority).
[0041] Interface SIM/USIM towards ME 102 providing the resulting sorted list:
[0000]
Sorted_PLMN_list_indication( PLMN_list )
Parameters:
PLMN_list:
{ Number_of_PLMNs;
PLMN_entry [PLMN_entry_1,...., PLMN_entry_n] };
PLMN_entry:
{ PLMN_code, Radio_Access_Technology };
Description:
Provision of the sorted/ranked list of PLMNs.
[0042] In other words, the smart card 104 provides a sorted list of PLMNs in the fornat as discussed above using the parameters “PLMN_list” and “PLMN_entry”.
[0043] In the following, some effects of the smart card communication network ranking process will be described in more detail:
[0044] a) It could be ensured that all PLMNs for which the operator wants to define a preference are considered by the PLMN ranking process, since the PLMN ranking process resides in the SIM/USIM, in particular in the smart card 104 .
[0045] b) The PLMN ranking process puts no constraints on the ME 102 in terms to ME RAM size, runtime, etc.
[0046] c) The PLMN ranking process is independent from the ME 102 (implementation); thus, the customer will always experience the same behaviour independent which ME 102 is used.
[0047] d) The operator has full control over the PLMN ranking process.
[0048] In accordance with another embodiment of the invention, the whole PLMN selection process is decriptively moved from the ME 102 towards the SIM/USIM, more accurately, to the smart card 104 . For this purpose, a set of, e.g. standardized, interface functions between the ME 102 and the smart card 104 will be defined.
[0049] As shown in a message flow diagram 400 in FIG. 4 , the ME 102 will indicate all possible events which could trigger a PLMN selection to the SIM/USIM in one or more trigger event messages 402 . The one or more trigger event messages 402 is/are transmitted from the ME 102 to the smart card 104 via the smart card input/output interface 120 . After having received the one or more trigger event messages 402 , the smart card 104 , e.g. the SIM/USIM is in charge to decide whether a PLMN selection shall be performed and in consequence which PLMN to select. For this propose, in accordance with one embodiment of the invention, the smart card 104 requests the ME 102 to perform a scan for all currently available PLMNs. This is implemented in that the smart card 104 generates a PLMN scan request message 404 and transmits the PLMN scan request message 404 to the ME 102 . After having received the PLMN scan request message 404 , the ME 102 carries out a scan for available PLMNs (e.g. determines mobile radio cells to communicate with), thereby determining a list of currently available PLMNs.
[0050] The determined list of available PLMNs is transmitted to the smart card 104 in a PLMN scan response message 408 via the smart card input/output interface 120 .
[0051] After the smart card 104 has received the PLMN scan response message 408 , it operates the smart card processing logic 124 selecting a communication network 410 to be used by a communication device using the smart card 104 . In one particular embodiment of the invention, the smart card processing logic 124 carries out a fully automized communication network selection process 410 by comparing the available PLMNs received in the PLMN scan response message 408 with the priority lists 130 , 132 , stored in the smart card RAM 128 . In one embodiment of the invention, in accordance with the communication network selection process 410 , the smart card processing logic 124 determines the available PLMN with the highest priority according to the priority lists 130 , 132 , for example.
[0052] After having determined the available PLMN with the highest priority, this PLMN is selected as the PLMN to be used by the communication device 100 . The information about the selected PLMN (e.g. a unique identifier identifying the PLMN) is transmitted in a PLMN select message 412 to the ME 102 via the smart card input/output interface 120 .
[0053] If a new PLMN is selected, the SIM/USIM will then request (also with the PLMN select message 412 , alternatively, using a separate message being transmitted to the ME 102 ) the ME 102 to select the new PLMN.
[0054] After having received the PLMN select message 412 indicating the communication network to be used, e.g. the PLMN to be used, the communication device 100 then, at 414 , sets up a communication connection to the selected communication network, e.g. the selected PLMN, e.g. to a base station of the selected communication network.
[0055] A description of the smart card input/output interface 120 for the above described embodiment in accordance with FIG. 4 will be provided in the following:
[0056] Interface ME 102 Towards SIM/USIM to Perform the PLMN Selection:
[0000]
Set_PLMN_Selection_mode(automatic/manual)
Set_MS_type( MS_type)
MS_type{ class_A, class_B, class_C_PS, class_C_CS }
Location_registration_result_indication( CN_domain,
current_RAI, LR_result_type, ePLMN_list )
CN_domain
current_RAI
LR_result_type { LA_not_allowed,
Nat_roaming_not_allowed, ... max_LR_attempts,
illegal_ME, Authentication_reject; ....}
ePLMN_list
Service_status_indication( current_RAI, service_status,
available_PLMN_list)
current_RAI
service_status {Normal_service, No_service}
available_PLMN_list
Limited_service_indication( current_RAI, limited_service_cause)
current_RAI
limited_service_cause {#12, #13, ...}
Get_initial_PLMN( )
Available_PLMNs_indication( available_PLMN_list)
[0057] In other words, a mechanism is provided for selecting the PLMN selection mode using the function “Set_PLMN_mode” with two subparameters being offered for selection, namely an automatic PLMN selection mode (subparameter “automatic”) or a manual PLMN selection mode (subparameter “manual”).
[0058] Furthermore, the function “Set_MS_type” enables the setting of the type of ME 102 used for the communication device 100 . The function “Set_MS_type” includes the parameter “MS_type” being a list of an arbitrary number of different selectable types of ME 102 , e.g. a class_A device, a class_B device, a class_C_PS (packet switched) device, or a class_C_CS (circuit switched) device.
[0059] Moreover, the function “Location_registration_result_indication” is used for indicating the result of a registration process, with which the ME 102 tries to registrate with a respective PLMN. The function “Location_registration_result_indication” includes the following parameters:
[0000]
- “CN_domain”, which describes the domain type (e.g. circuit-switched or
packet-switched) of the core communication network of the respective PLMN;
- “current_RAI” describing the current routing area identifier;
- “LR_result_type” describing the result of the location registration process;
the parameter “LR_result_type” having the following subparameters:
-- “LA_not_allowed” indicating that the Location Area (LA) has not been
allowed;
-- “Nat_roaming_not_allowed” indicating that a national roaming is not
allowed;
-- “max_LR_attempts” indicating a maximum number of allowed location
registration attempts;
-- “illegal_ME” indicating an illegal ME;
-- “Authentication_reject” indicating a rejection of the authentication
attempt;
- “ePLMN_list” including the so called Equivalent HPLMN (Home PLMN)
list.
[0060] Using the function “Service_status_indication”, the respective status of a current RAI is provided. The function “Service _status_indication” uses the following parameters:
[0000]
- “current_RAI” indicating the current RAI;
- “service_status” indicating the service status of the current RAI; the
parameter “service_status” includes the subparameters
-- “Normal_service” indicating that the RAI is operating in a
normal way;
-- “No_service” indicating that the RAI is currently out of service;
- “available_PLMN_list” including the PLMNs that are currently
available for the communication device 100.
[0061] The function “Limited_service_indication” is used to indicate that a respective RAI is currently only providing a limited service. The function “Limited_service_indication” uses the following parameters:
[0000]
- “current_RAI” indicating the current RAI;
- “limited_service_cause” indicating the cause for the limitation
of the available service, for example reasons “#12, #13, ...”.
[0062] The function “Get_initial_PLMN” is used to request the smart card 104 to determine the initial PLMN.
[0063] The function “Available_PLMNs_indication” is used to provide the list of currently available PLMNs to the smart card 104 . The function “Available_PLMNs_indication” includes the parameter “available_PLMN_list” including the names or identifiers of the respectively available PLMNs.
[0064] Interface SIM/USIM Towards ME 102 :
[0000]
Scan_for_available_PLMNs_request( )
Select_PLMN_request( PLMN_code, Radio_Access_Technology )
[0065] In other words, the interface SIM/USIM towards ME 102 provides two functions, a function “Scan_for_available_PLMNs_request” requesting the ME 102 to scan for available PLMNs, and a function “Select_PLMN_request” requesting the ME 102 to select a PLMN indicated in this function as a parameter. In detail, the function “Select_PLMN_request” has the following parameters:
[0000]
- “PLMN_code” indicating the respective selected PLMN; and
- “Radio_Access_Technology” indicating the radio access
technology that should be used when setting up a communication
connection with the selected PLMN.
[0066] In the following, some effects of the communication network selection process described above will be described in more detail:
[0067] a) All effects listed for the smart card communication network ranking process described above.
[0068] b) The operator has full control, not only over the PLMN ranking, but also over the trigger criterions, i.e. when to perform a PLMN (re-)selection.
[0069] To be compatible with older SIM/USIMs or a respective smart card, not supporting the SIM/USIM based PLMN selection process according to the described embodiments, the ME 102 should support the conventional ME based PLMN selection process. If a SIM/USIM is not interested in the ME 102 or not activated (i.e. the PIN is not validated) the conventional ME 102 based PLMN selection process for this case will be executed.
[0070] While the invention has been particularly shown and described with reference to specific embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. The scope of the invention is thus indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are thefore intended to be embraced.
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Smart cards, a communication device, methods for selecting a communication network to be used by a communication device, and a computer program product.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is related to an arrangement coupled to a transducer which converts an electric signal into an acoustic or a mechanic signal. The arrangement is used to protect the transducer against destruction caused by high signal amplitudes. The arrangement is connected to the electric terminals of the transducer and changes the electric input signal under overload conditions.
2. Description of the Prior Art
Transducers converting an electric signal into an acoustic or mechanic signal (loudspeakers, headphones and actuators) can be endangered to malfunction or permanent destruction when a electric or mechanic variable of the transducer exceeds an allowed limit value. For example, the displacement of the voice coil of an electrodynamic transducer is limited by the geometry of the suspension and the motor structure.
Overloading the transducer can be prevented by operating the transducer with an amplifier supplying a maximal output power lower than the power handling capacity of the transducer. Input signals with high amplitude will always be limited by the amplifier and will not endanger the transducer. However, unpleasant distortions are generated if the amplifier is limiting.
Protecting the transducer by amplifier limiting is unacceptable in professional sound enhancement and initialized the development of special protection systems as disclosed in U.S. Pat. No. 4,490,770 by H. R. Phillimore entitled OVERLOAD PROTECTION OF LOUDSPEAKERS, U.S. Pat. No. 4,330,686 by R Stephen entitled LOUDSPEAKER SYSTEMS, U.S. Pat. No. 4,301,330 by T. Bruce entitled LOUDSPEAKER PROTECTION CIRCUIT, U.S. Pat. No. 4,296,278 by S. B. Cullison entitled LOUDSPEAKER OVERLOAD PROTECTION CIRCUIT and U.S. Pat. No. 3,890,465 by Y. Kaizu entitled CIRCUIT ARRANGEMENT FOR PROTECTION OF A SPEAKER SYSTEM. These systems protect the transducer against thermal overload related to the electric power supplied to the transducer successfully but fail in the protection of transducers against mechanical destruction caused by high amplitudes of mechanical variables.
If the displacement of the voice coil exceeds an allowed maximal value the loudspeaker works under mechanic overload and is endangered to permanent destruction. The amplitude of the displacement depends from the spectral power density of the electric signal as well as from the transfer characteristic of the transducer. While the temperature of the voice coil changes slowly with time constants about 1 s, the displacement is a low-pass filtered signal with a spectral power density decreasing by 12 dB per octave above the resonance frequency. These spectral components make high demands to the control system to reduce the electric input signal of the transducer in time.
The protection systems of prior art as disclosed in U.S. Pat. No. 4,864,624 to Tichy, in U.S. Pat. No. 4,583,245 to Gelow and as described by Klippel entitled The Mirror filter--a New Basis for Reducing Nonlinear Distortion Reduction and Equalizing Response in Woofer Systems, J. Audio Eng. Soc. 32 (9), pp. 675-691, (1992) have deficiencies in protecting the transducer against transient input signals of high amplitudes. If the protection system is activated at a defined threshold value, the final peak value of the displacement always exceeds the threshold value due to the reaction time inherent in the control system. Therefore, the threshold value must be set lower than the allowed limit to ensure protection against transient singles. However, this low threshold value limits the amplitude of steady state signals unnecessarily and reduces the output signal of the transducer in cases where no attenuation is required.
Thus, there is a need for a protection system for loudspeakers which can provide an improved protection of the transducer against overload caused by an arbitrary electric signal such as music, speech or secondary sound in active noise control.
A protection circuit is required which has a very short reaction time for coping with transient signals with high amplitude and for attenuating the electric signal at the transducer input in time.
Another object of the invention is to provide protection of the loudspeaker while causing a minimal change of the transducer's input signal. Therefore, a minimal amount of linear and nonlinear distortions are generated by the protection circuit.
SUMMARY
This invention protects a transducer, which converts an electric signal u L (t) into an acoustic or a mechanic signal, against overload and destruction. The protection circuit consists of a controller, a monitor and an envelope detector.
The monitor provides a relevant signal of the transducer (e.g. displacement) indicating the mechanic or electric load of the transducer. According to the invention the peak value of the signal is anticipated by using a predictive filter in the envelope detector or by implement a delay element in the controller. If the peak value exceeds a defined limit the controller is activated and the transducer input signal is attenuated in time to ensure that the monitored signal will not exceed the defined limit. The predictive liter contains a Hilbert transformer or a simple differentiator to estimate the envelope of the signal.
This invention allows to provide reliable protection of the loudspeaker with a minimum of signal distortion generated by the protection system. The electric signal supplied to the loudspeaker is only changed in critical situations when the loudspeaker is endangered. The protection system has a linear transfer characteristic for signals with a stationary time characteristic.
This invention provides an improved protection, requires a few number of elements and can be implemented in a digital signal processing system at low costs.
The head room of the transducer, which is required without or insufficient protection can be reduced. Driving the loudspeaker at a higher amplitude without exposing the transducer to danger results in a higher output amplitude (e.g. increased sound pressure level). Thus, a transducer with a smaller volume of the enclosure and a smaller weight can produce the required amplitude of the mechanic or acoustic output signal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic flow diagram showing the protection system with feed-forward control.
FIG. 2 shows the schematic flow diagram of the protection circuit with feedback control.
FIG. 3 is a protection system using feedback of a sensed acoustic signal.
FIG. 4 is an embodiment of a protection system with envelope estimation.
FIG. 5 is an embodiment of the feed-forward protection circuit.
DETAILED DESCRIPTION
The protection arrangement can be realized either in a feedback or in a feed-forward structure. FIG. 1 shows a feed-forward protection arrangement 1 which is connected to the electric terminals of the transducer 2. The protection system 1 comprises a linear filter 3, an envelope detector 4 and a controller 5.
The controller 5 has a signal input 7 connected with input 6 of the protection arrangement 1, an output 9 connected via output 11 of the protection arrangement 1 to transducer 2 and a control input 8 for changing the transfer characteristic of the controller 5. If the signal at the control input 8 is constant than the transfer characteristic of the controller between input 7 and output 9 is linear and constant.
The input of the linear filter 3 is connected to the input 6 of the protection arrangement. This filter 3 provides a signal at the output 10 which is equivalent to the monitored signal. Monitoring the displacement of a woofer loudspeaker system is described as an example. However, this protection arrangement can also be applied to other kinds of transducer where different variables (stress, force, velocity) have to be monitored. In the case of a woofer system comprising a driver in a closed box system the filer 3 has a second-order low-pass characteristic and the cut-off frequency corresponds to the resonance frequency of the transducer. This filter provides a signal at the output 10 which is equivalent to the displacement x(t). The output 10 is connected via envelope detector 4 with the control input 8 of the controller 5.
The output of the envelope detector 4 provides a signal A(t) which corresponds with the peak value of the displacement x(t). If the amplitude signal A(t) exceeds a defined limit S then the controller 5 is activated and the input signal u L (t) is changed in time to ensure that the resulting displacement will not exceed the limit.
FIG. 2 shows an alternative embodiment of the invention based on a feedback structure which shows some advantages in comparison to the feed-forward structure depicted in FIG. 1. The embodiment 14 in FIG. 2 comprises a controller 15, a filter 16 and an envelope detector 17. The input 12 providing the input signal u(t) is connected via the controller 15 with the input of the filter 16 and via output 13 with the loudspeaker 2. The filter 16 has the transfer characteristic of the loudspeaker 2 between the terminal voltage and the displacement and provides the monitored signal x(t). The output of the filter 16 is connected via the envelope detector 17 with the control input 20 of the controller 15.
FIG. 3 shows a third embodiment of the invention which has also a feedback structure but uses instead of the filter 16 an additional sensor 21. The input 24 of the protection system is connected via the input 25 and the output 26 of the controller 22 with the loudspeaker 2. The sensor 21 measures a mechanic or acoustic signal at the loudspeaker and supplies a displacement signal x(t) via the envelope detector 23 to the input 27 of the controller 22.
In order to improve the protection of the loudspeaker reproducing transient signals the controller should be activated in case of approaching overload as early as possible to compensate for the additional reaction time inherent in the controller. According to the invention the peak value of the monitored signal is anticipated by two different approaches:
1. If the monitored signal is a low-pass filtered signal, like the displacement x(t) in the discussed example, then the instantaneous envelope can be anticipated by a nonlinear, predictive filter implemented in the envelope detector 4, 17 and 23 of the feed-forward and feedback control, respectively. Anticipating the peak value in the zero crossing of the monitored signal gives the controller one quarter of a period more time for the attenuation of the transducer input signal.
2. Only the feed-forward structure depicted in FIG. 1 allows an alternative approach. The electric signal at the controller input 7 is delayed in respect to the envelope signal at input 8. The envelope detector can implemented as a simple peak detector without any anticipation. However, the protection system causes an additional time delay in the electric signal according to the attenuation time.
The predictive filter in the first approach determines the instantaneous envelope A(t) of monitored signal by generating the analytic continuation
x.sub.a (t)=x(t)+jx.sub.i (t)=A(t)e.sup.jφ(t) (1)
from the monitored signal x(t) with the time varying amplitude ##EQU1## The conjugated signal x i (t) is produced from the real signal by using a Hilbert transformer 28. The Hilbert transformation in the time domain ##EQU2## and in the frequency domain
X.sub.i (jω)=-jsgn(ω)X(jω) (5)
shows the relationship between the time signals x(t) and x i (t) and Fourier transformed signals X(jω) and X i (jω), respectively. The used sign function sgn(n) is defined by sgn(n)=1 for n>0, sgn(0)=0 and sgn(n)=-1 for n<0. A Hilter-Transformer can be realized by a time-discrete transveral filter (FIR-Filter) as shown by A. Oppenheim and R. W. Schafer: Discrete-time Signal Processing, Prentice Hall, Englewood Cliffs, N.J., 1989. The transfer characteristic of the filter has the required 90°-phase shift, a constant amplitude response but an additional phase shift growing with the frequency linearly. This additional phase shift is caused by a constant time delay which is required to realize the Hilbert-transformer in a FIR-filter as a casual system. Especially at low frequencies the time delay becomes substantial due to the long filter length. This time delay reduces the time between the recognition of an overload-situation and the start of the actual event. Therefore, it is more convenient to approximate the Hilbert transformer by one or more recursive, time-discrete IIR-Filter as shown in I. J. Gold, et al.: Theory and Implementation of the Discrete Hilbert Transform, Proc. Symp. Computer Processing in Communications, vol. 19, Polytechnic Press, N.Y., 1970.
According to Eq. (2) the envelope detectors 4, 17 and 23 contain a Hilbert-transformer, two squarers, a summer and a static nonlinear system which performs the root extraction of the summed signal. However, the embodiment in FIG. 4 contains only one nonlinear element 36 which takes into account the threshold S as well as the root extraction. The input 32 of the envelope detector 17 is connected to the input of the first squarer and via the Hilbert-transformer 28 to the input of the second squarer 30. The outputs of both squarers 29 and 30 are connected via the summer 31 with the output 33 of the envelope detector 17.
Alternatively, the conjunctive signal x i (t) in Eq. (1) can be replaced by the time derivative of the monitored signal x(t). In this case the element 28 in FIG. 4 is a simple differentiator. In the discussed example the time derivative of x(t) can be interpreted as velocity v(t). It has also the 90°-phase shift as the conjunctive signal x i (t) but the amplitude increases by 6 dB/octave. Taking v(t) and x(t) as the real imaginary part of a complex signal the envelope can be approximated by the instantaneous magnitude ##EQU3## where f R is the resonance frequency of the loudspeaker.
The differentiator causes an error in the amplitude estimation. Supplying a sinusoidal at the resonance frequency f R to the loudspeaker the signal at the output of filter 16 is
x(t)=X.sub.0 sin(2πf.sub.R t) (7)
and the output of the predictor corresponds with the true amplitude X 0 according to Eq. (6). However, for a sinusoidal tone with f≠f R the predicted amplitude A(t) consist of a constant value and a superimposed sinusoidal tone with the frequency 2f. At the positive and negative peaks of x(t) where v(t)=0 the estimated value A(t) equals X 0 but there is no prediction. At the zero crossing where x(t)=0 the predictor anticipates the maximal displacement for the next quarter of the period and the error in the predicted amplitude in percent comes up to ##EQU4## In spite of this error the implementation of a simple differentiator is useful because spectral components below the resonance frequency (f<f R ) have a longer period and the predictive filter can activate the controller in time despite the increased prediction error. Spectral components above the resonance frequency f>f R ) contribute to a smaller extent to the displacement due to the decay in spectral power density at higher frequencies.
In an alternative embodiment it is possible to approximate the square-root-calculation to determine the magnitude of the complex in Eq. (2) and Eq. (6) by the sum of the absolute values of the real and imaginary signal ##EQU5## respectively. Eq. (10) shows that the prediction is based on a linear prediction about the instantaneous displacement using the gradient of x(t) and a time constant.
The determination of the magnitude value can be performed by an two-way-rectification using a network of diodes. The differentiator can be realized in a digital signal processor with a sufficient low constant delay time so that the whole prediction time T=1/2πf R in Eq. (10) is available for adjusting the control system.
FIG. 4 shows also the embodiment of the controller 15 in the protection system 14. The controller 15 contains a attenuation element 34, an integrator 35 and a static, nonlinear transfer element 36. The attenuation element 34 is connected between the input 18 and the output 19 of the controller 15. For a loudspeaker (e.g. sub-bass woofer) which is part of a multi-speaker-system and radiates only band-limited signals the attenuation element 34 can be realized as a controllable amplifier as shown in FIG. 4. The output signal of the amplifier 34
u.sub.L (t)=(1-u.sub.S (t))u(t) (11)
can be attenuated by the signal u S (t) at control input 37.
However, a broadband loudspeaker system requires a filter with controllable transfer characteristic (e.g. high-pass with variable cut-off frequency) to attenuate only the amplitude of the frequency components which contribute to the resulting displacement.
The system 36 has a nonlinear transfer characteristic without memory. This nonlinear system 36 can simply embodied by a diode-network. It realizes the threshold value where the protection starts and the optimal characteristic of the controller. The output signal is zero as long as the input signal is lower than the threshold value S but if the signal at the input 20 exceeds the threshold S system 36 supplies a signal via the integrator 35 to the control input 37 of the amplifier 34. The integrator 35 performs a leakage integration using a short time constant for rising slopes (usually below 1 ms) and a long time constant for the decay (usually above 1 s) to avoid modulations of the audio signals by the control signal.
The feed-forward structure depicted in FIG. 1 can be implemented by the alternative approach using an additional delay element instead of a predictive filter in the envelope detector 4. The embodiment depicted in FIG. 5 shows the controller 5 and the envelope detector 4 in detail. The envelope detector 4 is connected via squarer 42 and integrator 43 with the output 45. The integrator 43 has a short time constant for rising slopes and long time constant for the decay to hold the peak value of the squared amplitude. The controller 5 comprises a time delay element 38 with a transfer function H(s)=e -ts , a controllable amplifier 39 for attenuating the transducer signal and a nonlinear transfer element 41 for realizing an optimal control characteristic. The input 7 is connected via the delay element 38 and the amplifier 39 to the output 9 of the controller. The squared envelope signal at the input 8 is supplied via the nonlinear element 41 to the control input 40 of the amplifier 39.
The above description shall not be construed as limiting the ways in which this invention may be practiced but shall be inclusive of many other variations that do not depart from the broad interest and intent of the invention.
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This invention relates to an arrangement (14) for protecting a transducer (2) which converts an electric signal into an acoustic or a mechanic signal against overload and destruction. The arrangement is connected to the electric terminals of the transducer and changes the electric input signal under overload condition. This protection arrangement comprises a controller (15), a monitor (16) and an envelope detector (17). The monitor (16) provides a signal indicating the electric or mechanic load of the transducer (2). The peak value of the signal is anticipated by using a predictive filter in the envelope detector (17) or a delay element in the controller (15). If the predicted peak value exceeds an defined limit an attenuation element in the controller (15) is activated and the input signal is changed in time to prevent an overload of the transducer. This invention provides protection of the loudspeaker with a minimum of signal distortion and allows to reduce the head room of the transducer and to convert signals with a higher amplitude.
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CLAIM OF PRIORITY
[0001] This application claims priority to U.S. Provisional Patent Application No. 60/230,647, filed Sep. 7, 2000.
FIELD OF THE INVENTION
[0002] The present invention generally relates to the repair of tissue defects in a patient, including such defects as hernia. The present invention specifically relates to devices and methods in the long-term cure of recurrent female urinary incontinence. More particularly, the present invention relates to slings for use in treating female urinary incontinence and methods of making and using the slings.
BACKGROUND OF THE INVENTION
[0003] Normal urination and continence is dependent upon normal function of the urinary tract, kidneys and nervous system. In addition, in women, continence requires correct coaptation and urethral support. Specifically, in order for continence to be maintained, the urethra must be supported and stabilized in its normal anatomic position behind the pubic bone, adjacent to the vaginal wall. The natural support system for the female urethra is a layer of support composed of pelvic and vaginal wall tissue and ligaments, which attach to the pubic bone. Relaxation, weakening or loss of this support system results in hypermobility of the urethra and bladder to an unnaturally low position within the pelvis. This defect contributes to about 30% of incontinence in women.
[0004] One form of incontinence, referred to as stress incontinence, is an involuntary loss of urine that occurs with increased abdominal pressure such as with coughing, sneezing, laughing, or lifting. Urethral hypermobility may be a result of pregnancy (one reason why stress incontinence is common in women who have had multiple pregnancies), or may be due to pelvic prolapse. In pelvic prolapse, there is a protrusion or falling of the bladder, urethra, or rectal wall into the woman's vaginal space. Additionally, in women with low estrogen levels such as in post-menopausal females, stress incontinence is more likely to occur due to decreased vaginal muscle tone resulting from the loss of estrogen.
[0005] Approaches for treating female urinary incontinence vary and include methods directed at elevating the urethra or the bladder neck (upper region of the urethra) to return it to its normal anatomical position behind the pubic bone. These methods include needle suspension procedures and sling procedures. The needle suspension procedure is a commonly used procedure which involves placement of sutures in the support tissue (fascia) on either side of the displaced urethra and attaching these sutures to fixed sites such as bone and soft tissue. Therefore, a variety of devices have been developed to aid in the fixed attachment of the sutures to the support structures. A disadvantage with this approach, however, is that the tissue support structures being used for the urethra are themselves stretched or otherwise deficient, thereby, making them inefficient as support structures and a less effective solution.
[0006] Another approach for treating female incontinence is the sling procedure. In this procedure a sling is formed by taking a piece of human abdominal tissue (fascia) or a piece of synthetic material and using this as a platform to provide support and/or restore the urethra to its normal retropubic position. Slings made of biological tissue require either growing or harvesting autologous tissue or using processed cadaveric tissue. Therefore, these types of sling materials are sometimes undesirable in that they increase the expense, surgeon's time required and complexity of the procedure.
[0007] As an alternative to human tissue, prefabricated or synthetic slings have been developed for use in treating incontinence and are described, for example, in U.S. Pat. No. 6,042,534. These slings are said to offer improvements to the sling procedure for treating incontinence in that the synthetic slings are supplied to the physician in shapes and dimensions adapted for urethral stabilization. This eliminates the need for sizing of the sling material by the surgeon during surgery, which greatly reduces the time required for the surgical procedure.
[0008] Another example of a synthetic sling and system for use in treating incontinence is described in U.S. Pat. No. 6,039,686 issued Mar. 21, 2000 to Kovac. The sling system of Kovac involves stabilizing the urethra using a mesh sling having an innovative mesh suturing pattern that is secured in vivo by short sutures attached to the posterior/inferior (lower, back) portion of the pubic bone instead of the superior (upper) portion of the pubic bone as with other methods.
[0009] The tissue and mesh used in prior slings can be fabricated or obtained from a variety of materials and sources. There does not appear to be any attention given to configuring, creating or modifying these slings in a manner to provide optimal elongation characteristics to the support tissue. Particular elongation properties are desirable in some circumstances, such as when the amount of tension or support at the region immediately surrounding the bladder neck of the urethra is important.
[0010] Tissue ingrowth, infection resistance and capacity to erode surrounding tissue are also factors in sling designs. The specific effect of the elasticity of the sling on these factors is not known in great detail.
[0011] In view of the above, although improvements in surgical treatment of urinary incontinence have been made, there is a need to provide even more improved sling systems so as to further enhance reliability and to better respond to patient kinetics.
SUMMARY OF THE INVENTION
[0012] In view of the foregoing, it is an object of the present invention to provide a surgical sling that addresses the limitations and disadvantages associated with prior devices and systems, yet meets the needs of the user.
[0013] A further object of the invention is to provide a sling apparatus having distinct elongation properties along its length and its width and that minimizes the complexities of the placement procedure for the surgeon.
[0014] A further object of the invention is to provide a surgical sling fabricated such that it has one elongation property in one direction and a second elongation property in a second direction.
[0015] An additional object of the invention is to provide a coating to a sling material that contributes to appropriate elongation property, improves biocompatibility and inhibits or resists infection.
[0016] An additional object of the invention is to provide a method of making and using a multiple elongation sling system for treatment of urinary incontinence. The system can include a surgical sling having several distinct elongation properties and adapted to be passed under the urethra for supporting the urethra in its normal anatomic position. When inserted into a patient, the sling can also prevent abnormal urethral descent in a patient.
[0017] An additional object of the invention is to provide a sling material made from a mesh wherein the mesh is coated but contains open holes or pores to promote tissue in-growth.
[0018] An additional object of the invention is to provide a sling material that provides visual indicia to the user that is indicative of a particular tensioned state of the sling material.
[0019] The present invention includes coated slings and slings having certain physical and biologic characteristics that increase the overall effectiveness and comfort of the sling once implanted in vivo. Such systems also include slings that provide visual indicia to the user indicating when the sling has been manipulated into a desired state, e.g., into a desired tension.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is a view of an uncoated base material for use as a sling in accordance with one embodiment of the invention;
[0021] FIGS. 2 A- 2 B are views of a first embodiment of a sling in accordance with the present invention;
[0022] FIGS. 3 A- 3 B are views of a second embodiment of a sling in accordance with the present invention;
[0023] [0023]FIG. 4 is a flow chart for fabricating a sling in accordance with one embodiment of the invention;
[0024] [0024]FIG. 5 is a schematic view of another preferred embodiment in accordance with the present invention;
[0025] [0025]FIGS. 6A and 6B are views of a sling material in accordance with one embodiment of the present invention and a method of determining tension in accordance with the present invention;
[0026] [0026]FIGS. 7A and 7B are views of a sling material in accordance with another embodiment of the present invention and a method of determining tension in accordance with the present invention; and,
[0027] [0027]FIGS. 8A and 8B are views of a sling material in accordance with another embodiment of the present invention and a method of determining tension in accorance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention provides efficient and reliable slings for use in treating males and females. The sling is particularly suitable for pelvic floor reconstruction surgery and for treating urinary incontinence. The features of the invention as described herein provide a surgical sling having at least two different elongation characteristics along its surface area. In addition, the slings may be coated with, for example, a silicone coating. Such coating is believed to contribute to the desired elongation properties of the mesh, assist with ensuring biocompatibility, and provide a carrier for anti-microbial agents.
[0029] Referring to FIG. 1, an enlarged plan view of a material 10 according to one aspect of the invention includes a material that is a surgical mesh 12 . Individual strands or filaments 14 collectively form a multifilament yarn 16 that can be woven or braided 18 to form the desired weave. The weave leads to a pattern of holes or pores 24 .
[0030] Materials suitable for use in fabricating the coated slings of the present invention include man-made materials such as filamentous mesh materials. Filamentous mesh materials include synthetic fibers such as polyester, polyurethane, nylon, or polypropylene which can be woven or braided to form a mesh 12 . The filaments in such materials may be oriented in a single direction or may be multidirectional.
[0031] As will be further described below, the pattern formed by the weave can be designed so as to provide a mesh material having directionally oriented elongation properties. In a preferred embodiment of the present invention, the mesh material comprises a weave pattern where the holes 24 have a diamond shape. As would be apparent to one skilled in the art, the degree of “stretch” or elongation properties in either direction of the mesh pattern can be adjusted as preferred by a user by altering the weave of the mesh material.
[0032] In a preferred embodiment, a synthetic filamentous material suitable for fabricating a mesh for use as a sling include a commercially available material comprised of a Rashel knit mesh made from 150 denier polyester yarn. Such a mesh has a hole size of approximately {fraction (1/32)}″ (0.794 mm) and a weight of approximately 4.7 oz/yd. (133.25 gr/0.914 m). The yarn is a multi-filament yarn. In another embodiment a mesh know as Mersilene™ may be used.
[0033] The weave of the mesh according to one aspect of the invention is such that it has greater elongation properties in one direction 20 than it does in a second direction 22 transverse (or perpendicular) to the first direction 20 .
[0034] In a preferred embodiment wherein the mesh is cut in a rectangular, sling-like configuration, the elongation properties of the mesh in the longitudinal direction are such that the mesh will elongate in the range of about 24%-28% beyond its normal state when placed in tension by a 20 lb. (9.072 kg) load. The elongation properties in a direction transverse (i.e., perpendicular) to the longitudinal direction, that is, in the latitudinal direction, are such that the mesh will elongate in the range of about 65% -75% beyond its normal state when placed in tension by a 20 lb. (9.072 kg) load.
[0035] By virtue of the longitudinal direction having lesser elongation properties than the latitudinal direction, there is less tendency for the longitudinal edges of the sling to curl in on themselves when the sling is in tension along the longitudinal direction. This is a desired property along the longitudinal direction of the mesh insofar as an implanted sling that becomes curled in this manner can be more prone to cause tissue irritation and ultimately tissue erosion in the patient.
[0036] Conversely, by virtue of the latitudinal direction of the mesh sling having greater elongation properties, the sling provides greater flexibility and “give” in a direction parallel to the urethra. As a result, the sling can still serve its function of treating incontinence but it does so with less trauma and greater comfort since the sling is now more responsive to patient movements and activities.
[0037] These desirable properties of the mesh are particularly acute in sling operations where the sling is attached to the pubic bone at the sling's opposite longitudinal ends. That is, the properties of the invention are best utilized when the sling is attached to opposite sides of the pubic bone and placed in tension along its longitudinal axis. In this manner, elongation is allowed in the longitudinal direction with minimal edge curling while at the same time the elongation is enhanced in the latitudinal direction to promote responsiveness to patient movement. This result is believed to make the sling procedure a more clinically stable procedure that improves patient comfort.
[0038] Alternatively, in some surgical procedures, the sling may be placed in the body in a tension free rest position. Even in this tension free rest position, the sling according to the present invention is believed to resist edge curling when anatomical movement (e.g. a stress event such as a cough) places tension on the sling.
[0039] As depicted in FIGS. 2 A- 3 B, the present invention further contemplates a sling wherein the above-described mesh material is coated with a substance to enhance its properties and, in some cases, provide a platform for the impregnation of therapeutic substances (drugs, antibiotics, etc.). One such coating may be silicone. In particular, when the material of the sling is constructed of individual yarns that have the potential for tissue ingrowth, the silicone 30 substantially coats the exposed surfaces of the yarns and fills in irregular surfaces of the yarns of the mesh material and between individual yarns of the mesh, thereby substantially preventing in-growth of tissue into the fibers of the yarn of the sling material. Minimizing the exposed surface area also reduces the ability of bacteria or microbes to reside within the mesh material if the sling is exposed to bacteria during the implantation procedure. This is particularly advantageous as it decreases the risk of infection to the patient following implantation of the sling. This also restricts bacterial ingrowth into and between any fibers of the yarn, thereby further resisting infections.
[0040] As is evident from the figures, the coating is applied in a manner such that the holes or pores 24 of the mesh remain open and clear of silicone. That is, the exposed surfaces within the holes or pores 24 themselves remain open and free of silicone. As a result, a sling is obtained that resists infection (due to the coating) but also promotes tissue in-growth (due to the holes or pores 24 ).
[0041] A synthetic sling fabric material that is coated with a substance such as silicone is also advantageous in that the coating can provide lubricating characteristics to the mesh that enables easier adjustment of the sling during the implantation procedure. Further, the silicone coating creates in the sling a composite structure of the fabric and the silicone that better interacts with the patient's tissue. The silicone also coats the yarn material to the degree that the yarn functions much like a monofilament. Such a monofilament is believed to be less prone to infection. It is also believed to lead to less erosion of the tissue.
[0042] A coating such as silicone provides a platform from which therapeutic substances like antibiotics or antimicrobial agents can be introduced to the patient. Such agents can be impregnated into the silicone coating or, alternatively, may be formulated with the composition comprising the silicone coating and applied during the coating procedure. In some embodiments, a silicone coating containing or impregnated with antibiotic agents may contain a drug that is formulated to be time-released. Examples of agents suitable for use include antibiotics and antimycotics such as, gentamicin, fungizone, rifampin or minocycline HCL. Other agents may also be incorporated in the silicone, such as, but not limited to antiseptic agents, radioopaque agents and other antimicrobial agents.
[0043] In a preferred embodiment of the invention, the coating of the sling will also impact the dual elongation properties of the sling. For example, the fabric mesh discussed previously, which is later coated with silicone, will result in a mesh that elongates in its longitudinal direction about 19.5%-21.5% beyond its normal state when placed in tension at about 20 lbs. (9.072 kg) of force. Conversely, the mesh elongates in its latitudinal direction about 120%-130% beyond its normal state when placed in tension at about 20 lbs. (9.072 kg) of force. This is a desired result insofar as elongation properties are tending to be enhanced in the latitudinal direction (to provide patient comfort) but are tending to be minimized in the longitudinal direction (to reduce any curling propensities).
[0044] In this preferred embodiment, the reduced elongation properties in the longitudinal direction are believed to have been achieved as a result of holding the mesh in tension in the longitudinal direction at the time the mesh was coated. In other words, it appears that pre-stretching, or at least pre-tensioning the mesh in the longitudinal direction during the coating process, led to the reduction in elongation properties in the longitudinal direction as compared to the elongation properties in the longitudinal direction in the uncoated mesh sling. As a result, it is contemplated as part of the invention, that, should it be desired to avoid reduction of the elongation properties in the longitudinal direction, the mesh should not be held in tension along the longitudinal direction and perhaps should be held free of tension altogether, or in uniform tension, or in tension along the latitudinal direction prior to silicone coating.
[0045] In this regard, a number of tests have been performed to more fully expand the explanation and implementation of the present invention. These tests involve the acquisition of data on the elongation properties of the sling according to how the sling has been processed with a silicone coating. The result of the tests are set forth in the following table.
TABLE A Si Coated w/ Si Coated w/ 5 Lb test Si Coated w/o Longitudinal Latitudinal load Uncoated Pre-Tension Pre-Tension Pre-Tension Longitudinal 8% 5% 2.5% 10.5% Elongation Latitudinal 36% N/A 65% 25% Elongation
[0046] As is evident from the table, there were four types of slings that were tested, namely: (1) an uncoated sling; (2) a sling that was not held in tension while being coated with silicone; (3) a sling that was held in longitudinal tension while being coated with silicone; and, (4) a sling that was held in latitudinal tension while being coated with silicone. As is also evident from the table, each of the four slings were tested for respective elongation properties both in the longitudinal direction and the latitudinal direction. These tests were conducted using a 5 lb tension-loading device.
[0047] The resulting data is consistent with the elongation figures discussed previously. For example, when the sling is coated with silicone while under longitudinal tension, there is a dramatic decrease in longitudinal elongation properties in the resulting sling accompanied with a dramatic increase in latitudinal elongation properties in the sling as compared to the corresponding elongation properties of an uncoated sling. In addition, a sling coated with silicone under latitudinal tension leads to a sling having increased longitudinal elongation properties accompanied with reduced latitudinal elongation properties. As a result, it can be seen that desirable elongation properties that would otherwise not be available under normal conditions can be “locked” into the sling during the coating process.
[0048] One embodiment of the invention that is particularly exemplary of a manner in which to exploit the invention is set forth in FIG. 5. In this embodiment, a sling 500 is provided that has different elongation properties at different regions or zones on the sling. These regions are a result of molding separately manufactured strips or portions of coated fabric into a single sling 500 .
[0049] For example, in one embodiment, the central region 502 of the sling 500 has been coated with silicone while in latitudinal tension thus giving this central region 502 a somewhat increased longitudinal elongation property and a somewhat decreased latitudinal elongation property over a non-pretensioned coated sling (see Table A).
[0050] The intermediate regions 504 of the sling 500 have been coated with silicone while in longitudinal pre-tension, thus giving the intermediate region 504 a dramatically decreased longitudinal elongation property and a dramatically increased latitudinal elongation property over a non-tensioned, coated sling. Moreover, the intermediate regions 504 may molded into place to form the sling in a transverse direction (i.e., rotated 90°) as compared to the configuration of the fabric in the central region 502 . As a result the longitudinal and latitudinal elongation properties exhibited by these intermediate regions 504 of the sling 500 actually correspond to the latitudinal and longitudinal properties, respectively, set forth in Table A for the sling that was silicone coated while in longitudinal tension.
[0051] The end regions 506 of the sling 500 have been coated with silicone while in longitudinal tension thus giving the end regions 506 a decreased longitudinal elongation property and an increased latitudinal elongation property (see Table A). The end result is a sling 500 that provides varying elongation properties along the length of the sling 500 that can be best suited to mitigate undesirable curling tendencies of the sling while enhancing the desirable flexibility characteristics of the sling.
[0052] Although the aforesaid embodiment is disclosed as comprising discrete portions of coated fabric that are molded into a complete sling, this aspect of the invention is not so limited. For example, it is within the scope of the invention to create a similar “multi-zone” sling merely by coating various regions or zones of a unitary sling under differing tension parameters at these various regions or zones.
[0053] In view of the above disclosure, it will be seen that the dual elongation properties of the invention as well as the coating by a substance such as silicone, enhances and improves the efficiency of the sling when placed in the patient. Furthermore, the coating and method of coating improves the lubricity between the mesh and the tissue and also appears to enhance the elongation properties of the sling. In other words, a sling in accordance with the present invention provides the needed long term support for effectively stabilizing the urethra to its normal anatomical position while also permitting temporary movement of the urethra (due to the dynamic nature of the patient's anatomy and movements) with the pelvis.
[0054] Depending upon the parameters of the coating process used, varying degrees of silicone thickness surrounding the mesh yarns can be obtained. However, in all circumstances, the holes or pores 24 remain open after coating. Referring to FIGS. 2A, 2B, 3 A and 3 B, depending upon the desire or need of the user, a sling can be coated so as to comprise a coated mesh material having a thickness ranging from about 0.024 inches (0.61 mm) to about 0.036 inches (0.914 mm) (FIGS. 3A, 3B) or from about 0.020 inches (0.508 mm) to about 0.025 inches (0.635 mm) (FIGS. 2A and 2B). In one embodiment, the thickness of the sling material in the uncoated state is about 0.020 inches (0.508 mm) plus or minus about 0.002 inches. In a preferred embodiment, the size of the holes or pores 24 after coating is preferably in the range of about 0.040 inches (1.016 mm) to about 0.055 inches (1.397 mm).
[0055] In a preferred embodiment, a silicone-coated sling will have a generally rectangular shape that is approximately 2-12 cm wide (more preferably 10 cm) and 5-20 cm long. In particular, a silicone-coated sling of the present invention will be of sufficient size and dimension so as to pass behind the urethra and support the urethra in its normal anatomic position when implanted in vivo. In addition, the silicone-coated sling should be adapted so as to be capable of preventing abnormal urethral descent under increased intra-abdominal pressure.
[0056] It is contemplated that the present invention can be used with a variety of sling systems and methods for treating urinary incontinence. For example, a coated sling in accordance with the present invention, can be used with the system for the long term cure of recurrent urinary female incontinence as described in co-pending U.S. patent application Ser. No. 09/236,212 filed Jan. 1, 1999 (Kovac), entitled “System and Method for Treating Female Urinary Incontinence,”) the entire disclosure of which is hereby incorporated by reference. When used in such a system, a silicone-coated sling can be installed in vivo using the vaginal installation procedure as described in the application. Alternatively, a coated sling in accordance with the present invention can be prefabricated according to the dimensions and shapes as described, for example, in U.S. Pat. No. 6,042,534 issued Mar. 28, 2000 entitled “Stabilization sling for use in minimally invasive pelvic surgery” and installed as described in U.S. Pat. No. 6,042,534. A coated sling of the present invention can also be installed abdominally or laparoscopically using procedures well known in the art.
[0057] In addition, sheets of silicone coated fabric may be prepared in a similar manner for general pelvic floor reconstruction.
[0058] Method for Silicone Coating a Sling
[0059] [0059]FIG. 4 illustrates one preferred embodiment of a process of applying a silicone coat to a mesh material for use as a sling. The method includes step 40 of providing a mesh material which can be manipulated for use as a sling. In a preferred method, a silicone dispersion is selected for use as the coating material. In step 40 , a preferred mesh material is as previously described. The silicone dispersion is preferably a medical grade silicone disperstion. The silicone dispersion is a result of mixing equal parts (100 g each) of a silicone such as Medium 6820 with 5 parts (500 g) solvent such as Xylene. The dispersion can be mixed by stirring on a stir plate in a fume hood. Mixing should be performed for a minimum of 20 minutes with the container covered so as to minimize evaporation.
[0060] Next, in step 50 , a container such as an aluminum pan is filled with the silicone dispersion for immersion of the mesh material. The pan should be kept covered (with foil, for example) when not in use, so as to prevent evaporation.
[0061] In step 60 , the mesh material is placed into the dispersion mix and is held flat by use of, for example, 6″ (15.24 cm) embroidery hoops. When using embroidery hoops, the mesh material should be pulled through the edges of the hoop until the mesh material is taut, flat, and constrained along most if not all of the peripheral edges of the mesh material. Care should be taken not to inordinately stretch the material as this could result in distortion of the holes of the mesh material or in uneven coating of the mesh material, which can affect the dual elongation aspect of the sling. The mesh material should be trimmed to be sized closely to the dimensions of the hoop so as to minimize material overlap. The hoop containing the mesh material is placed into the pan containing the silicone dispersion for about 15 seconds, or more, and then removed.
[0062] In other embodiments, the sling material can be held in tension at opposite ends of the sheet prior to applying the coating. As discussed previously, depending on which direction of the mesh is in tension during coating, differing elongation properties in the sling may be obtained.
[0063] In step 70 , excess silicone dispersion 42 is removed by allowing the silicone to drip off of the mesh material as the hoop is placed flat over the pan for about 1-5 minutes.
[0064] In step 80 , the coating within the holes of the mesh material are cleared. This can be performed by using a foot-controlled air nozzle having an air setting of approximately 55-psi and 600 pulses per minute. Using the air nozzle, the coated mesh material can be continuously sprayed to clear the openings until there are minimal or no holes filled with silicone dispersion mix. In one embodiment, the spraying is performed intermittently. For example, pulsed air may be used.
[0065] In step 90 , the coated mesh material is rested, air-sprayed side up, for approximately 5 to 15 minutes.
[0066] In step 100 , the entire procedure outlined above in steps 50 - 90 is then repeated with the exception that the second side of the mesh material is now air-sprayed so as to ensure a uniform distribution of the silicone coating over all surfaces of the mesh material.
[0067] The spraying steps are performed also to ensure that the holes or pores of the mesh are not filled or closed with silicone. As stated previously in one embodiment of the invention, the sling has been coated with silicone but still contains open holes or pores to promote tissue growth.
[0068] In a preferred embodiment, the entire procedure outlined in steps 50 - 100 is repeated until both sides of the mesh material have 2 coats or more of dispersion 120 . During the repeating process, alternate sides of the mesh material may be air-sprayed.
[0069] In step 140 , the silicone coating is heated to set the silicone dispersion. This can be performed, for example, by hanging the hoops holding the mesh in an oven that is set at 160° C. (±10°) for about 20 minutes.
[0070] It is noted that the sling according to the present invention may be constructed using a batch processor a continuous process. For example, in a continuous process, the silicone dispersion may be placed in a large reservoir, and the strip material may be provided in an elongate, substantially continuous strip that is substantially continusously fed into the reservoir using, for example, rollers and/or mechanical clamping structures.
[0071] In step 160 , the silicone coated mesh material is removed from the oven and allowed to cool. Following cooling, the material is then cut from the hoop. If desired, an anti-microbial substance or medicament can be impregnated into the silicone elastomer in a subsequent process.
[0072] After removing the material from the hoops, the silicone coated mesh material can then be fabricated as desired into a sling for use in treating urinary incontinence. As described previously, a silicone coated mesh material of the present invention, can be used to fabricate a sling such as described in co-pending U.S. application Ser. No. 09/236,212, filed Jan. 1, 1999 and then surgically implanted into a patient suffering from urinary incontinence.
[0073] In another embodiment, the sling material is configured in a long narrow elongated piece of mesh. The width is approximately the same width as a sling used in a patient. When coated, the edges of the material along the length of the material are coated with the silicone. When an elongated material is used in this manner, all that is required to obtain a sling suitable for use in a patient is to cut the elongated material through its width at the desired length of the sling. This will yield a sling that has the edges along the longitudinal side of the sling completely coated with silicone. In other words, since there is no necessary cutting in the longitudinal direction (because the material is already formulated to have the desired sling width) to obtain a desired size of sling, the integrity of the coating along the uncut edges remains intact, thus better ensuring the advantageous properties introduced in the sling as a result of coating.
[0074] A silicone coated sling as described herein can be fabricated into a variety of dimensions or can be manipulated to conform to a variety of sling specifications, depending upon user or manufacturer's preference. In addition, the coated sling can also be adapted so as to include structures to aid in the attachment or connection of the sling to the patient in vivo. It is also to be emphasized that silicone is only one coating that may be used, and, as such, is only exemplary, not limiting, in the context of the invention.
[0075] In still further embodiments in accordance with the present invention, it is desired to enable the user to more easily determine the presence and magnitude of tension in the sling material during placement of the sling. The ability to accurately make this determination will allow the user to adapt the fixation of the sling in the patient in a manner to maximize the potential of successfully treating the incontinence problem.
[0076] Referring to FIGS. 6A and 6B, a sling material 600 is shown in both the unstretched, condition (FIG. 6A) and in the tensioned condition (FIG. 6B). This sling material 600 can be comprised of any of the types and variations of mesh material previously discussed in this specification or any other type of mesh material that allows an elongation of the sling when placed under tension.
[0077] When in the unstretched condition (FIG. 6A) the sling 600 has a normal width 602 (e.g., approximately 5 cm) in the central region of the sling 600 . When the sling 600 is placed into tension (FIG. 6B), however, the sling 600 takes on a reduced width 604 (e.g., approximately 1 cm) in the central region of the sling. By virtue of this phenomenon, a mesh material having certain known elongation (discussed above) properties can be used so that when the sling 600 achieves the reduced width 604 , a known tension thus exists in the sling. Moreover, this known tension can be selected to exist in the range that is most optimum for treating the incontinence. Furthermore, by using a mesh material in accordance with previously discussed embodiments, the optimum tension can be achieved without the undesirable curling in the mesh that can cause tissue erosion. In the end, a mesh material is provided that potentially minimizes many of the undesirable aspects of placing a sling into a patient while at the same time optimizing the placement so as to enhance the prospect of successfully treating the incontinence condition.
[0078] Referring to FIGS. 7A and 7B, another embodiment of a sling 700 that provides a visual tension indicia is disclosed. In this embodiment, the sling material is fabricated so that there is a geometrical pattern in the form of a square 702 visibly evident on the surface of the untensioned sling 700 (FIG. 7A). However, as the sling is placed in tension, the geometrical pattern 702 becomes distorted. Moreover, using the known elongation properties of the sling, the sling can be fabricated such that when the geometrical pattern achieves a different known shape due to tensioning, say, for example, a circle, ellipse or polygonal structure with one or more arcuate portions (e.g. 702 A), the sling will have achieved the desired tension for proper placement in the patient.
[0079] The invention as disclosed in the embodiment of FIGS. 7A and 7B is not limited to visual indicia in the form of geometrical patterns. For example, the visual indicia could be a series of seemingly random lines that, under the target tension, become alligned into a straight line or into a geometrical pattern such as a triangle. As another example, the visual indicia could be a collection of marks or characters that, under the target tension, become alligned to spell a word such as “OK,” or “STOP,” or “LIMIT.” In one embodiment the word could even spell the manufacturer of the sling, such as “AMS.”
[0080] The visual indicia described above could be integrated into the mesh material a variety of ways. For example, the mesh could actually be integrated into the fibers that are woven into the mesh so that the indicia is present upon weaving the material. In another example, the visual indicia could be added to the mesh as a component of a coating (e.g., silicone) applied to the mesh material.
[0081] Referring next to FIGS. 8A and 8B, an embodiment of the invention is disclosed wherein the visual tension indicia is in the form of changes in the weave of the mesh. For example, a mesh 800 could be used such that it takes on a substantially square hole pattern (FIG. 8A) in the untensioned condition. Then, when the mesh 800 is stretched the hole pattern becomes distorted. Based on the known elongation properties of the mesh, the mesh can be manufactured such that a particular desired tension is present in the mesh when the hole material has changed into a different, recognizable pattern. In one embodiment, that new hole pattern could be a parallelogram structure as shown in FIG. 8B.
[0082] It will be evident to the reader that the visual tension indicia component of the present invention is not limited to the isolated embodiments disclosed in the figures and that various combinations of visual tension indicia is also contemplated. For example, a mesh using a varying hole pattern indicia as in FIGS. 8A and 8B could be combined with either of the visual indicia ideas contemplated in the embodiments of FIGS. 6A, 6B, 7 A and 7 B. In the end, the principle to guide the use of indicia is that the user be better enabled to know when a desired tension has been achieved in the sling by simple visual observation.
[0083] The present invention provides a simple, safe and stable system for treating urinary incontinence. The invention, as described herein, with reference to preferred embodiments, provides a coated sling that supports an abnormally distended urethra to effectively remedy urinary incontinence.
[0084] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
[0085] All publications and patent applications in this specification are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated by reference.
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The present invention relates to a sling, methods of making and using a sling, and kits comprising a sling for treating urinary incontinence. The sling has multiple elongation properties that serve to improve the support of the urethra. The sling may comprise a coated material adapted for urethral suspension. The coated sling has properties that appear to enhance the sling elongation characteristics. The coated sling further includes properties that reduce its susceptibility to bacterial infections. The sling further includes properties to enhance the proper tensioning of the sling.
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[0001] This application claims priority from U.S. Provisional Patent Application Serial No. 60/240,168 filed Oct. 13, 2000. The entirety of that provisional application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to devices for card mixing, and in particular to an automatic card mixing device for discarded cards dealt from a card shoe.
[0004] 2. Background of the Technology
[0005] Existing methods of dealing of Blackjack and other multideck casino card games provide unscrupulous players with opportunities to take advantage of the house. In standard play in casinos, every card is turned up at the end of play so that players are able to see the cards following the play. The cards are then placed in perfect order in a discard rack. This procedure occurs for each hand. One reason for this approach is to allow the house to back out of a hand.
[0006] One problem with these existing approaches is that, upon completion of discard of all of the cards in a shoe, a player or card tracker with a good memory (e.g., a photographic memory) may have a perfect picture of the order of 80% of the cards. If the house fails to make a thorough shuffle, the cards can be tracked.
[0007] There remains a need for devices, particularly automated devices, for assuring thorough and random mixing of discarded cards prior to shuffling and continued play with the cards.
SUMMARY OF THE INVENTION
[0008] The present invention, referred to as an “automatic discard rack” is usable to assure thorough and random mixing of cards, such as cards discarded during play of casino card games, prior to shuffling and continued play with the cards. The present invention thus automatically increases randomness of the cards for shuffling.
[0009] With the present invention, when the dealer inserts, for example, a dead hand into the discard rack, a preset or optionally adjustable delay starts, followed by a clamping portion controlled by a controller and a moving engine within the rack, such as a pair of gripper arms, placing any cards already in the clamping portion onto the pile of cards in the device, and randomly picking up a portion of the discarded cards. The delay allows the dealer to retrieve the cards placed into the device prior to mixing, upon, for example, an error or challenge occurring during the course of play of the card game. The clamping portion holds the cards until the dealer inserts the next hand, and so on for each additional hand. The present invention, which, in one embodiment, is capable of holding up to eight decks of cards, thus randomly mixes the dead hands, reducing the likelihood that trackers are able to track the cards discarded or otherwise placed into the rack following discard. The device is also configurable to handle any number of decks of cards.
[0010] In an embodiment of the present invention, the clamping portion operates within or from a housed portion of the rack, the housed portion also including a moveable lifting portion for moving the clamping portion, a moving engine, such as an electric motor or solenoid for causing the movement of the clamping portion, including clamping via, for example, gears, levers, ratcheting devices, arms, and/or other features known in the art, a controller, such as a processor for controlling operation of the clamping portion, a sensor, such as an electric or electronic eye for sensing placement of cards in the device and initiating movement of the clamping portion, and optional other features, such as a “kill switch” and an on/off switch.
[0011] The present invention thus allows the casino operator to perform a simple and quick shuffle and to still have confidence in complete protection against cheaters. As a result, casinos potentially make more revenue due to the increased number of hands that may be played, owing to the reduced shuffle time, while reducing the likelihood of lost revenue due to card counting or tracking.
[0012] Additional advantages and novel features of the invention set forth in part in the description that follows, considered in conjunction with the accompanying drawing figures, will become more apparent to those skilled in the art upon examination of the following or upon learning by practice of the invention. It is to be understood, however, that the drawings are designed solely for the purposes of illustration and not as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE FIGURES
[0013] In the drawings:
[0014] [0014]FIG. 1 presents a perspective view of an automatic discard holder, in accordance with one embodiment of the present invention;
[0015] [0015]FIG. 2 shows a second example layout and design for an automatic discard holder, in accordance with an embodiment of the present invention;
[0016] [0016]FIG. 3 presents an example of mixing of cards in the rack of FIG. 1, following random grasping and pickup of a portion of a stack of cards, in accordance with an embodiment of the present invention;
[0017] [0017]FIG. 4 is a side view of an automatic discard holder device, in accordance with an embodiment of the present invention; and
[0018] [0018]FIG. 5 is an overhead view of another embodiment of an automatic discard holder device in accordance with the present invention.
DETAILED DESCRIPTION
[0019] The present invention is a device for automatically mixing cards placed into the device, including, for example, cards discarded in the course of standard play of a card game, such as a card game at a casino, prior to the cards being shuffled for use in additional play.
[0020] References will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0021] [0021]FIG. 1 presents a perspective view of an automatic discard holder, in accordance with one embodiment of the present invention. As shown in FIG. 1, the holder 1 , includes a base 2 , such as a plastic or other material bottom, a top cover 3 , and an opening 4 for receiving cards into the holder 1 . The opening 4 allows observers, such as card game players, to view the mixing of the cards by the holder 1 . The holder 1 also includes a housing portion 10 and one or more side extensions 12 . The arrangement and design of the housing 10 , side 12 , top 3 , and bottom 2 of the rack 1 , as shown in FIG. 1, are merely illustrative of one design and layout for the device. As will be obvious to one skilled in the art, many arrangements and designs for the the device are possible without departing from the scope of the invention. A second example layout and design for a rack 20 , in accordance with a second embodiment of the present invention, is shown in FIG. 2.
[0022] As shown in FIG. 1, in use of the holder 1 , in accordance with one embodiment of the present invention, upon, for example, discard of hands in the course of play of a casino game, the discarded cards are placed in a stack on the bottom 2 of the holder 1 . As will be described further, following a short delay, a clamping device 13 , 14 , including, for example, gripper arms, proceeds to move via a moving device housed in the housing 10 .
[0023] [0023]FIG. 3 shows an example of mixing of cards in the rack of FIG. 1, following random grasping and pickup of a portion of a stack of cards, in accordance with an embodiment of the present invention. As shown in FIG. 3, the clamping portion 13 , 14 , such as or including gripper arms, the gripper arms including, for example, rubber or other clamp ends, randomly grasps for a portion of the cards 15 of the stack of cards 15 , 16 in the rack 1 , and picks up the portion of the cards 15 . The clamping portion 13 , 14 , remains in the position shown in FIG. 3 (or at another preset stop location above the portion of the cards 14 on the bottom 2 ) until the next cards for mixing are placed on top of the portion of the cards 14 on the bottom 2 of the rack 1 . The clamping portion 13 , 14 , then releases the portion of the cards 15 , adding these cards 15 to the portion of the cards 16 on the bottom 2 of the rack 1 , including any newly added cards (e.g., cards newly discarded between the clamped card portion 15 and the portion of the cards 16 on the bottom 2 ). The clamping portion 13 , 14 is designed with materials and so adjusted so as to ensure no marks, bends, or other impacts occur on the cards, which players could use to their advantage.
[0024] The process then repeats, with the clamping portion 13 , 14 randomly moving to pick up another portion of the cards, to enhance mixing. In an embodiment of the present invention, the action of the clamping portion 13 , 14 is triggered by a sensor, such as an electric or electronic eye, which senses placement of cards in the rack 1 . A controller, such as a processor and/or electronic circuitry, controls motion of the clamping portion 13 , 14 , including any preset delay.
[0025] [0025]FIG. 4 is a side view of an automatic discard holder device, in accordance with one embodiment of the present invention. As shown in FIG. 4, the rack 1 includes bottom 2 , top, 3 , at least one side portion 12 , and housed portion 10 . In this embodiment, inside the housed portion 10 are a moveable lifting portion 30 , such as or including a ratchet mechanism, for incrementally or smoothly raising and lowering the clamping portion 13 , 14 . Opening and closing of the clamping portion 13 , 14 is also controlled via the moveable lifting portion 30 .
[0026] A moving engine 32 , such as an electric motor and/or solenoid, coupled 33 to the moveable lifting portion 30 , causes motion of the clamping portion 13 , 14 , both upwardly and downwardly, as shown in FIG. 4, along the moveable lifting portion 30 , and to open and close the clamping portion 13 , 14 for grasping and releasing cards. A controller 35 , such as or including a processor and/or electronics, controls the operation of the moving engine 32 , thereby controlling movement of the clamping portion 13 , 14 via the moveable lifting portion 30 , in both the upward and downward directions, as shown in FIG. 4, and to open and close the clamping portion 13 , 14 . A sensor 36 , such as an electric eye or other mechanism for sensing that cards are placed in the device 1 , is connected by coupling 37 , such as by a wire or wires, to the controller 35 .
[0027] In operation, the clamping portion 13 , 14 is initially in a stop position, such as a position toward the top of the device 1 , as shown in FIG. 4, and the clamping portion 13 , 14 is closed so as to hold any cards grasped by the clamping portion 13 , 14 . Cards, such as discarded cards, are placed onto the bottom 2 or onto cards already placed on the bottom 2 of the device 1 . The controller 35 , upon sensing, by the sensor 36 via the coupling 37 , that cards have been placed in the device 1 , begins a cycle of operation. First, a preset delay occurs, so as to allow the newly placed cards in the device 1 to be removed, if, for example, a challenge or error occurs during course of play of the card game. The controller 35 then causes the clamping portion 13 , 14 to drop or place any cards that are in the clamping portion 13 , 14 onto the cards on the bottom 2 .
[0028] A randomizer in the controller 35 then determines a random location for the clamping portion 13 , 14 to move relative to the cards in the device 1 , the random location being a random height above the bottom 2 of the device 1 . This randomly determined height corresponds to a random number of cards in the pile. The controller 35 then causes the clamping portion 13 , 14 , to grasp and pick up any cards at or above the random location and move those cards to the predetermined stop location. This cycle is complete and the device appears as shown in FIG. 3, with, for example, a portion of the cards 15 in the clamping portion 13 , 14 and a portion of the cards 16 on the bottom 2 . (Note that, if the clamping portion 13 , 14 moves randomly to a location above the top of the pile of cards on the bottom 2 , the clamping portion 13 , 14 will grasp no cards before moving to the stop location; this scenario is a random event within the scope of the present invention.) The device 1 also includes an optional release button coupled to the controller 35 for causing the release of cards from the clamping portion 13 , 14 without further movement of the clamping portion 13 , 14 , as occurs, for example, when all cards are to be removed for shuffling and play of a card game.
[0029] The device 1 of the present invention includes a power supply or coupling for connection to a power supply, such as a wire coupling and plug for connection to a 110 or 230 volt alternating current (AC) or other outlet. The power supply may also be self-contained, such as a battery within the device 1 . The present invention also includes an optional “kill switch” or other cutoff switch coupled to the controller 35 or to the power supply to interrupt power to the device in emergency situations.
[0030] [0030]FIG. 5 is an overhead view of another embodiment of the automatic discard holder device of the present invention. In the variation of FIG. 5, the clamping portion 13 , 14 includes a knife portion 40 for insertion into the stacked cards during pickup. The moveable lifting portion 30 , as shown in FIG. 5, includes gears, levers, ratcheting features, and attachments to the clamping portion 13 , 14 and the engine portion 32 , as are known in the art, so as to allow the sequential combinations of motions to grasp, move, and release portions of the cards, in accordance with embodiments of the present invention.
[0031] Also shown in FIG. 5 is an example connection 44 , such as wired connection, to the controller 35 , and coupling 45 , such as plug for plugging the device 1 into a power supply, such as a 110 or 230 volt AC wall outlet.
[0032] Thus, while there have been shown, described, and pointed out fundamental novel features of the invention as applied to embodiments thereof, it will be understood that various omissions, substitutions, and changes in the form and the details of the disclosed invention may be made by those skilled in the art without departing from the spirit of the invention.
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A device, referred to as the “automatic discard rack” for use on casino gaming tables or elsewhere to hold and mix playing cards, such as cards discarded following each hand of a played game. The device includes features for randomly picking up a portion of cards placed in the rack to allow cards inserted into the rack to be randomly inserted into cards already in the rack, and the cards to be repeatedly mixed by the device. Variations of the device include a housing, clamping portion, a moveable lifting portion for moving the clamping portion, a moving engine for causing the movement, including clamping, of the clamping portion, a controller for controlling all movement, sensor for sensing placement of cards in the device and initiating movement, a “kill switch,” and an on/off switch.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The invention relates to a roll-top type structure, placeable on a flat desk or table. Basically the structure is an imitation of the conventional solid roll-top desk, however, without the sliding cover, elevating legs and supporting flat desk surface.
The introduction of the solid roll-top desk, dates back to the 19th century, but because of its utility and nostalgia, it has become a much sought after item. In contrast to the conventional roll-top desk, the structure, according to the invention, may be shipped in a knocked-down state and rather quickly assembled for placing on the top of a desk. Furthermore, the structure is made, preferably of flexible lightweight prefabricated components, in decorative color(s), so that it will softly blend in with existing furniture.
The invention, basically serves the same purpose as the conventional roll-top desk, i.e., providing a number of horizontal and vertical pigeon compartments or holes for insertion of letters and files, drawers for storage of stationery, etc. The structure includes wings, projecting outwardly curved (which, in the original type roll-top desk holds the sliding cover) so as to give the person, e.g., a student, businessman, etc., the feeling of privacy when writing letters, etc.
The cost of manufacturing and shipping the prefabricated knocked-down unit made e.g., of corrugated fiber board is, of course far below that of the solid wooden roll-top desk.
(2) Prior Art
The inventor is not aware of any prior art that would anticipate his invention.
SUMMARY OF THE INVENTION
In addition to what was stated under (d) above, the invention refers to a light weight desk top organizer, which is made of corrugated fiber board section, however, possessing sufficient strength to carry the weight of sundry office supplies, including staplers, files, and the like. In assemblying--from a completely knocked down state--a number of partitions parallely, respectively perpendicularly to each other, one is able to construct a rigid sub-assembly containing open-ended double-walled pigeon holes, openings for drawers, etc. A supportive tray is then appropriately folded and mounted onto the back, top, bottom and side surfaces of the sub-assembly, and finally, a wrap-around section is loosely attached onto the bottom and vertical sides of the supportive partitioned tray in a manner that portions thereof are projecting forwardly and beyond the perimeter of the partitioned tray sub-assembly to form a table or writing surface and two lateral wings, which extend outwardly from the sides of the sub-assembly. In completing the desk top organizer, according to the invention, one has, thus constructed an imitation of the classical roll top desk, when placed on top of a plain table, desk, counter or supporting surface.
It is, thus the object of the invention to provide lightweight, and easy to assemble flexible components for a desk top organizer placeable on a table surface.
It is a further object of the invention to provide and create an illusion of the conventional roll top desk by way of inexpensive material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective front view of a desk top organizer in its entirety according to the invention.
FIG. 2 is a plan view of a number of partitions mountable into a sub-assembly of the desk top organizer.
FIG. 3 is a perspective view of two partitions, being assembled.
FIG. 4 shows the assembly of four partitions.
FIG. 5 shows the completed sub-assembly of partitions.
FIG. 6 shows a tray-like section extending in front, behind and laterally of the partition sub-assembly, for mounting thereon.
FIG. 7 shows the tray-like section laid out flat prior to placing the partition sub-assembly thereon.
DESCRIPTION OF THE INVENTION
In the drawings like reference characters designate similar parts in the several views of the drawings.
In a preferred embodiment of the invention, the complete unit is shown in FIG. 1 and is indicated by numeral 10.
Although the unit 10 may consist of an arbitrary number of components, the preferred embodiment, according to the invention, has a total of 14 parts, including, for example nine partitions 2, 14, 16, 18, 20, 22, 24, 26 and 28 (FIG. 2), three drawers 36 (FIG. 1), one main tray 32 (FIG. 7) and an outer wrap 34 (FIG. 1). The drawers 36 are optional and are made from a foldable flat fiber board section, in a known manner. The main tray 32 could be mounted to and enclose the assembled partitions 12 through 28, in any appropriate way, as long as it will ensure a rigid structure of unit 10. The outer wrap may, likewise be attached to the completed unit 10 in any suitable fashion.
As it appears from FIG. 2, partitions 12 through 28 are dissimilar in size and shape (except for partitions 22, 24). However, all of the partitions have some features in common. For example, each partition is provided with center double score lines aa, thus 12 aa through 28 aa. The purpose of the score lines is to facilitate the folding of each partition in half along these lines, so as to constitute, in folded state, double walled compartments or pigeon holes when assembled in conjunction with other partitions of unit 10. Each of the nine partitions are folded in a similar manner, as noted, preferably, simultaneously along the double score lines so as to form slightly spaced apart double walls.
Except for partitions 18, 22, 24, each partition (FIG. 2) has at least one die cut slot. For example, partitions 12, 20 and 26 have pairs of aligned first slots b, extending from and through the edges of opposite sides of the partitions towards score lines aa. Partitions 14, 16 and 28 have second slots bb extending, resp. equidistantly from and perpendicularly to the center of the partitions. Partitions 12, 16, 20 and 28 have third slots c, extending within the border lines of the partitions. The slots of a particular partition are labelled, e.g., 12b, 12c, 16bb, as the case may be.
The short sides of partitions 12 through 28 form die cut pairs of bendable flaps dd, thus the flap extensions (in continuation of score lines aa) of each short side of partitions 12 through 28 are respectively, indicated by numerals 12dd-28dd. Flap pairs dd of one folded partition are, thus intended to be paired--once the partition is folded along score line aa- and inserted through slot c of another partition, then bent outwardly, to planarly form a rigid gripping connection between two thusly crosswise assembled partitions. FIG. 3 illustrates how this is accomplished in the case of assemblying partitions 12 and 14. When partitions 12, 14 have been so assembled, the double walls of partition 12 are pressed together (as indicated by arrow) and can be temporarily held together by e.g., adhesive tape, until the infra-structure of unit 10 has been completed. The unengaged pairs of flaps dd will be inserted within interior spaces appearing in portions of tray 32 (FIG. 6), when folded.
Some of the flaps dd may have a somewhat rounded or square shape, which may, as required facilitate or strengthen the insertion of the flaps into adjacent partitions and the tray.
Sub-assemblies 16-18, 20-22-24 are basically assembled and mounted in a similar manner, as described above for sub-assembly 12-14.
In other words, sub-assembly 16-18 is assembled by inserting flaps dd of 18 in slot c of 16. Flaps dd of sub-assembly partitions 22-24 are inserted through slots c of partition 20.
As one may visualize from FIG. 3 aligned slots b and bb in partitions 12, 14, 16, 20, 26 and 28 will coincide with one another, when the partitions are folded up along score lines aa.
The basic functions of slots b and bb are illustrated in FIG. 4. For example, slots b of partition 12 ride in coinciding center slot bb of partition 16 of sub-assembly 16-18, in that slots b of poartitions 12 are slit through center slot 16bb and is supported by the solid portion of the latter (in extention of its slots bb).
Thus partition pairs 12-14, 16-18, 20-22-24 are interconnected, as described above.
Folded partition 26 is inserted parallely to partition 12, by having the coinciding slots b of the former slit down through slot bb of partition 16.
The end flaps dd of the three partitions 12, 18, 26 are, then respectively inserted in the three slots c of partition 28, and sub-assembly 20-22-24 is then inserted in remaining slots of partitions 14, 16 and 28, in order to complete the sub-assembly 30 of partitions 12 through 28 of unit 10. This is shown in FIG. 5.
There is provided means for enclosing the back and four sides of the completed sub-assembly 30. This may, e.g.; take the shape of a tray 32 (FIG. 6) within which sub-assembly 30 may be locked. Tray 32 is provided with double and single foldable score lines, 32a and 32b respectively, along which tray 32 is folded, so as to receive and enclose top, bottom, back and sides of sub-assembly 30. Tray 32 has a back portion 32c, a top portion 32d side portions 32e, 32i, and bottom portion 321, components of which, respectively are, folded, mounted onto and inserted in portions of sub-assembly 30, forming a compact supportive gripping tray there around, as is explained in more detail hereinafter.
In order to facilitate the interlocking of sub-assembly 30 and tray 32, one should place tray 32 on a table and prefold first along double score lines 32a and then along single score lines 32b. Sub-assembly 30 is placed on the center or main tray 32c of tray 32. All unengaged flaps dd of sub-assembly 30 are folded at 90° angle to their respective partitions, in order to engage and support the folded-up portions or panels of tray 32 (FIG. 6).
The middle portion of the top 32d of tray 32 is inserted into center section of sub-assembly 30. The side portions of the top 32d of tray 32 is then inserted into sub-assembly 30 (FIG. 6). Tabs 32f, g and ends of side section 32e are folded up and tab 32g is inserted under adjacent corner panel of top 32d. Panel 32h of side 32e is now inserted into sub-assembly 30. Side section 32i (opposite 32e) is folded and interconnected with sub-assembly 30 in the same manner as described for side 32e.
The panels 32k of the bottom portion 321 of tray 32 are then inserted into sub-assembly 30, by folding outer halves of panels 32k down at 90° angle to other halves of panels and inserting folded panels, resp., into partition sub-assembly 30. Finally, panel 32m of side main tray 32i is inserted into sub-assembly 30 and panel 32h of side main tray 32e is inserted into sub-assembly 30.
Outer wrap 34 may now be attached to the assembled sub-assembly 30 and tray 32, as shown in FIG. 1.
While the foregoing has illustrated and described what is now contemplated to be the best mode of carrying out the invention, the description is, of course, subject to modifications without departing from the spirit and scope of the invention. Therefore, it is not desired to restrict the invention to the particular constructions illustrated and described, but to cover all modifications that may fall within the scope of the appended claims.
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The disclosure describes an office organizer for placement on a desk, comprising a sub-assembly of folded partitions mounted paralelly, respectively perpendicularly to one another to form double walled compartments, a tray folded around the sides, top and bottom of the sub-assembly of partitions and a wrap, having a rectangular center portion and curved end sections and attachable to the sides and bottom of the tray, being so dimensioned as to provide forwardly projecting winged sides for and an extension of the bottom surface of the tray.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part application of U.S. patent application Ser. No. 10/687,854, filed Oct. 17, 2003, entitled Mobile Flame Sterilizer, and is incorporated by reference herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO MICROFICHE APPENDIX
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates generally to a flamer. More particularly the present invention relates to a fuel supply pressure controller for a stationary or mobile flamer.
[0006] 2. Background Art
[0007] Poultry litter may be sterilized by chemical means. As usual, the issue becomes that of chemical retention and the effect of the chemicals on the environment. Poultry litter may also be sterilized by flame heat, as disclosed by Mackenzie in U.S. Pat. No. 3,962,044. Because he discloses stationary equipment for litter sterilization, the method of Mackenzie '044 requires a significant investment in machinery to handle the litter for sterilization. Space for the machinery and appropriate shelter is also necessary.
[0008] A tractor drawn flamer was disclosed by Pivonka in U.S. Pat. No. 6,014,835 for the purpose of flame cultivation. Because of its open-flame design, the flamer of Pivonka '835 is not suitable for sterilization purposes. Because the use of the Pivonka '835 flamer for sterilization was not considered, there was no motivation to make the flamer enclosed for sterilization.
[0009] Handheld torches and flamers are available, again especially for weed control and ice melting. These flamers are not suitable for the large task of sterilizing large amounts of poultry litter or soil, etc. due to their small coverage and the weight that must be supported or drawn by the user.
[0010] Propane, commonly called Liquified Petrolium (LP), is usually the fuel used for flamers such as those used to sterilize poultry litter. The equilibrium pressure inside a propane tank containing a saturated mixture of liquid and vaporous propane is strictly a function of the temperature of these contents. However, during periods of heavy fuel usage, the pressure inside the tank may fluctuate due to finite times required for boiling off of the liquid into vapor and variations in temperature.
[0011] The rate flow of the fuel for a flamer is a function of the tank pressure. When the tank pressure varies, the fuel flow rate varies as well. Flaming, then, regardless of the purpose, may suffer in quality as long as the tank pressure is permitted to vary.
[0012] A tractor drawn flamer was disclosed by Pivonka in U.S. Pat. No. 6,014,835, which is hereby incorporated by reference. This tractor drawn flamer is used for flame cultivation.
[0013] A tractor drawn or mounted flamer was disclosed by Pivonka in U.S. Patent Application 2005/0084409 (Ser. No. 10/687,854), which is hereby incorporated by reference. This tractor drawn flamer is used for flame sterilization of poultry litter.
[0014] Neither of the above mobile flamers make use of a pressure control system.
[0015] There is therefore a need for a fuel pressure control system to use in conjunction with stationary and mobile flamers.
BRIEF SUMMARY OF THE INVENTION
[0016] An object of the present invention is to provide control of the fuel supply pressure for a flamer. Such stationary and mobile flamers may be used, for instance, to sterilize materials such as poultry litter, soil, and pavement; or for weed eradication, or softening asphalt. Tractors are ubiquitous in the agricultural industry. Because of tractors' versatility, implements are often made to mount to a tractor or be drawn behind a tractor. Heat has long been used for sterilization. So is it possible to utilize a tractor for transporting a mobile flamer to provide heat for sterilization. Such a flamer is mounted on the tractor—preferably on a three-point hitch or quick coupler. An additional embodiment of the present invention is represented by a flamer on wheels or skids and drawn behind a vehicle as a trailer.
[0017] The fuel supply pressure control system of the present invention provides a way to keep the fuel tank pressure near a predetermined value even during heavy fuel usage. To effect this control, fuel feed is selected from the vaporous and liquid components of the fuel. When vapor is being drawn from the tank, an equal amount of liquid must boil off to replace the vapor removed, plus a small volume equal to the volume of liquid converted to vapor. In contrast, when liquid is drawn off the fuel tank, the volume of liquid is much smaller than the volume of the same mass of liquid, i.e. the volume of the liquid is much smaller that the volume of the vapor. So the volume of vapor that must boil off in the tank to maintain the fuel tank pressure is greatly reduced.
[0018] The fuel supply pressure control system of the present invention preferably makes use of a pressure switch, set to make or change contacts at a predetermined pressure.
[0019] This is the pressure set point for the fuel supply. As long as the pressure is greater than the pressure set point, the flamer will utilize vaporous fuel. If the fuel supply pressure drops to or below the pressure set point, the contacts in the pressure switch will change, closing a vapor solenoid valve and opening a liquid solenoid valve, and liquid will be utilized by the flamer. The liquid fuel is vaporized after leaving the fuel supply tank. As the fuel travels toward the flamer torches, the pressure rises toward ambient. Boiling of the liquid fuel will result when it reaches the vaporizing portion of the torches, as the fuel attempts to reach an equilibrium state. Hence, at the torches, the fuel burned is vaporous, regardless of which solenoid valve is open at the time.
[0020] Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0021] FIG. 1 is a perspective view of the tractor-mounted flamer with a fuel tank mounted thereon;
[0022] FIG. 2 is a side elevation view of the tractor-mounted flamer;
[0023] FIG. 3 is a side elevation view of the tractor-mounted flamer;
[0024] FIG. 4 is a rear elevation view of the tractor-drawn flamer;
[0025] FIG. 5 is a perspective view of a wheel mounted flamer with the fuel tank mounted thereon;
[0026] FIG. 6 is a perspective view of the underside of the tractor-mounted flamer; and
[0027] FIG. 7 is a side elevation view of the tractor-mounted flamer being used to sterilize a surface;
[0028] FIG. 8 is a first piping schematic for a flamer fuel supply pressure control system;
[0029] FIG. 9 is a second piping schematic for a flamer fuel supply pressure control system;
[0030] FIG. 10 is a first wiring detail for the flamer fuel supply pressure control system;
[0031] FIG. 11 is a second wiring detail for the flamer fuel supply pressure control system;
[0032] FIG. 12 is a flow diagram of the logic for the flamer fuel supply pressure control system; and
[0033] FIG. 13 is a third piping schematic for a flamer fuel supply pressure control system; and
[0034] FIG. 14 is a detail of a flamer fuel supply pressure controller.
DETAILED DESCRIPTION OF THE INVENTION
[0035] A perspective view of one embodiment of the present invention is shown in FIGS. 1 and 2 . A side view and a rear view are seen in FIGS. 3 and 4 , respectively. A mobile flamer 100 is shown mounted on an implement hitch 105 of a tractor 110 . Fuel may, optionally, be carried on the flamer in a fuel tank 120 . In a second embodiment, the fuel may be separate from the flamer 100 , for instance, carried on the tractor in a tractor-mounted fuel tank 220 .
[0036] A hood for the flamer 100 comprises an external frame 130 and skin 140 . Because the frame is external to the skin 140 , the frame is exposed to less radiant heat transfer, reducing the problems such as oxidation and fatigue caused by high temperatures and thermal cycling. In addition, the flamer 100 can be insulated while maintaining a reflective surface inside the flamer because frame 130 members are not in the way.
[0037] The skin 140 substantially contains the high temperature gases, protecting the surroundings and concentrating the heat to the material to be sterilized.
[0038] Adjustable skids 150 are used to maintain an appropriate height above the litter or other material 700 (see FIG. 7 ) to be sterilized. The weight of the flamer 100 may be shifted between the tractor hitch 105 and the skids 150 , as needed. The flamer 100 is picked up with the tractor hitch 105 and carried off the surface for transport, cooling, etc.
[0039] An additional embodiment is shown in FIG. 5 wherein the flamer 100 is carried on wheels 510 and drawn behind the tractor 110 by its tongue 520 . The wheels may be drawn up, allowing the flamer 100 to rest on its skids 150 when in use. One advantage to this embodiment is that the flamer 100 may be towed behind any of a multitude of vehicles such as a truck, four-wheeler, or tractor.
[0040] The underside of the tractor-mounted flamer 100 is shown in FIG. 6 . A plurality of burners 610 are arrayed across the front of the flamer 100 , the angles of which are adjustable, as shown by the dashed lines. A barrier 620 may optionally be provided to assist in concentrating the heat, containing the gases, and protecting the surroundings. An additional option is shown as a set of rake teeth 630 to loosen and stir the material 700 being sterilized.
[0041] The mobile flamer 100 of the present invention is shown in operation in FIG. 7 . The surface material 700 being sterilized may be poultry litter, other livestock manure, soil, concrete, etc.
[0042] A schematic of the piping and instrumentation of the flamer fuel supply pressure control system is shown in FIG. 8 . Propane is stored in the fuel supply tank 120 . A vapor fuel line 805 and a liquid fuel line 810 are plumbed into the fuel supply tank 120 . Note that this schematic is valid for mobile and stationary flamers.
[0043] Various pressure gages 815 are provided to give insight into the current operation of the fuel system. The pressure gages 815 may be electronic and the readings displayed at a central location. The pressure gage readings may also be incorporated into a sophisticated control system.
[0044] Pressure relief valves 820 are provided at various locations throughout the fuel system. The pressure relief valves 820 shown in FIG. 8 expel overpressured fuel into the atmosphere. Another configuration would have the overpressured fuel piped to torches 825 .
[0045] The fuel supply control system 800 is shown inside the dashed lines in FIG. 8 . The fuel supply control system 800 comprises a vapor line solenoid valve 830 and a liquid line solenoid valve 835 . These valves are controlled by a pressure switch 840 .
[0046] A second example of a flamer fuel system is shown in FIG. 9 . In this example, a shutoff valve 910 is used to positively shut the flamer 100 down so no fuel flows.
[0047] Examples of the electrical relationships between the pressure switch 840 and the solenoid valves 830 , 835 are illustrated in FIGS. 10 and 11 . In both these circuits, a battery 1010 is connected to the pressure switch 840 via an on/off switch 1020 which provides a shutdown of the flamer 100 .
[0048] The system shown in FIG. 10 is especially suited for the piping shown in FIG. 8 . In FIG. 10 , the pressure switch 840 comprises a single pole double throw pressure switch. The solenoid valves 830 , 835 are normally closed valves, requiring electrical excitation to open. When the fuel source pressure decreases to the preset pressure set point, the pressure switch 840 is actuated, thereby changing the pole to which the battery 1010 is connected. At high pressures, the vapor solenoid valve 830 is open while the liquid solenoid valve 835 is closed. When the pressure drops to the pressure set point and the pressure switch 840 is actuated, the liquid solenoid valve 835 opens and the vapor solenoid valve 830 closes.
[0049] The circuit shown in FIG. 11 is suited for use with the plumbing illustrated in FIG. 9 . In FIG. 11 , the pressure switch 840 comprises a single pole single throw pressure switch. The vapor solenoid valve 830 is a normally open valve, while the liquid solenoid valve 835 is a normally closed valve, requiring excitation to close. When the fuel source pressure decreases to the preset pressure set point, the pressure switch 840 is actuated, thereby energizing both solenoid valves 830 , 835 . At high pressures, when neither valve is energized, the vapor solenoid valve 830 is open while the liquid solenoid valve 835 is closed. When the pressure drops to the pressure set point and the pressure switch 840 is actuated, providing connection to the solenoid valves 830 , 835 , the liquid solenoid valve 835 opens and the vapor solenoid valve 830 closes.
[0050] Because the vapor solenoid valve 830 is a normally open valve and thus, fuel may flow at any time, the additional, shutoff solenoid valve 910 is needed to provide secure shutoff of the fuel. This shutoff solenoid valve 910 is a normally closed valve, hence is closes when no power is provided to it. Note that the secure shutoff solenoid valve 910 may be used with the normally closed solenoid valves 830 , 835 illustrated in FIGS. 8 and 10 as well, providing redundant shutoff and the associated safety.
[0051] Other wiring configurations are possible, and the present invention is not limited to those shown in FIGS. 10 and 11 .
[0052] Regardless of whether the fuel is from the liquid or vapor fractions of the tank 120 , the fuel pressure is dropped through a pressure regulator 845 . A shutoff solenoid valve 850 is used to turn the flamer 100 off except for a small flame, the fuel for which is provided through a needle valve 855 , bypassing the shutoff solenoid valve 850 . The small flame permits the torches 825 to be refired at any time.
[0053] In FIG. 12 , a logic diagram is shown for the flamer fuel supply pressure control system 800 . The fuel supply pressure 1210 is compared to a predetermined pressure set point in a comparator block 1220 . This comparison is preferably carried out mechanically in the pressure switch 840 . If the fuel supply pressure 1210 is greater than or equal to the pressure set point, p sp , the vapor solenoid valve 830 is open and vaporous fuel is used 1230 by the flamer 100 . If the fuel supply pressure 1210 is less than the pressure set point, p sp , the liquid solenoid valve 835 is open and liquid fuel is used 1240 by the flamer 100 .
[0054] Note that appropriate hysteresis is required in the pressure switch 840 to avoid rapid switching between liquid and vaporous fuel.
[0055] A second embodiment of the present invention includes the flamer fuel pressure control system 1300 depicted in FIGS. 13 and 14 . In this embodiment, an electronic controller 1310 , either analog or digital, accepts a flow signal from a flow transmitter 1320 and a pressure signal from a pressure transmitter 1340 . Measurement and/or calculation of these values are well known to those of ordinary skill in the art. The electronic controller 1310 uses these signals to calculate an output for each of two control valves 1330 , 1335 . The flow of vapor is continuously controlled by the vapor control valve 1330 , while the flow of liquid is continuously controlled by the liquid control valve 1335 .
[0056] The electronic controller 1310 is detailed in FIG. 14 . The flow and pressure signals, from the associated transmitters 1320 , 1340 are shown input into the electronic controller 1310 . A flow set point 1410 is also available to the electronic controller 1310 , adjustable by an operator. The pressure set point 1420 may be predetermined by an operator, or it may be calculated as a function of a tank temperature signal from a temperature sensor 1350 , also shown in FIG. 13 . In the usual fashion, as understood by those of ordinary skill in the art, errors, ε f , and ε p for each of the controlled variables, f and p, are calculated in the respective calculation blocks 1430 , 1440 . These are utilized in a control algorithm or algorithms 1450 such as a pair of Proportional Integral Differential (PID) loops with decoupling between the loops, or a multivariable algorithm such as a matrix control algorithm. These algorithms, as well as others, are well known in the art. The present invention is not limited to a particular automatic control algorithm 1450 .
[0057] Outputs of the control algorithm 1450 include valve position set points 1460 , 1470 for each of the two control valves 1330 , 1335 .
[0058] The above embodiments are the preferred embodiments, but this invention is not limited thereto. It is, therefore, apparent that many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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A flamer may be used to sterilize poultry litter, soil, concrete, etc. The stationary or mobile flamer disclosed comprises a hood to contain the heat, an external frame, and burners. A fuel tank may be carried on the flamer or on a tractor. An additional embodiment provides for mounting the flamer on wheels, permitting the unit to be towed by a truck, four-wheeler, tractor, etc. The burners are adjustable as to angle, and fueling rate. A pressure in the fuel system is controlled by selectively switching between the liquid and vaporous components of the fuel. By limiting how low the pressure may fall, the flow of fuel from the tank to the torches is more consistent.
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CROSS REFERENCE TO RELATED PATENT
In U.S. Pat. No. 4,143,142, 5H-pyrido(2',1':2,3)imidazo(4,5-b)indoles and antihypertensive pharmaceutical compositions containing same are described and claimed.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns preparation of novel pyrimidazoindole derivatives and pharmaceutically acceptable acid addition salts thereof; and pharmaceutical compositions for treating excess iron in mammals comprising as an active ingredient a pyrimidoimidazoindole derivative or a pyridoimidazoindole derivative.
2. Description of the Prior Art
The compound 1,2,3,5-tetrahydroimidazo(2,1-b)quinazoline and some of its derivatives with three-ring systems have structural similarity to our compounds with four ring systems and have been reported by Loev, et al., Journal of Medicinal Chemistry, 15, 727 (1972) and Jen, et al., Journal of Medicinal Chemistry, 15, 727 (1972) as effective antihypertensive agents in animals. However, insofar as is presently known, no one has prepared applicant's imidazoindole derivatives.
SUMMARY OF THE INVENTION
According to this invention there are provided novel 5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole derivatives having the formula I ##STR3## and pharmaceutically acceptable acid addition salts thereof wherein R 1 , R 2 , R 3 and R 4 each are selected from the group consisting of hydrogen, halogen and alkyl containing one to four carbon atoms, with the proviso that when taken together they constitute the following substituents on the tetracyclic ring, 1-halo, 2-halo, 3-halo, 4-halo, 1-alkyl, 2-alkyl, 3-alkyl, 4-alkyl, 1,3-dihalo, 2,3-dihalo, 2,4-dihalo, 3,4-dihalo, 1,3-di-alkyl, 2,3-di-alkyl, 1,4-di-alkyl; R 5 is selected from the group consisting of hydrogen and alkyl containing one to four carbon atoms, and R 6 and R 7 are each selected from the group consisting of hydrogen and halo. Preferably R 5 ,R 6 , and R 7 of formula I are hydrogen.
Furthermore according to the present invention there are provided pharmaceutical compositions for chelating excess iron in a mammal and facilitating the removal of excess iron from the mammalian body which comprise an effective amount of an iron-chelating agent selected from the group consisting of 5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole derivative having the formula I ##STR4## and pharmaceutically acceptable acid addition salts thereof wherein R 1 , R 2 , R 3 and R 4 each are selected from the group consisting of hydrogen, halogen and alkyl containing one to four carbon atoms, with the proviso that when taken together they constitute the following substituents on the tetracyclic ring, 1,-halo, 2-halo, 3-halo, 4-halo, 1-alkyl, 2-alkyl, 3-alkyl, 4-alkyl, 1,3-dihalo, 2,3-dihalo, 2,4-dihalo, 3,4-dihalo, 1,3-di-alkyl, 2,3-di-alkyl, 1,4-di-alkyl; R 5 is selected from the group consisting of hydrogen and alkyl containing one to four carbon atoms, and R 6 and R 7 are each selected from the group consisting of hydrogen and halo; 5-pyrido(2',1':2,3)imidazo(4,5-b)indole derivatives having the formula II ##STR5## and pharmaceutically acceptable acid addition salts thereof wherein R 5 ', R 6 ', R 7 ', and R 8 ' each are selected from the group consisting of hydrogen, halogen and alkyl containing one to four carbon atoms, with the proviso that taken together they constitute the following substituents on the tetracyclic ring, 10-halo, 8,10-dihalo, 8,9-di-alkyl and 7,9-di-alkyl; R 1 ', R 2 ', R 3 ' and R 4 ' are selected from the group consisting of hydrogen, halogen and alkyl containing one to four carbon atoms, with the proviso that when taken together they constitute the following substituents on the tetracyclc ring, 1-halo, 2-halo, 3-halo, 4-halo, 1-alkyl, 2-alkyl, 3-alkyl, 4-alkyl, 1,3-dihalo, 2,3-dihalo, 2,4-dihalo, 3,4-dihalo, 1,3-di-alkyl, 2,3-di-alkyl, 1,4-di-alkyl; and mixtures thereof in association with a pharmaceutical carrier.
Furthermore according to the present invention there are provided methods for chelating excess iron in mammals, for example humans and valuable warm-blooded animals such as laboratory rats, dogs, cats and other domestic animals, and facilitating the removal of excess iron from the mammalian body which comprises administering to a mammal suffering from an excess amount of iron in its body an effective amount of the above described iron-chelating agents, e.g., in form the aforesaid pharmaceutical compositions.
Further objects, features and advantages of the present invention will become apparent from the detailed description of the invention and its preferred embodiments which follows.
DETAILED DESCRIPTION OF THE INVENTION
Most of the compounds of formula I and II are prepared by the phosphite reduction of the corresponding nitroso compounds. The reduction of a nitroso compound by triethylphosphite is described by J. I. Cadogan, Synthesis,1, 11 (1972). The nitroso intermediates of pyridine and pyrimidine are prepared by condensation of an ω-haloacetophenone respectively with 2-aminopyridine and 2-aminopyrimidine as described by Almirante et al., Journal of Medicinal Chemistry, 8, 305 (1968) and Almirante et al., Journal of Medicinal Chemistry, 9, 29 (1966) and then nitrosation of the resulting base with sodium nitrite and acetic acid as described by LaRocca et al., Journal of Pharmaceutical Sciences, 60, 74 (1971).
The preferred method of recovering the imidazoindoles from the phosphite reduction mixture is to let the mixture solidify (about 24 hours required), wash with carbon tetrachloride on a glass filter and recrystallize the residue from 2-propanol or carbon tetrachloride.
The imidazoindoles may also be recovered from the phosphite reduction mixture by allowing it to solidify, washing the solid on a glass filter with cold carbon tetrachloride, taking the residue in a small quantity of chloroform, and eluating it over a column of activated alumina (80-325 mash). The first colored zone is collected, evaporated to dryness and then recrystallized once from 2-propanol.
For the synthesis of most of imidazoindole derivatives of my invention, known phenacyl halides or their ring substituted derivatives are used for condensation respectively with 2-aminopyridines or 2-aminopyrimidine. In those isolated cases where a phenacyl halide with a desired halogen substitution in the ring is not readily available, the desired substitution in the phenyl ring is accomplished by first synthesizing the respective tetracyclic compound without the phenyl ring substituent and later introducing the desired substituent by halogenation. For example: meta-halo-phenacyl halides are not readily available. Therefore the synthesis of 4-halo-5H-pyrido(2',1':2,3)imidazo(4,5-b) indole is achieved by subsequent halogenation of the respective unsubstituted tetracyclic imidazoindole derivative.
The condensation reaction and subsequent phosphite reductions may be represented schematically by the following reaction schemes wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 1 ', R 2 ', R 3 ', R 4 ', R 4 ', R 5 ', R 6 ', R 7 ' and R 8 ' are as defined above. ##STR6##
In the foregoing definitions of the substituents, alkyl means methyl, ethyl, propyl, isopropyl, butyl, and the isomeric forms thereof. Halo means chloro, bromo, iodio and fluoro. In the case of a pyridine derivative, the phosphite reduction is complete with 15-30 minutes of refluxing. Further heating yields gradual decomposition of this derivative.
Pharmaceutically acceptable acid addition salts of the compounds of formula I are prepared by reacting a free base of formula I with a stoichiometric amount of an acid, such as hydrogen chloride, hyrogen bromide, hydrogen iodide, sulfuric acid, phosphoric acid, acetic acid, lactic acid, citric acid, succinic acid, benzoic acid, salicylic acid, pamoic acid, cyclohexanesulfamic acid, and the like.
This invention relates also to the pharmaceutical compositions, e.g., in dosage unit forms, for systemic administration (oral and parenteral administration) for treating body iron overload in mammals including humans. The term "dosage unit form" as used in this specification and in the claims refers to physically discrete units suitable as unitary dosages for mammalian subjects, each unit containing a pre-determined quantity of the essential active ingredient, i.e., a compound of formula I or a compound of formula II or a pharmaceutically acceptable acid addition salt thereof, calculated to produce the desired effect in combination with the required pharmaceutical means which adapt the said ingredient for systemic administration. Examples of dosage unit forms in accordance with this invention are tablets, capsules, orally administered liquid preparations in liquid vehicles, sterile preparations in liquid vehicles for intramuscular and intravenous administration, suppositories, and sterile dry preparations for the extemporaneous preparation of sterile injectable preparations in a liquid vehicle. Solid diluents or carriers for the solid oral pharmaceutical dosage unit forms are selected from the group consisting of lipids, carbohydrates, proteins, and mineral solids, for example, starch, sucrose, kaolin, dicalcium phosphate, gelatin, aracia, corn syrup, corn starch, talc and the like. Capsules, both hard and soft, are formulated with conventional diluents and excipients, for example, edible oils, talc, calcium carbonate, calcium stearate and the like. Liquid preparations for oral administration are prepared in water or aqueous vehicles whicadvantageously contain suspending agents, such as for example, ethanol, sodium carboxymethylcellulose, aracia, polyvinyl pyrrolidone, polyvinyl alcohol and the like. In the instance of injectable forms, they must be sterile and must be fluid to the extent that easy syringeability exists. Such preparations must be stable under the conditions of manufacture and storage, and ordinarily contain in addition to the basic solvent or suspending liquid, preservatives in the nature of bactericidal and fungicidal agents, for example, parabens, chlorobutanol, benzyl, alcohol, phenol, thimerosal, and the like. In many cases it is preferable to include isotonic agents, for example sugars or sodium chloride. Carriers and vehicles include vegetable oils, ethanol and polyols, for example, glycerol, propylene glycol, liquid polyethylene glycol and the like. Any solid preparations for subsequent extemporaneous preparation of sterile injectable preparations are sterilized, preferably by exposure to a sterilizing gas, such as for example ethylene oxide. The aforesaid carriers, vehicles, diluents, excipients, preservatives, isotonic agents and the like constitute the pharmaceutical means which adapt the preparations for systemic administration.
The pharmaceutical dosage unit forms are prepared in accordance with the preceeding general description to provide from about 10 mg to about 1 g of the essential active ingredient per dosage unit form.
The compounds of formula I and their pharmaceutically acceptable acid addition salts as well as the compounds of formula II and their pharmaceutically acceptable acid addition salts are capable of binding excess iron in a mammalian body into a chelate-complex as is indicated in standard tests in animals. The adverse physiological effects of such excess iron are substantially reduced and its excretion from the body is largely facilitated.
Due to their capability of chelating body iron the compounds are useful in the treatment of pysiological disorders in mammals in particular humans, which are characterized by an excess amount of iron in the body. Thus the compounds are useful in the treatment of a acute iron intoxication to reduce the toxic effects of the excess iron and facilitate its removal from the body. The compounds are also useful for reducing increased iron-levels in the body in the treatment of chronic iron storage diseases.
In particular the compounds are useful in counteracting transfusional iron overload caused by regular blood transfusions in the treatment of refractory anemia.
For the above mentioned uses the administered doses can vary considerably depending on the type of the compound, the mammal, the mode of administration, the condition which is to be treated and the therapy which is desired. Usually satisfactory body iron reducing effects are obtained with dosages in the range of between about 1 and about 50 mg/kg body weight. These doses can be administered internally, preferably orally, or parenterally. For example, daily oral doses for larger mammals can be chosen between about 100 mg and 500 mg. It is a special advantage of the body-iron chelating compounds of formula I and II that they are expected to be effective upon oral administration.
Among the compounds of formula I and their pharmaceutically acceptable acid addition salts, the compounds wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 and R 7 each are hydrogen, that is 5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole or a pharmaceutically acceptable acid addition salt thereof, are preferred.
Among the compounds of formula II and their pharmaceutically acceptable acid addition salts, the compounds wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 and R 7 each are hydrogen, that is 5H-pyrido(2',1':2,3)imidazo(4,5-b)indole or a pharmaceutically acceptable acid addition thereof, are preferred.
Furthermore the following compounds of formula I and their acid addition salts are suitable for use as body-iron chelating agents according to the present invention:
3-methyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3-chloro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1,3-dichloro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1,3-dimethyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3-bromo-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3-ioda-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3-fluoro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1,3-dibromo-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1,3-diioda-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1,3-difluoro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3-ethyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3-propyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3-isopropyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3-n-butyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3-sec-butyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3-tert-butyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
4-chloro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2-chloro-5H pyrimido(2',1':2,3)imidazo(4,5-b)indole
1-chloro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
4-bromo-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2-bromo-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1-bromo-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
4-iodo-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2-iodo-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1-iodo-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
4-fluoro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2-fluoro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1-fluoro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
4-ethyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2-ethyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1-ethyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
4-propyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2-propyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1-propyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
4-isopropyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2-isopropyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1-isopropyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
4-n-butyl-5H-pyrimido(2',1':2,3)imidazo-(4,5-b)indole
2-n-butyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1-n-butyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
4-sec-butyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2-sec-butyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1-sec-butyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
4-tert-butyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2-tert-butyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1-tert-butyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2,4-dimethyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2,3-dimethyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1,2-dimethyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
1-methyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2-methyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
4-methyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2,3-dichloro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2,4-dichloro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3,4-dichloro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2,3-dibromo-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
2,4-dibromo-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
3,4-dibromo-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
b 3,4-dimethyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
Furthermore the following compounds of formula II and their acid addition salts are suitable for use as body-iron chelating agents according to the present invention:
1-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3-chloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8-chloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7-methyl-5H-pyride(2',1':2,3)imidazo(4,5-b)indole
8-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
9-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1-ethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2-ethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3-ethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4-ethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7-ethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8-ethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
9-ethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-ethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1-propyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2-propyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3-propyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4-propyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7-propyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8-propyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
9-propyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-propyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1-isopropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2-isopropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3-isopropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4-isopropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7-isopropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8-isopropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
9-isopropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-isopropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1-n-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2-n-butyl-5H-pyrido(2',1':2,3)imidazo94,5-b)indole
3-n-butyl-5H-pyrido(2',1':2,3)imidazo-(4,5-b)indole
4-n-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7-n-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8-n-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
9-n-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-n-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1-sec-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2-sec-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3-sec-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4-sec-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7-sec-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8-sec-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
9-sec-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-sec-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1-tert-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2-tert-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3-tert-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4-tert-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7-tert-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8-tert-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
9-tert-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-tert-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1-chloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2-chloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3-chloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7-chloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8-chloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
9-chloro-5H-pyrido)2',1':2,3)imidazo(4,5-b)indole
10-chloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1-bromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2-bromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3-bromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7-bromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8-bromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
9-bromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-bromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1-fluoro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2-fluoro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3-fluoro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8,9-diisopropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1,7-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1,8-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1,9-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1,10-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,7-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,8-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,9-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,10-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3,7-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3,8-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3,9-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3,10-dimehtyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4,7-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4,8-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4,9-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4,10-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,4-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-chloro-4-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-bromo-4-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-chloro-4-ethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-chloro-4-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-chloro-4-propyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-chloro-2,4-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-chloro-2,4-diethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-chloro-2,4-dipropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7-fluoro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8-fluoro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
9-fluoro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-fluoro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1-iodo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2-iodo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3-iodo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7-iodo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8-iodo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
9-iodo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-iodo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1,3-dichloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,3-dichloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,4-dichloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3,4-dichloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
1,3-dibromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,3-dibromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,4-dibromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
3,4-dibromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8,10-dibromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8,10-dichloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7,9-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7,9-diethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7,9-dipropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7,9-diisopropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
7,9-di-n-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8,9-dimethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8,9-diethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
8,9-dipropyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-chloro-2,4-dibutyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4,10-dichloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4,10-dibromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-chloro-2,4-dibromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-chloro-2,4-dichloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-bromo-2,4-dibromo-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
10-bromo-2,4-dichloro-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
4-chloro-9-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,4-dichloro-9-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,4-dichloro-9-ethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,4-dichloro-9-propyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,4-dichloro-9-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,4-dibromo-9-methyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,4-dibromo-9-ethyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,4-dibromo-9propyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
2,4-dibromo-9-butyl-5H-pyrido(2',1':2,3)imidazo(4,5-b)indole
The preparation of the above listed 5H-pyrido(2',1':2,3)imidazo(4,5-b)indole derivatives is disclosed in U.S. Pat. No. 4,143,142, the disclosure of which is hereby incorporated by reference.
The following examples describe the manner and process of making and using the invention and set forth the best mode contemplated by the inventor of carrying out the invention but are not to be construed as limiting.
EXAMPLE 1
Preparation of the intermediate compound 3-nitroso-2-phenylimidazo(1,2-a)pyrimidine
(A) A mixture of 9.5 g of 2-aminopyrimidine (0.1 mole), 20 g of ω-bromoacetophenone (0.1 mole) and 200 ml of 95% ethanol is refluxed for three hours and then heated at 60° for an additional 12 hours with stirring. After cooling, the reaction product is condensed to a thick liquid by evaporating it in a rotary evaporator. The residue is mixed with 500 ml of methylene chloride and 100 ml of 3 N sodiumhydroxide solution. The mixture is stirred for 10 minutes and then separated in two layers in a separatory funnel. The lower layer (solvent) is collected, washed with 100 ml of water and then evaporated to dryness under reduced pressure. The residue is washed with 2-propanol on a glass filter and dried in vacuum to yield about 20 g of 2-phenylimidazo(1,2-a)pyrimidine, m.p. 200° to 202° C.
(B) A mixture of 20 g of 2-phenylimidazo(1,2-a)pyrimidine, 200 ml of glacial acetic acid and 20 ml of water is warmed with stirring until the solids are completely dissolved. The solution is next cooled to 5° C. in an ice/salt bath. A solution of 15 g of NaNO 2 in 50 ml of water is added dropwise to the cooled acetic acid solution while the solution is kept between 0°-5° C. throughout the addition of NaNO 2 solution and three hours thereafter. The reaction mixture is further stirred for 12 more hours at room temperature. The green precipitate is filtered and washed thoroughly with water on a glass filter. The residue is recrystallized once from 2-propanol to yield about 15 g of 3-nitroso-2-phenylimidazo(1,2-a)pyrimidine, m.p. 223°-225° C.
EXAMPLE 2
Preparation of pyrimidino(2',1':2,3)imidazo(4,5-b)indole
A mixture of 9.0 g of analytically pure 3-nitroso-2-phenylimidazo(1,2-a)pyrimidine (0.04 mol) and 10 ml of 97% triethylphosphite (0.05 mol) in 50 ml of anhydrous toluene is refluxed for 1 hour with stirring and under a constant flow of dry nitrogen gas. The temperature of the oil bath is kept between 110° and 120° C. After cooling the solvent and excess triethylphosphite are removed by vacuum distillation at 0.2 Torr. The temperature of the oil bath was kept under 120° C. during the distillation. The residue, which is a thick liquid, is kept overnight at 0° C. during which time it solidifies. The solid is washed on a glass filter with cold carbon tetrachloride and then recrystallized from CCl 4 . Yield about 5 g, m.p. 96° to 98° C.
Analysis calculated for C 12 H 8 N 4 --found: C:69.34; H:3.95: N:26.79.
EXAMPLE 3
Preparation of 3-methyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
Utilizing the procedure of Example 2 and substituting 3-nitroso-2-(4-methylphenyl)imidazo(1,2-a)pyrimidine for 3-nitroso-2-phenylimidazo(1,2-a)pyrimidine, the compound 3-methyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole is obtained.
EXAMPLE 4
Preparation of 3-chloro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
Utilizing the procedure of Example 2 and substituting 3-nitroso-2-(4-chlorophenyl)imidazo(1,2-a)pyrimidine for 3-nitroso-2-phenylimidazo(1,2-a)pyrimidine, the compound 3-chloro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole is obtained.
EXAMPLE 5
Preparation of 3,1-dichloro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
Utilizing the procedure of Example 2 and substituting 3-nitroso-2-(2,4-dichlorophenyl)imidazo(1,2-a)pyrimidine for 3-nitroso-2-phenylimidazo(1,2-a)pyrimidine, the compound 3,1-dichloro-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole is obtained.
EXAMPLE 6
Preparation of 3,1-dimethly-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole
Utilizing the procedure of Example 2 and substituting 3-nitroso-2-(2,4-dimethylphenyl)imidazo(1,2-a)pyrimidine for 3-nitroso-2-phenylimidazo(1,2-a)pyrimidine, the compound: 3,1-dimethyl-5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole is obtained.
Further utilizing the procedure of Example 2 and substituting the appropriate nitroso compounds, the derivatives of the pyrimido-imidazo-indoles which are listed on Pages 14 to 16 are prepared.
Starting materials for preparing the nitroso intermediates of the pyrimidine derivatives are commercially available or may be synthesized by methods known in the art.
EXAMPLE 7
Pharmaceutical compositions for the treatment of excess body iron
A. Capsules
Composition per single dosage unit:
5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole 50 mg of analytically pure compound per capsule to be given 1 to 4 times daily.
B. Solution for Injection
Composition per single dosage unit:
5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole hydrochloride 40 mg in sterile water, 2 ml per ampule to be given i.v.; s.c.; or i.p. 1 to 4 times daily.
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Pharmaceutical composition for chelating excess iron in a mammal and facilitating the removal of excess iron from the mammalian body are disclosed which comprise as active ingredient an iron-chelating agent selected from the group consisting of 5H-pyrimido(2',1':2,3)imidazo(4,5-b)indole having the formula ##STR1## 5H-pyrido(2',1':2,3)imidazo(4,5-b) indole having the formula ##STR2## or lower alkyl and/or halogen substituted derivatives thereof and pharmaceutically acceptable acid addition salts thereof. Furthermore the preparation of novel 5H-pyrimido(2',1':2,3)imidazo(4,5-b)indoles and intermediates thereof are disclosed.
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FIELD OF THE INVENTION
[0001] This invention relates generally to a reduction system for removing soil to expose underground utilities (such as electrical and cable services, water and sewage services, etc.), and more particularly to a drill base that is attached to a surface using a vacuum.
BACKGROUND OF THE INVENTION
[0002] With the increased use of underground utilities, it has become more critical to locate and verify the placement of buried utilities before installation of additional underground utilities or before other excavation or digging work is performed. Conventional digging and excavation methods such as shovels, post hole diggers, powered excavators, and backhoes may be limited in their use in locating buried utilities as they may tend to cut, break, or otherwise damage the lines during use.
[0003] Devices have been previously developed to create holes in the ground to non-destructively expose underground utilities to view. One design uses high pressure air delivered through a tool to loosen soil and a vacuum system to vacuum away the dirt after it is loosened to form a hole. Another system uses high pressure water delivered by a tool to soften the soil and create a soil/water slurry mixture. The tool is provided with a vacuum system for vacuuming the slurry away.
SUMMARY OF THE INVENTION
[0004] The present invention recognizes and addresses disadvantages of prior art constructions and methods, and it is an object of the present invention to provide an improved drilling apparatus. This and other objects may be achieved by a drilling apparatus comprising a base having a top surface and a bottom surface and a first passageway extending from the top surface to the bottom surface, a drill coupled to the base, and a connector coupled to the top surface and defining a second passageway through the connector, the passageway being in fluid communication with the first passageway. The bottom surface of the base abuts a surface proximate a location to be drilled and surrounding the first passageway so that when a vacuum air stream is drawn through the first passageway into the second passageway, a vacuum connection is defined between the base and the surface, thereby fixedly securing the drill above the location to be drilled.
[0005] In another embodiment, a drill base comprises a base having a top surface and a generally planar bottom surface and a first passageway extending from the top surface to the bottom surface. A drill is coupled to the base so that the drill moves relative to the base. A connector is coupled to the top surface and defines a second passageway through the connector, the second passageway being in fluid communication with the first passageway. The bottom surface of the base abuts a surface proximate a location to be drilled and surrounding the first passageway so that when a vacuum air stream is drawn through the first passageway into the second passageway, a vacuum connection is defined between the base and the surface, thereby fixedly securing the drill above the location to be drilled.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] A full and enabling disclosure of the present invention, including the best mode thereof directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0007] FIG. 1 is a perspective view of a drilling and backfill system constructed in accordance with one embodiment of the present invention;
[0008] FIG. 2 is a perspective view of a key hole drill for use with the drilling and backfill system of FIG. 1 ;
[0009] FIG. 3 is a perspective view of a reduction tool for use with the drilling and backfill system of FIG. 1 ;
[0010] FIG. 4 is bottom view of the reduction tool shown in FIG. 3 ;
[0011] FIG. 5 is a partial perspective view of the reduction tool of FIG. 3 in use digging a hole;
[0012] FIG. 6 is a perspective view of a key hole drilling tool base for use with the key hole drill of FIG. 2 ;
[0013] FIG. 6A is a bottom perspective view of the tool base shown in FIG. 6 ;
[0014] FIG. 7 is a perspective view of the reduction tool of FIG. 3 in use digging the hole;
[0015] FIG. 8 is a perspective view of the drilling and backfill system of FIG. 1 , showing the hole being backfilled;
[0016] FIG. 9 is a perspective view of the drilling and backfill system of FIG. 1 , showing the hole being tamped; and
[0017] FIG. 10 is a schematic view of the hydraulic, electric, water, and vacuum systems of the drilling and backfill system of FIG. 1 .
[0018] Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.
DETAILED DESCRIPTION
[0019] Reference will now be made in detail to presently preferred embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope and spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0020] Referring to FIG. 1 , a drilling and backfill system 10 generally includes a water reservoir tank 12 , a collection tank 14 , a motor 16 , a drilling apparatus 18 , and back fill reservoirs 20 and 22 , all mounted on a mobile chassis 24 , which is, in this embodiment, in the form of a trailer. Trailer 24 includes four wheels 38 (only three of which are shown in FIG. 1 ) and a draw bar and hitch 40 . Drilling and backfill system 10 generally mounts on a platform 42 , which is part of trailer 24 . It should be understood that while drill and backfill system 10 is illustrated mounted on a trailer having a platform, the system may also be mounted on the chassis of a vehicle such as a truck or car. Further, a chassis may comprise any frame, platform or bed to which the system components may be mounted and that can be moved by a motorized vehicle such as a car, truck, or skid steer. It should be understood that the components of the system may be either directly mounted to the chassis or indirectly mounted to the chassis through connections with other system components.
[0021] The connection of the various components of system 10 is best illustrated in FIG. 10 . Motor 16 is mounted on a forward end of trailer 24 and provides electricity to power two electric hydraulic pumps 30 and 172 , and it also drives both a water pump 26 and a vacuum pump 28 by belts (not shown). Motor 16 is preferably a gas or diesel engine, although it should be understood that an electric motor or other motive means could also be used. In one preferred embodiment, motor 16 is a thirty horsepower diesel engine, such as Model No. V1505 manufactured by Kubota Engine division of Japan, or a twenty-five horsepower gasoline engine such as Model Command PRO CH25S manufactured by Kohler Engines. The speed of motor 16 may be varied between high and low by a wireless keypad transmitter 108 that transmits motor speed control to a receiver 110 connected to the throttle of motor 16 .
[0022] The water system will now be described with reference to FIG. 10 . Water reservoir tank 12 connects to water pump 26 , which includes a low pressure inlet 44 and a high pressure outlet 46 . In the illustrated embodiment, water pump 26 can be any of a variety of suitable pumps that delivers between 3,000 and 4,000 lbs/in 2 at a flow rate of approximately five gallons per minute. In one preferred embodiment, water pump 26 is a Model No. TS2021 pump manufactured by General Pump. Water tank 12 includes an outlet 50 that connects to a strainer 52 through a valve 54 . The output of strainer 52 connects to the low pressure side of water pump 26 via a hose 48 . A check valve 56 is placed inline intermediate strainer 52 and low pressure inlet 44 . High pressure outlet 46 connects to a filter 58 and then to a pressure relief and bypass valve 60 . In one preferred embodiment, pressure relief and bypass valve 60 is a Model YUZ140 valve manufactured by General Pump.
[0023] A “T” 62 and a valve 64 , located intermediate valve 60 and filter 58 , connect the high pressure output 46 to a plurality of clean out nozzles 66 mounted in collection tank 14 to clean the tank's interior. A return line 68 connects a low pressure port 69 of valve 60 to water tank 12 . When a predetermined water pressure is exceeded in valve 60 , water is diverted through low port 69 and line 68 to tank 12 . A hose 70 , stored on a hose reel 73 ( FIG. 1 ), connects an output port 72 of valve 60 to a valve 74 on a digging tool 32 ( FIG. 3 ). A valve control 76 ( FIG. 3 ) at a handle 78 of digging tool 32 provides the operator with a means to selectively actuate valve 74 on digging tool 32 . The valve delivers a high pressure stream of water through a conduit 80 ( FIGS. 3, 5 , 7 , and 10 ) attached to the exterior of an elongated pipe 82 that extends the length of digging tool 32 .
[0024] Referring to FIG. 3 , digging tool 32 includes handle 78 for an operator 34 ( FIG. 7 ) to grasp during use of the tool. A connector 84 , such as a “banjo” type connector, connects the vacuum system on drilling and back fill system 10 ( FIG. 1 ) to a central vacuum passage 86 ( FIG. 4 ) in digging tool 32 . Connector 84 is located proximate handle 78 . Vacuum passage 86 extends the length of elongated pipe 82 and opens to one end of a vacuum hose 88 . The other end of hose 88 connects to an inlet port 90 on collection tank 14 ( FIG. 7 ). It should be understood that other types of connectors may be used in place of “banjo” connector 84 , for example clamps, clips, or threaded ends on hose 88 and handle 78 .
[0025] Referring to FIGS. 4 and 5 , a fluid manifold 92 , located at a distal end 94 of digging tool 32 , connects to water conduit 80 and contains a plurality of nozzles that are angled with respect to one another. In one preferred embodiment having four nozzles, two nozzles 96 and 98 are directed radially inwardly at approximately 45 degrees from a vertical axis of the digging tool, and the two remaining nozzles 100 and 102 are directed parallel to the axis of the digging tool. During use of the drilling tool, nozzles 96 and 98 produce a spiral cutting action that breaks the soil up sufficiently to minimize clogging of large chunks of soil within vacuum passage 86 and/or vacuum hose 88 . Vertically downward pointing nozzles 100 and 102 enhance the cutting action of the drilling tool by allowing for soil to be removed not only above a buried utility, but in certain cases from around the entire periphery of the utility. In other words, the soil is removed above the utility, from around the sides of the utility, and from beneath the utility. This can be useful for further verifying the precise utility needing service and, if necessary, making repairs to or tying into the utility.
[0026] Digging tool 32 also contains a plurality of air inlets 104 formed in pipe distal end 94 that allow air to enter into vacuum passage 86 . The additional air, in combination with the angled placement of nozzles 96 and 98 , enhances the cutting and suction provided by tool 32 . Returning to FIG. 6 , digging tool 32 may also include a control 106 for controlling the tool's vacuum feature. Control 106 may be an electrical switch, a vacuum or pneumatic switch, a wireless switch, or any other suitable control to adjust the vacuum action by allowing the vacuum to be shut off or otherwise modulated. An antifreeze system, generally 190 ( FIGS. 1 and 2 ), may be provided to prevent freezing of the water pump and the water system. Thus, when the pump is to be left unused in cold weather, water pump 26 may draw antifreeze from the antifreeze reservoir through the components of the water system to prevent water in the hoses from freezing and damaging the system.
[0027] Turning now to FIGS. 7 and 10 , vacuum pump 28 is preferably a positive displacement type vacuum pump such as that used as a supercharger on diesel truck. In one preferred embodiment, vacuum pump 28 is a Model 4009-46R3 blower manufactured by Tuthill. A hose 112 connects an intake of the vacuum pump to a vacuum relief device 114 , which may be any suitable vacuum valve, such as a Model 215V-H01AQE spring loaded valve manufactured by Kunkle. Vacuum relief device 114 controls the maximum negative pressure of the vacuum pulled by pump 28 , which is in the range of between 10 and 15 inches of Hg in the illustrated embodiment. A filter 116 , located up stream of pressure relief valve 114 , filters the vacuum air stream before it passes through vacuum pump 28 . In one preferred embodiment, the filter media may be a paper filter such as those manufactured by Fleet Guard. Filter 116 connects to an exhaust outlet 118 of collection tank 14 by a hose 120 , as shown in FIGS. 1, 7 , 8 , and 9 . An exhaust side 122 of vacuum pump 28 connects to a silencer 124 , such as a Model TS30TR silencer manufactured by Cowl. The output of silencer 124 exits into the atmosphere.
[0028] The vacuum air stream pulled through vacuum pump 28 produces a vacuum in collection tank 14 that draws a vacuum air stream through collection tank inlet 90 . When inlet 90 is not closed off by a plug 127 ( FIG. 1 ), the inlet may be connected to hose 88 leading to digging tool 32 . Thus, the vacuum air stream at inlet 90 is ultimately pulled through vacuum passage 86 at distal end 94 of tool 32 . Because it is undesirable to draw dirt or other particulate matter through the vacuum pump, a baffle system, for example as described in U.S. Pat. No. 6,470,605 (the entire disclosure which is incorporated herein), is provided within collection tank 14 to separate the slurry mixture from the vacuum air stream. Consequently, dirt, rocks, and other debris in the air flow hit a baffle (not shown) and fall to the bottom portion of the collection tank. The vacuum air stream, after contacting the baffle, continues upwardly and exits through outlet 118 through filter 116 and on to vacuum pump 28 .
[0029] Referring once again to FIG. 1 , collection tank 14 includes a discharge door 126 connected to the main tank body by a hinge 128 that allows the door to swing open, thereby providing access to the tank's interior for cleaning. A pair of hydraulic cylinders 130 (only one of which is shown in FIG. 8 ) are provided for tilting a forward end 132 of tank 14 upwards in order to cause the contents to run towards discharge door 126 . A gate valve 140 , coupled to a drain 142 in discharge door 126 , drains the liquid portion of the slurry in tank 14 without requiring the door to be opened. Gate valve 140 may also be used to introduce air into collection tank 14 to reduce the vacuum in the tank so that the door may be opened.
[0030] Running the length of the interior of collection tank 14 is a nozzle tube 132 ( FIG. 10 ) that includes nozzles 66 for directing high pressure water about the tank, and particularly towards the base of the tank. Nozzles 66 are actuated by opening valve 64 ( FIG. 10 ), which delivers high pressure water from pump 26 to nozzles 66 for producing a vigorous cleaning action in the tank. When nozzles 66 are not being used for cleaning, a small amount of water is allowed to continuously drip through the nozzles to pressurize them so as to prevent dirt and slurry from entering and clogging the nozzles.
[0031] Nozzle tube 132 , apart from being a conduit for delivering water, is also a structural member that includes a threaded male portion (not shown) on an end thereof adjacent discharge door 126 . When discharge door 126 is shut, a screw-down type handle 134 mounted in the door is turned causing a threaded female portion (not shown) on tube 132 to mate with the male portion. This configuration causes the door to be pulled tightly against an open rim (not shown) of the collection tank. Actuation of vacuum pump 28 further assists the sealing of the door against the tank opening. Discharge door 126 includes a sight glass 136 to allow the user to visually inspect the tank's interior.
[0032] Backfill reservoirs 20 and 22 are mounted on opposite sides of collection tank 14 . The back fill reservoirs are mirror images of each other; therefore, for purposes of the following discussion, reference will only be made to backfill reservoir 22 . It should be understood that backfill reservoir 20 operates identically to that of reservoir 22 . Consequently, similar components on backfill reservoir 20 are labeled with the same reference numerals as those on reservoir 22 .
[0033] Referring to FIG. 1 , back fill reservoir 22 is generally cylindrical in shape and has a bottom portion 144 , a top portion 146 , a back wall 148 , and a front wall 150 . Top portion 146 connects to bottom portion 144 by a hinge 152 . Hinge 152 allows backfill reservoir 22 to be opened and loaded with dirt by a front loader 154 , as shown in phantom in FIG. 1 . Top portion 146 secures to bottom portion 144 by a plurality of locking mechanisms 156 located on the front and back walls. Locking mechanisms 156 may be clasps, latches or other suitable devices that secure the top portion to the bottom portion. The seam between the top and bottom portion does not necessarily need to be a vacuum tight seal, but the seal should prevent backfill and large amounts of air from leaking from or into the reservoir. Front wall 150 has a hinged door 158 that is secured close by a latch 160 . As illustrated in FIG. 8 , hydraulic cylinders 130 enable the back fill reservoirs to tilt so that dirt can be off loaded through doors 158 .
[0034] As previously described above, backfill reservoirs 20 and 22 may be filled by opening top portions 146 of the reservoirs and depositing dirt into bottom portion 144 with a front loader. Vacuum pump 28 , however, may also load dirt into back fill reservoirs 20 and 22 . In particular, back fill reservoir 22 has an inlet port 162 and an outlet port 164 . During normal operation, plugs 166 and 168 fit on respective ports 162 and 164 to prevent backfill from leaking from the reservoir. However, these plugs may be removed, and outlet port 164 may be connected to inlet port 90 on collection tank 14 by a hose (not shown), while hose 88 may be attached to inlet port 162 . In this configuration, vacuum pump 28 pulls a vacuum air stream through collection tank 14 , as described above, through the hose connecting inlet port 90 to outlet port 164 , and through hose 88 connected to inlet port 162 . Thus, backfill dirt and rocks can be vacuumed into reservoirs 20 and 22 without the aide of loader 154 . It should be understood that this configuration is beneficial when backfill system 10 is being used in an area where no loader is available to fill the reservoirs. Once the reservoirs are filled, the hoses are removed from the ports, and plugs 166 and 168 are reinstalled on respective ports 162 and 164 .
[0035] Referring once more to FIG. 10 , hydraulic cylinders 130 , used to tilt collection tank 14 and backfill reservoirs 20 and 22 , are powered by electric hydraulic pump 30 . Hydraulic pump 30 connects to a hydraulic reservoir 170 and is driven by the electrical system of motor 16 . A high pressure output line 171 and a return line 173 connect pump 30 to hydraulic cylinders 130 . Hydraulic pump 172 , mounted on trailer 24 , is separately driven by motor 16 and includes its own hydraulic reservoir 174 . An output high pressure line 175 and a return line 186 connect pump 172 to a pair of quick disconnect couplings 182 and 184 , respectively. That is, high pressure line 175 connects to quick disconnect coupling 182 ( FIGS. 1 and 2 ) through a control valve 178 , and return line 186 connects quick disconnect coupling 184 to reservoir 188 . A pressure relief valve 176 connects high pressure line 175 to reservoir 188 and allows fluid to bleed off of the high pressure line if the pressure exceeds a predetermined level. A pressure gauge 180 may also be located between pump 172 and control valve 178 .
[0036] Quick disconnect coupling 182 provides a high pressure source of hydraulic fluid for powering auxiliary tools, such as drilling apparatus 18 , tamper device 185 , or other devices that may be used in connection with drilling and backfill system 10 . The high pressure line preferably delivers between 5.8 and 6 gallons per minute of hydraulic fluid at a pressure of 2000 lbs/in 2 . Hydraulic return line 186 connects to a quick disconnect coupling 184 ( FIGS. 1 and 2 ) on trailer 24 . Intermediate quick disconnect coupling 184 and hydraulic fluid reservoir 174 is a filter 188 that filters the hydraulic fluid before returning it to hydraulic reservoir 174 . While quick disconnect couplings 182 and 184 are shown on the side of trailer 24 , it should be understood that the couplings may also be mounted on the rear of trailer 24 .
[0037] Referring to FIGS. 1 and 2 , drilling apparatus 18 is carried on trailer 24 and is positioned using winch and crane 36 . Drilling apparatus 18 includes a base 192 , a vertical body 194 , and a hydraulic drill motor 196 slidably coupled to vertical body 194 by a bracket 198 . A high pressure hose 200 and a return hose 202 power motor 196 . A saw blade 204 attaches to an output shaft of hydraulic motor 196 and is used to drill a coupon 206 ( FIG. 7 ) in pavement, concrete or other hard surfaces to expose the ground above the buried utility. The term coupon as used herein refers to a shaped material cut from a continuous surface to expose the ground beneath the material. For example, as illustrated in FIG. 7 , coupon 206 is a circular piece of concrete that is cut out of a sidewalk to expose the ground thereunder.
[0038] Body 194 has a handle 220 for the user to grab and hold onto during the drilling process. Hydraulic fluid hoses 200 and 202 connect to two connectors 222 and 224 ( FIG. 10 ) mounted on body 194 and provide hydraulic fluid to hydraulic drill motor 196 . A crank 226 is used to move the drill motor vertically along body 194 . Drilling apparatus 18 is a Model CD616 Hydra Core Drill manufactured by Reimann & Georger of Buffalo, N.Y. and is referred to herein as a “core drill.”
[0039] In prior art systems, base 192 was secured to pavement or concrete using lag bolts, screws, spikes, etc. These attachment methods caused unnecessary damage to the surrounding area and required additional repair after the utility was fixed and the hole was backfilled. Additionally, having to drill additional holes for the bolts or screws or pounding of the spikes with a sledge hammer presented unnecessary additional work. Thus, the drilling apparatus of the present invention uses the vacuum system of drilling and backfill system 10 to secure base 192 to the pavement.
[0040] Referring to FIGS. 6 and 6 A, base 192 includes a flat plate 195 having a connector 206 attached to a top surface thereof. Connector 206 attaches to an outlet port 208 formed in a top surface of plate 195 that is in fluid communication with a recessed chamber 210 ( FIG. 6A ) formed in a bottom surface 212 of plate 195 . Outlet port 208 has a passageway therethrough that extends between the top and bottom surfaces of plate 195 . A groove 230 formed in bottom surface 212 receives a pliable gasket 232 that forms a relatively air tight seal between the bottom surface 212 and the pavement or concrete being drilled. It should be understood that while a gasket is shown, it may not be necessary to use a gasket since the generally planar bottom surface surrounding the outlet port passageway can form a sufficient seal with the pavement or concrete depending on the strength of the vacuum air stream being pulled through connector 206 . A bracket 214 coupled to a top surface of plate 195 fixedly secures body 194 ( FIG. 2 ) to base 192 . A bolt or screw 216 is received through body 194 and into a threaded bore 218 to secure the body to the base. Wheels attached to the base allow the drilling apparatus to be moved around the work area after it has been off loaded the trailer by winch and crane 36 . The term “base” as used herein refers to a drill support structure that maintains a secure connection of the drill to a surface proximate the area to be drilled. The drill base should have a generally planar bottom surface, and the remaining structure of the base may be of any suitable shape to secure the drill motor to the base.
[0041] Referring to FIG. 2 , hose 88 connects to connector 206 by a suitable clamp (not shown). Once core drill 18 is positioned, vacuum pump 26 is turned on and a vacuum is pulled through hose 88 into chamber 210 , providing a vacuum of between 12-15 inches of Hg, which is sufficient to fixedly secure base 192 to the pavement or concrete during the drilling process. Prior to moving core drill 18 , vacuum pump 28 is shut down to eliminate the vacuum produced in chamber 210 .
[0042] The operation of the drilling and backfill system will now be described with reference to FIGS. 2, 7 to 9 and 10 . Prior to using drilling and backfill system 10 , water is added to water tank 12 , and valve 54 is opened to allow water to flow to water pump 26 . Motor 16 is powered up, and water pressure is allowed to build in the system.
[0043] Referring to FIG. 2 , if a utility is located under concrete, core drill 18 is positioned over the utility, and vacuum hose 88 is connected from inlet port 90 on collection tank 14 to connector 206 on base plate 195 . Hydraulic hoses 200 and 202 are connected to hydraulic motor 196 at connectors 222 and 224 , and vacuum pump 28 and hydraulic pump 172 are powered up. Saw 204 is used to cut coupon 206 ( FIG. 7 ) from the concrete to expose the ground over the utility. Hose 70 connects to saw 204 and provides a steady stream of water that flushes the drill bit during the drilling process. Coupon 206 is removed from the hole and placed aside so that it can be reused in repairing the hole after it is backfilled.
[0044] Next, and referring to FIG. 7 , the user disconnects vacuum hose 88 from connector 206 and connects the hose to digging tool handle 78 using banjo connector 84 . High pressure water hose 70 is also connected to valve 74 to provide water to the digging tool. As tool 32 is used, it is pressed downwardly into the ground to dig a hole. For larger diameter holes, digging tool 32 is moved in a generally circular manner as it is pressed downward. Slurry formed in the hole is vacuumed by tool 32 through vacuum passage 86 ( FIGS. 4 and 5 ) and accumulates in collection tank 26 . Once the hole is completed and the utility exposed, the vacuum system can be shut down, and the operators may examine or repair the utility as needed.
[0045] After work on the utility is completed, and referring to FIG. 8 , the operator may cover the utility with clean backfill from backfill reservoirs 20 and 22 . In particular, trailer 24 is positioned so that one of backfill reservoirs 20 or 22 is proximate the hole. Hydraulic cylinders 130 are activated, causing the tanks to tip rearward so that backfill can be delivered through door 158 into the hole. Once the hole is sufficiently filled, hydraulic cylinders 130 return reservoirs 20 and 22 to their horizontal position, and door 158 is secured in the closed position.
[0046] With reference to FIG. 9 , operator 34 may use a tamping device 185 to tamp the backfill in the hole. Tamping device 185 connects to hydraulic pump 172 through quick disconnect couplings 182 and 184 via hydraulic lines 200 and 202 . Tamping device 185 is used to pack the backfill in the hole and to remove any air pockets. Once the hole has been filed and properly packed, coupon 206 is moved into the remaining portion of the hole. The reuse of coupon 206 eliminates the need to cover the hole with new concrete. Instead, coupon 206 is placed in the hole, and grout is used to seal any cracks between the key and the surrounding concrete. Thus, the overall cost and time of repairing the concrete is significantly reduced, and the need for new concrete is effectively eliminated.
[0047] Drilling and backfill system 10 can be used to dig multiple holes before having to empty collection tank 14 . However, once collection tank 14 is full, it can be emptied at an appropriate dump site. In emptying collection tank 14 , motor 16 is idled to maintain a vacuum in tank 14 . This allows the door handle to be turned so that the female threaded member (not shown) is no longer in threading engagement with the male member (not shown) on nozzle rod 132 , while the vacuum pressure continuing to hold the door closed. Once motor 16 is shut down, the vacuum pressure is released so that air enters the tank, thereby pressurizing the tank and allowing the door to be opened. Once opened, hydraulic cylinders 130 can be activated to raise forward end 132 upward dumping the slurry from the tank.
[0048] Collection tank 14 may also include a vacuum switch and relay (not shown) that prevents the tank from being raised for dumping until the vacuum in the tank has dropped below a predetermined level for door 126 to be opened. Once the vacuum in the tank has diminished to below the predetermined level, tank 14 may be elevated for dumping. This prevents slurry from being pushed up into filter 116 if door 126 can not open.
[0049] It should be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope and spirit of the invention. It is intended that the present invention cover such modifications and variations as come within the scope and spirit of the appended claims and their equivalents.
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A drilling apparatus comprising a base having a top surface and a bottom surface and a first passageway extending from said top surface to said bottom surface, a drill coupled to said base, and a connector coupled to said top surface and defining a second passageway through said connector, said second passageway being in fluid communication with said first passageway, wherein said bottom surface of said base abuts a surface proximate a location to be drilled and surrounding said first passageway so that when a vacuum air stream is drawn through said first passageway into said second passageway, a vacuum connection is defined between said base and said surface, thereby fixedly securing the drill above the location to be drilled.
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FIELD OF THE INVENTION
[0001] The present invention relates to a female element of a quick connection and to a quick connection incorporating such an element.
BACKGROUND OF THE INVENTION
[0002] In the domain of the removable join of pipes through which a fluid passes, it is known to use a female connecting element which comprises controlled means for locking a male endpiece in a configuration fitted in the female element, i.e. with the pipes in connected configuration. The locking means may, in certain cases, be controlled by a sleeve mobile in a direction parallel to the axis of the female element. The locking elements may also be controlled by a press-button mobile in a direction substantially perpendicular to that axis, the user depressing the button when it is necessary to clear the passage for the male connection when it is to be extracted from the female element.
[0003] The present invention is applicable to this second particular type of female connecting elements, starting from the observation that it is sometimes necessary to prevent connection or disconnection of the male and female elements of a connection. This is particularly the case when safety imperatives, associated with the nature of the fluid transiting through the connection, impose a limitation of the risks of false manoeuvre. It is sometimes necessary to provide that only authorized staff can proceed with the connection or disconnection of the male and female elements of a connection, for example in the medical domain or when dangerous fluids are to be manipulated. In certain applications, the connectors may also have to be secured against the risks of theft of the fluid that they allow to circulate.
[0004] Up to the present time, it is not possible to secure such a connection efficiently.
[0005] It is a more particular object of the present invention to overcome these drawbacks.
SUMMARY OF THE INVENTION
[0006] To that end, the present invention relates to a female connecting element of the afore-mentioned type, i.e. comprising a press-button for controlling means for locking a male endpiece, which is characterized in that the button bears controlled means for selectively blocking the locking means in a configuration where a part of an endpiece is retained and/or in a configuration opposing the introduction of a part of an endpiece.
[0007] Thanks to the invention, it is possible to immobilize the button, with respect to the normal location of the endpiece in the female element, in a position where it blocks, thanks to the locking means, passage for the male endpiece, which avoids untimely connections and disconnections, while the overall dimensions of the connection are not increased to a substantial degree. The additional safety obtained by the blockage of the button is operational both when the connection is closed, in which case this blockage prevents the connection from opening, and when the connection is open, in which case such blockage prevents closure of the connection.
[0008] According to advantageous aspects, a female connecting element according to the invention incorporates one or more of the following characteristics:
[0009] The button defines a volume for receiving a part of an endpiece, this button being provided with at least one inner element in relief adapted to cooperate with at least one outer element in relief of the endpiece in order to lock it in fitted configuration, while the button is adapted to control a movement of relative moving apart of these relief elements and the blocking means may immobilize the endpiece in the housing, with the result that it is impossible to move apart these inner and outer relief elements. Thanks to this aspect of the invention, a displacement of the button does not make it possible to release the male endpiece. In a variant, the blocking means may be provided to be able to immobilize the button in a position where it is impossible to move apart the afore-mentioned relief elements. In that case, the button, blocked in its afore-mentioned position, prevents the outer relief element of the endpiece from moving apart from the inner relief element of the button, with the result that the endpiece is immobilized with respect to the button. Whatever the variant, means for elastically loading the button towards a position of engagement of its inner relief element with the outer relief element of an endpiece, may be provided.
[0010] The button is equipped with a bolt controlled by a lock.
[0011] In a first embodiment of the invention, this bolt is mobile in a direction substantially parallel to the direction of displacement of the button with respect to the body, this bolt being adapted to exert on a male endpiece an effort of hold of the endpiece in position of engagement of an outer relief element of the endpiece with an inner relief element of the female element. In that case, the button advantageously defines a housing in which an endpiece may be introduced, with the possibility of transverse movements with respect to a longitudinal axis of the female element, this bolt being adapted to prevent the transverse movements of an endpiece in this housing.
[0012] In another advantageous embodiment, the bolt is mobile in a direction substantially perpendicular to the direction of displacement of the button with respect to the body, between a first position where it does not interfere with the body, and a second position where it projects radially with respect to the button and may come into abutment against the body, limiting a displacement of the button in a radial direction with respect to the longitudinal axis of the female element.
[0013] Whatever the embodiment of the invention, the lock may be a cylinder lock completely integrated in the button and provided with means for obturating by default the hole in which a key is introduced in the lock. In this way, the overall dimensions of the button are not substantially modified with respect to the button of the connections of the prior art, with the result that the overall dimensions of the connection remain virtually unchanged.
[0014] The invention also relates to a quick connection for removably joining two pipes, which comprises a male endpiece and a female element as described hereinbefore. Such a connection is more secure than the prior art connections, while it remains easy to use for staff authorized to manipulate the means for blocking the button.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention will be more readily understood on reading the following description of two forms of embodiment of a quick connection in accordance with its principle, given solely by way of non-limiting example, with reference to the accompanying drawings, in which:
[0016] [0016]FIG. 1 schematically shows a quick connection according to the invention before its male and female elements have been joined, the female element being shown in section, while the male endpiece is shown in outside view.
[0017] [0017]FIG. 2 is a view similar to FIG. 1 while the male and female elements are coupled.
[0018] [0018]FIG. 3 is a view similar to FIG. 1 when the male endpiece is extracted from the female element.
[0019] [0019]FIG. 4 is a view similar to FIG. 1 when the male endpiece cannot be extracted from the female element, and
[0020] [0020]FIG. 5 is a view similar to FIG. 4 for a device according to a second form of embodiment of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0021] Referring now to the drawings, a quick connection shown in the Figures comprises a female element A and a male endpiece B provided to fit in each other. The rear part of the female element A is connected fluidically to a pipe C 1 . Similarly, the rear part of the endpiece B is connected to a second pipe C 2 . By way of example, it may be considered that pipe C 1 is fixed while pipe C 2 is fast with an apparatus or a system forming part of a series of apparatus or systems that may be successively connected on pipe C 1 . In that case, the female element A is intended to cooperate successively with different male endpieces B.
[0022] The geometry of the endpiece B is conventional. This endpiece comprises a first tubular part 11 on which the pipe C 2 is connected, this first part extending in a second part 12 , of smaller diameter, comprising a flange 13 and joined to part 11 by a section of transition 14 .
[0023] [0023] 15 denotes the front end of the endpiece B, i.e. the end of part 12 opposite the section 14 .
[0024] The flange 13 is defined between an annular surface 13 a substantially perpendicular to the longitudinal axis X B of the endpiece B and a truncated surface 13 b which converges in the direction of end 15 . A cylindrical radial surface 13 c joins the surfaces 13 a and 13 b of the flange 13 .
[0025] The female element A comprises a substantially tubular principal body 21 on which the pipe C 1 is connected. X A denotes the longitudinal axis of the element A. The body 21 is hollow and defines a housing 22 for receiving the endpiece B and for circulation of fluid, which makes it possible to join pipes C, and C 2 . The body 21 is provided with an opening 23 of circular cross-section centred on the axis X A . The body 21 also defines a bearing surface 24 for a ring 25 equipped with O-rings (not shown) to ensure seal, on the one hand, with endpiece B and, on the other hand, with the bearing surface 24 .
[0026] A device for retaining the endpiece B in the element A is provided and comprises a press-button 26 disposed in a part of the housing 22 and forming a housing 27 for receiving the part 12 . The button 26 is disposed in a bore 29 made in the body 21 , in the direction of an axis Y A perpendicular to axis X A , i.e. radial with respect thereto. The respective dimensions of the bore 29 and of the button 26 are such that this button can slide along axis Y A with respect to the body 21 . A spring 30 is arranged in a housing 31 provided in the bottom 32 of the bore 29 and exerts on the button 26 an elastic effort F, tending to push it upwardly in FIG. 1, i.e. to drive it from the bore 29 . The button 26 comprises an extension 26 a which comes into abutment against the ring 25 under the effect of the effort F 1 , in order to limit the movement of extraction of the button 26 with respect to the bore 29 .
[0027] When the endpiece B is introduced in the housing 22 , its part 12 traverses the housing 27 and the flange 13 is disposed between the ring 25 and an inner flange 26 b of the button 26 . In practice, the flange 26 b extends only over the lower part of the inner periphery of the housing 27 . The configuration is in that case that of FIG. 2 where the endpiece B is retained in position in the element A by the cooperation of the flanges 13 and 26 b.
[0028] More precisely, the flange 26 b is defined between an annular surface 26 c, substantially perpendicular to a central axis X 27 of the housing 27 , and a truncated surface 26 d converging in the direction of the ring 25 . A cylindrical surface 26 e joins the surfaces 26 c and 26 d.
[0029] The surface bearing of the surfaces 26 c and 13 a allows an efficient locking of the endpiece B in the female element A.
[0030] When the endpiece B is to be released, it suffices to exert on the button 26 an effort, represented by arrow F 2 in FIG. 3, this effort having the effect of displacing the button 26 against the effort F, exerted by the spring 30 . This disengages the flange 26 b from the path of the flange 13 during extraction of the endpiece B which is represented by arrow F 3 in FIG. 3.
[0031] According to the invention, a cylinder lock 50 is integrated in the button 26 and controls a bolt 51 which may or may not project towards the bottom 32 of the bore 29 depending on the state of the lock included in the cylinder 50 , this lock being controlled with the aid of a key 52 .
[0032] When the bolt 51 does not project out of the cylinder 50 , the configuration is that of FIGS. 1 to 3 where the male endpiece B can be introduced into the female element A or extracted therefrom.
[0033] When the connection formed by elements A and B is to be locked in configuration of connection of the pipes C 1 and C 2 , the key 52 is introduced in the cylinder 50 to manoeuvre the bolt 51 which then reaches the position of FIG. 4 where it prevents an offset of axes X B and X 27 which in that case substantially merge. In effect, an effort F 2 exerted on the button 26 in the configuration of FIG. 4 has the effect of displacing the button 26 against the effort F 1 , exerted by the spring 30 but the flange 26 b cannot be offset with respect to the flange 13 as the bolt 51 prevents the transverse movements of the button 26 in the bore 29 in direction Y A . In other words, the bolt 51 ensures that the flanges 13 and 26 b remain in abutment against each other, which prevents any untimely extraction of the endpiece B with respect to the female element A.
[0034] The bolt 51 also makes it possible to prevent an untimely connection of elements A and B insofar as, if the cylinder 50 is manoeuvred in the configuration of FIG. 1 to cause the bolt 51 to project towards the bottom 32 of the bore 29 , the bolt 51 opposes the passage of the flange 13 at the level of flange 26 b. In this way, when it is attempted to introduce the part 12 in the housings 27 and 22 , the button cannot be shifted in the bore 29 towards the bottom 32 , as is the case when the bolt is retracted in the cylinder 50 .
[0035] In the second form of embodiment of the invention shown in FIG. 5, elements similar to those of the first embodiment bear identical references. This embodiment differs from the preceding one in that the bolt 51 here is controlled by the cylinder 50 to project, or not project, radially with respect to the button 26 , i.e. in a direction X′ A substantially perpendicular to direction Y A of slide of the button 26 in the bore 29 .
[0036] The direction X′ A may or may not be parallel to direction X A .
[0037] When the bolt 51 projects, as shown in FIG. 5, it prevents an effort F 2 exerted on the button 26 from allowing it to be displaced towards the bottom 32 of the bore 29 , with the result that the part 12 of the male endpiece B remains immobilized in the female element A.
[0038] This mode of blocking the button 26 also prevents an untimely connection of elements A and B.
[0039] As shown in the accompanying Figures, the integration of a cylinder 50 in a button 26 of a connection according to the invention does not substantially modify the dimensions of this button, which is particularly advantageous from the standpoint of manoeuvrability of the connections according to the invention.
[0040] Taking into account the environment in which a connection according to the invention is likely to be used, the cylinder 50 is advantageously protected from outside pollution by means obturating the hole in which the key 52 is introduced. Such means may comprise a sliding or pivoting member which moves aside from the hole in question when the key is introduced.
[0041] The invention has been shown with a button 26 in one piece. However, it is applicable with a button formed by a plurality of assembled pieces.
[0042] The invention is not limited to a device comprising a lock controlled by a key. It is also applicable to a lock with remote-control or with a system of combinations.
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This invention relates to a female element of a rapid connection for removably joining two pipes through which a fluid passes, said element comprising a body defining a housing for receiving a part of a male endpiece and means for locking said endpiece in fitted configuration in said female element. The locking means are controlled by a press-button which bears controlled means, such as a cylinder controlling a bolt, for selectively blocking the locking means in configuration of hold of said part of the endpiece in the housing and/or in a configuration opposing the introduction of a part of an endpiece in said housing.
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This application is a divisional application of application Ser. No. 08/154,925, filed Nov. 18, 1993, now U.S. Pat. No. 5,423,749.
This invention relates to an administration system for cardioplegia, and to a method of administering cardioplegia.
BACKGROUND AND SUMMARY OF THE INVENTION
Cardioplegia is a commonly used technique for protecting a heart during open heart surgery in which cardioplegia solution is circulated through the heart tissues. The cardioplegia solution typically comprises a mixture of a medication, such as a potassium solution, and blood or a blood substitute. The cardioplegia solution stops the heart and provides oxygen to minimize damage to the heart. The selection of the particular content of the cardioplegia solution depends upon the particular physician. Moreover, it is becoming common to vary the content of the cardioplegia solution during the procedure.
Until this invention, the adjustable mixing of the components of a cardioplegia solution has been accomplished by providing separate pumps for each component. However, providing multiple pumps is expensive. Using multiple pumps also makes it difficult to make adjustments in the composition of the cardioplegia solution without changing the flow rate, or to change the flow rate without changing the composition of the solution.
The cardioplegia system of the present invention is adapted for mixing and administering cardioplegia medication and/or blood to a patient's heart during cardiopulmonary bypass surgery. The system comprises a tubing set, a positive displacement pump, and a mixing system. The tubing set includes a cardioplegia supply tube adopted for connection to a source of cardioplegia medication; a blood supply tube adopted for connection to a source of blood or blood substitute; and a cardioplegia administration tube connected to the cardioplegia and blood supply tubes, the cardioplegia administration tube being adapted to supply cardioplegia solution to the patient's heart.
The positive displacement pump is adapted for pumping fluid through the cardioplegia administration tube.
The mixing system controls the ratio of cardioplegia medication and blood or blood substitute in the cardioplegia administration tube. The mixing system comprises pinch valves for alternately-continually pinching the cardioplegia and blood supply tubes to close and open the cardioplegia and blood supply tubes such that only one of the cardioplegia and blood supply tubes is open at a time, and a controller for controlling the intervals during which the pinch valves are open with respect to each of the cardioplegia and blood supply tubes to control the ratio of the cardioplegia medication and blood or blood substitute administered through the cardioplegia administration tube.
The pinch valves can comprise a single double-acting solenoid valve that simultaneously allows one of the cardioplegia and blood supply tubes to open as it closes the other of the cardioplegia and blood supply tubes, or the pinch valves can comprise separate solenoid valves for each tube.
The tubing set may also include a recirculation tube, in which case the mixing system might also include a pinch valve for opening and closing the recirculation tube, the controller allowing only one of the cardioplegia supply, blood supply, and recirculation tubes to be open at any give time. A pressure transducer can monitor the pressure in the cardioplegia administration tube, and in response to a pressure exceeding a predetermined threshold, the controller can cause the fluid to open the recirculation tube pinch valve to simply recirculate. Also, the recirculation line provides a recirculation option to the surgeon who might wish to temporarily discontinue the administration of cardioplegia solution.
In a preferred embodiment of the invention, the tubing set can be provided as part of a cassette adapted to interfit with the control unit. The cassette would contain at least the cardioplegia and blood supply tubes, and preferably the recirculation tube as well. The cassette functions to hold these tubes, and position them properly with respect to the controller so that the pinch valves on the controller can operate to open and close the tubes.
The method of this invention provides for the mixing and administering cardioplegia medication and/or blood to a patient's heart during cardiopulmonary bypass surgery. Generally, this method comprises the steps of providing a tubing set, comprising a cardioplegia supply tube in fluid communication with a source of cardioplegia medication, a blood supply tube in fluid communication with a source of blood or blood substitute, and a cardioplegia administration tube connected to the downstream ends of the cardioplegia and blood supply tubes; mounting the cardioplegia administration tube in a positive displacement pump for pumping fluid through the cardioplegia administration tube; mounting the cardioplegia and blood supply tubes in pinch valves; and alternately-continually pinching the cardioplegia and blood supply tubes with the pinch valves to close and open the cardioplegia and blood supply tubes such that only one of the cardioplegia and blood supply tubes is open at a time, controlling the intervals during which the pinch valves are open with respect to each of the cardioplegia and blood supply tubes to control the ratio of the cardioplegia medication and blood or blood substitute administered through the cardioplegia administration tube.
The system and method of the present invention allow the composition of the cardioplegia solution to be easily changed without affecting the flow rate, which is determined by the pump. Moreover, the system and method allow the flow rate of cardioplegia solution to be changed without affecting the composition of the solution, which is determined by the controller. Finally, the system and method provide for the delivery of the cardioplegia solution in a closed, sterile pathway. The tubing set can be made to be quickly attached to and removed from the controller and the pump, so that it can be disposed of after use, eliminating the need to clean or sterilize the controller and pump after each use.
These and other features and advantages of the invention will be in part apparent, and in part pointed out hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a first embodiment of a cardioplegia administration system constructed according to the principles of this invention;
FIG. 2 is a timing diagram, illustrating the control of the first embodiment of the cardioplegia administration system;
FIG. 3 is a schematic diagram of an alternate construction of the first embodiment of a cardioplegia administration system;
FIGS. 4A and 4b are timing diagram, illustrating the control of the alternate construction of the first embodiment;
FIG. 5 is a schematic diagram of a second embodiment of a cardioplegia administration system constructed according to the principles of this invention;
FIGS. 6A, 6b, and 6c are timing diagram, illustrating the control of the system of the second embodiment;
FIG. 7A is a view of an alternate construction of the second embodiment with the recirculation tube open;
FIG. 7B is a view of an alternate construction of the second embodiment with the blood supply tube open;
FIG. 7C is a view of an alternate construction of the second embodiment with the cardioplegia supply tube open;
FIG. 8 is a drawing of a disposable cassette system for implementing the system of the second embodiment;
FIG. 9 is a plan view of the cassette for implementing the second embodiment;
FIG. 10 is a cross-sectional view through the cassette, showing the cardioplegia supply tube open;
FIG. 11 is a cross-sectional view through the cassette, showing the cardioplegia blood supply tube open; and
FIG. 12 is a cross-sectional view through the cassette, showing the recirculation tube open.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A first embodiment of a cardioplegia administration system constructed according to the principles of this invention is shown schematically as 20 in FIG. 1. The system 20 comprises a tubing set 22, a positive displacement pump 24, and a mixing system 26.
The tubing set 22 comprises a cardioplegia supply tube 28, having upstream and downstream ends 30 and 32, respectively. The upstream end 30 of the cardioplegia supply tube 28 is adapted to be connected to a source 34 of cardioplegia medication. The tubing set 22 also comprises a blood supply tube 36, having upstream and downstream ends 38 and 40, respectively. The upstream end 38 of the blood supply tube 36 is adapted to be connected to a source 42 of blood or blood substitute. The tubing set 22 also comprises a cardioplegia administration tube 44 connected to the downstream ends 32 and 40, respectively, of the cardioplegia supply tube 28 and the blood supply tube 36. The cardioplegia administration tube 44 is adapted to supply a cardioplegia solution consisting of cardioplegia medication and/or blood or blood substitute to the patient's heart.
The positive displacement pump 24 is preferably a conventional roller pump, with a track 46 for receiving a portion of the cardioplegia administration tube 44.
The mixing system 26 comprises pinch valves for alternately but continually pinching one of the cardioplegia and blood supply tubes 28 and 36, to open and close these tubes so that only one of these tubes is open at any given time. In system 20, the pinch valves comprise seats 48 and 50 for receiving the cardioplegia and blood supply tubes 28 and 36. The pinch valves also comprise a solenoid 52 positioned so that the plunger 54 of the solenoid impinges on either the cardioplegia supply tube 28 or the blood supply tube 36. The solenoid 52 is preferably positioned so that when the solenoid is not energized, the plunger 54 impinges on the cardioplegia supply tube 28, and when the solenoid is energized (as shown in FIG. 1) the plunger 54 impinges on the blood supply tube 36. The arrangement provides a fail-safe mode in which the system continues to provide blood or blood substitute through the cardioplegia administration tube 44 in the event of failure of the mixing system 26.
The mixing system 26 also comprises a controller 56, that controls the solenoid 52 to control the composition of the fluid supplied to the cardioplegia administration tube 44. As shown on the FIG. 2 timing diagram, when the controller 56 applies no voltage to the solenoid 52, the plunger 54 impinges on the cardioplegia supply tube 38, indicated by t B on FIG. 2. When the controller 56 applies a positive voltage +V to the solenoid 52, the plunger 54 moves from its position pinching the cardioplegia supply tube 28 to a position pinching the blood supply tube 36 as shown in FIG. 1. This is indicated by t A on FIG. 2. Because the pump 24 provides a constant flow rate of fluid through the cardioplegia administration tube 44, the controller 56 can control the relative proportions of cardioplegia solution and blood or blood substitute supplied to the cardioplegia administration tube 44, by controlling the amount of time each of the cardioplegia and blood supply tubes 28 and 36 is open. The content of the cardioplegia solution is in direct proportion to the relative amounts of time t A and t B each supply tube 28 or 36 is open.
An alternate construction of the first embodiment of the cardioplegia administration is shown as 20' in FIG. 3. The system 20' is similar to system 20, and corresponding parts are identified with corresponding reference numerals. However, instead of a single solenoid 52, the system 20' employs two solenoids 60 and 62. The solenoid 60 has a plunger 64 which, when the solenoid 60 is energized, pinches the cardioplegia supply tube 28. Similarly, solenoid 62 has a plunger 66 which, when the solenoid 62 is energized, pinches the blood supply tube 36. The controller 56 provides signals to the solenoids 60 and 62 to simultaneously energize one of the solenoids while de-energizing the other of the solenoids, so that only one of the cardioplegia and blood supply tubes 28 and 36 is open at any time. As shown in the timing diagram of FIG. 4A and 4b , when the controller 56 provides a positive voltage +V to solenoid 60, it provides 0 voltage to solenoid 62, thus solenoid 60 is energized, solenoid 62 is not energized, and the blood supply tube 36 is open while the cardioplegia supply tube 28 is closed. This is indicated as t A in FIGS. 4A and 4b . Similarly, when the controller 56 provides a positive voltage +V to solenoid 62, it provides 0 voltage to solenoid 60. This is indicated by t B in FIGS. 4A and 4b. (Of course, one of the solenoids 60 or 62 could be biased oppositely of the other so that the same signal causes one valve to open and the other to close. This would also allow a selection of one of the supply tubes 28 and 36 to remain open in the event of a power failure. As with system 20, the controller 56 controls the relative proportions of cardioplegia solution and blood or blood substitute applied to the cardioplegia administration tube 44 by controlling the amount of time each of the cardioplegia and blood supply tubes 28 or 36 is open. The tubes 28 and 36 in systems 20' may be of sizes selected so that if there is a failure of the mixing system 26, the pinch valves open and fluid of a preselected composition (determined by the relative sizes of the tubes) is delivered to the cardioplegia administration tube 44.
A second embodiment of a cardioplegia delivery system constructed according to the principles of this invention is indicated generally as 100 in FIG. 5. The system 100 is similar to system 20', described above. The system 100 comprises a tubing set 102, a positive displacement pump 104, and a mixing system 106.
The tubing set 102 comprises a cardioplegia supply tube 108, having upstream and downstream ends 110 and 112, respectively. The upstream end 110 of the cardioplegia supply tube 108 is adapted to be connected to a source 114 of cardioplegia medication. The tubing set 102 also comprises a blood supply tube 116, having upstream and downstream ends 118 and 120, respectively. The upstream end 118 of the blood supply tube 116 is adapted to be connected to a source 122 of blood or blood substitute. The tubing set 102 also comprises a cardioplegia administration tube 124 connected to the downstream ends 112 and 120, respectively, of the cardioplegia supply tube 108 and the blood supply tube 116. The cardioplegia administration tube 124 is adapted to supply cardioplegia solution consisting of cardioplegia medication and/or blood or blood substitute to the patient's heart.
Unlike the tubing set 22 described above, the tubing set 102 also comprises a recirculation tube 126, that parallels a portion of the cardioplegia administration tube 124, for recirculating cardioplegia fluid around the pump 104, as described in more detail below.
The positive displacement pump 104 is preferably a conventional roller pump, with a track 128 for receiving the portion of the cardioplegia tube 124 that is parallel to the recirculation tube 126.
The mixing system 106 comprises pinch valves for alternately but continually pinching two of the cardioplegia supply tube 108, blood supply tubes 116, and the recirculation tube 126, to open and close these tubes so that only one of these tubes is open at any given time. In system 100, the pinch valves comprise seats 130, 132 and 134, for receiving the cardioplegia supply tube 108, the blood supply tube 116 and the recirculation tube 126, respectively. The pinch valves also comprise solenoids 136, 138, and 140. The solenoid 136 has a plunger 142 which, when the solenoid 136 is energized, pinches the cardioplegia supply line 108. Similarly, solenoid 138 has a plunger 144 which, when the solenoid 138 is energized, pinches the blood supply tube 116. Similarly, solenoid 140 has a plunger 146 which, when the solenoid 140 is energized, pinches the recirculation tube 126.
The mixing system also comprises a controller 148, that controls the solenoids 136, 138, and 140 to control the composition of the fluid supplied to the cardioplegia administration tube 124. As shown on the timing diagrams of FIGS. 6A, 6b, and 6c, when the controller 148 applies a positive voltage +V to the solenoid 136, the plunger 142 moves from its position pinching the cardioplegia supply tube 108, opening the tube 108. The controller 148 simultaneously applies a 0 voltage to the solenoids 138 and 140, so that the blood supply tube 116 and the recirculation tube 126 are pinched closed. When the controller 144 applies a positive voltage +V to the solenoid 138, the plunger 144 moves from its position pinching the blood supply tube 116, opening the tube 116. The controller 148 simultaneously applies a 0 voltage to the solenoids 130 and 134, so that the cardioplegia supply tube 108 and the recirculation tube 126 are pinched closed. When the controller 148 applies a positive voltage +V to the solenoid 140, the plunger 146 moves from its position pinching the recirculation tube 126, opening the tube 126. The controller 148 simultaneously applies a 0 voltage to the solenoids 136 and 138, so that the cardioplegia supply tube 108 and the blood supply tube 116 are closed. (As discussed above, with regard to the first embodiment, the solenoids may be oppositely biased from each other so that the same signal causes one solenoid to open and another to close. This arrangement also allows a selection of one of the valves to remain open in the event of a power failure.)
Because the pump 104 provides a constant flow rate, the controller 148 can control the relative proportions of the cardioplegia medication and blood or blood substitute supplied to the cardioplegia delivery tube 124, by controlling the amount of time each of the cardioplegia supply tube 108 (t A in FIG. 6A, 6b and 6c) and blood supply tube 116 (t B in FIG. 6A, 6b and 6c) are open. The content of the cardioplegia solution is in direct proportion to the relative amounts of time each of the supply tubes 108 or 116 is open. The controller 148 can also alleviate pressure build-up by closing the cardioplegia and blood supply tubes 108 and 116, and simply recirculating the cardioplegia solution by opening the recirculation tube 126. The system 100 also includes a pressure transducer 150 connected to the controller 148 with a pressure line 151, that monitors the pressure of the cardioplegia solution in the cardioplegia administration tube 124, and provides this information to the controller 148. In response, the controller can energize the solenoid 140, and de-energize solenoids 136 and 138, opening the recirculation tube 126. This is represented by t R in FIGS. 6A, 6b and 6c. Controls can also be provided to allow the surgeon to select the recirculation mode to temporarily discontinue the administration of cardioplegia solution.
The controller 148 may optionally include a module 152 and position sensors for monitoring the status of the solenoids 136, 138, and 140. These position sensors may be, for example, limit switches 154, 156 and 160 that are opened or closed depending upon the position of solenoids 136, 138 and 140. The data on the positions of the solenoids from the sensors can be provided to the controller 148 via the module 152. The controller 148 can implement a fail safe procedure, or simply shut the system 100 down in the event of an error. For example, the controller 148 could remove power to all of the solenoids if it detects one of the following conditions: (1) More than one pinch valve is open; (2) None of the pinch valves is open; or (3) A valve position is different from the control signal. Alternatively, the solenoids could be configured so that in the event of a failure of the mixing system 106, one or both of the supply tubes 108 and 116 remain open while recirculation tube 126 is closed. In the event both supply tubes 108 and 116 remain open, the composition of the fluid supplied to cardioplegia administration tube 124 is a preselected composition (determined by the relative sizes of supply tubes 108 and 116).
The controller 148 also includes a selection module 162 for setting the composition and the pressure threshold.
An alternate arrangement of the pinch valves of the second embodiment employing two double-acting solenoids 162 and 164 is illustrated in FIG. 7. As shown in FIG. 7A, solenoids 162 and 164 are de-energized. The plunger 166 of the solenoid 162 impinges on the blood supply tube 116, closing it. The plunger 168 of the solenoid 164 impinges on the cardioplegia supply tube 108, closing it. The recirculation tube 126 is left open. As shown in FIG. 7B, when only the solenoid 162 is energized, the plunger 166 of the solenoid 162 impinges on the recirculation tube 126, closing it. The plunger 168 of the solenoid 164 impinges on the cardioplegia supply tube 108, closing it. The blood supply tube 116 is left open. As shown in FIG. 7C, when both the solenoids 162 and 164 are energized, the plunger 166 of the solenoid 162 impinges on the recirculation tube 126, closing it, and the plunger 168 of the solenoid 164 impinges on the blood supply tube 116. The cardioplegia supply tube 108 is left open. By maintaining the solenoid 162 energized and alternately energizing and de-energizing the solenoid 164, the cardioplegia supply tube 108 and the blood supply tube 116 are alternately opened and closed.
As shown in FIG. 8, the tubing set can be incorporated into a cassette 200, adapted to be fit into a socket 202 in the mixing system unit 204. The cassette 200 comprises a box-like frame containing a three-way connector 206 joining the cardioplegia supply tube 108, the blood supply tube 116, and the recirculation tube 126, all to the cardioplegia administration tube 124, as shown in FIG. 9. The cassette 200 may also include a pressure line 151 extending to the pressure transducer 150. In the cassette 200, the pressure line 151 connects to a contact 208 which contacts a contact 210 when the cassette is properly seated in socket 202. The cassette 200 supports the tubes, and may even form part of the seats 130, 132 and 134 of the pinch valves against which the plungers 142, 144 and 146 of the solenoids 136, 138 and 140 act to pinch closed their respective tubes. To this end, the back of the cassette 200 is either open, or has one or more openings allowing access to the separate tubes 108, 116 and 126 by the solenoid plungers on the mixing system unit 204. The cassette also serves to contain the noise from the activation of the plungers so that the system operates quietly.
The mixing system unit 204 is adapted to receive the cassette 200 to position the tubes 108, 116 and 124 so that the solenoids 136, 138, and 140 can pinch the various tubes 108, 116 and 124 closed. As shown in FIG. 10, during the period t A on the timing diagram of FIGS. 6A, 6b and 6c, the plunger 142 of solenoid 136 on unit 202 is energized to unpinch the tube 108 in seat 130 in cassette 200. The plungers 144 of solenoid 138, and 146 of solenoid 140, on unit 202 are de-energized to pinch the tubes 116 and 124 in their respective seats 132 and 134 in the cassette 200. As shown in FIG. 11, during period t B , the plunger 144 of solenoid 138 on unit 202, is energized to unpinch the tube 116 in seat 132 in cassette 200. The plungers 142 of solenoid 136 and 146 of solenoid 140 on unit 102 are de-energized to pinch the tubes 108 and 124 in their respective seats 130 and 134 in the cassette 200. As shown in FIG. 12, during period t R , the plunger 146 of solenoid 140 on unit 202, is energized to unpinch the recirculation tube 126 in seat 134 in cassette 200. The plungers 142 of solenoid 154 and 144 of solenoid 136 on unit 202 are de-energized to pinch tubes 108 and 16 in their respective seats 130 and 132 in the cassette 200.
OPERATION
The systems 20 and 20' of the first embodiment are quickly and easily set up for the administration of cardioplegia to a patient undergoing cardiac surgery. The tubing set 22 is first connected to the sources of cardioplegia medication and blood or blood substitute. The end 30 of the cardioplegia supply tube 28 is connected to a source 34 of cardioplegia medication, which may be, for example, a flexible bag. The end 38 of the blood supply tube 36 is connected to a source 42 of blood or blood substitute, which may be, for example, a flexible bag. A portion of the tube 28 is then placed in the seat 48 of the pinch valve, and a portion of the tube 36 is placed in the seat 50 of the pinch valve. A portion of the cardioplegia administration tube 44 is then placed in the track 46 of the roller pump 24. The system is primed. The tubing set 22 provides a sterile containment, mixing, and delivery for the cardioplegia solution and blood or blood substitute. The tubing set 22 is designed to minimize the internal volume, and thus the amount of cardioplegia medication and blood or blood substitute used.
The system 20 or 20' is then ready for use. The end of the cardioplegia administration tube 44 is connected to the patient's heart, and the controller 56 is programmed with the desired composition of the cardioplegia solution to be delivered to the patient's heart. In system 20, the controller 56 alternately energizes and de-energizes the solenoid 52 so that the plunger alternately opens cardioplegia supply tube 28 and closes blood supply tube 36 for a period t A , and opens the blood supply tube 36 and closes cardioplegia supply tube 28 for a period t B . In system 20' the controller 56 alternately energizes solenoid 60 while de-energizing solenoid 62, and energizes solenoid 62 while de-energizing solenoid 60 so that the plunger 64 of solenoid 60 opens the cardioplegia supply tube 28 for a period t A while the plunger 66 of solenoid 62 pinched the blood supply tube 36 closed, and so that the plunger 66 of the solenoid 62 opens the blood supply tube 36 for a period t B while the plunger 64 of the solenoid 60 pinches the cardioplegia supply tube 28 closed.
The periods t A and t B are automatically determined by the controller 56, taking into account the opening and closing properties of the pinch valves, to provide the selected composition of the cardioplegia solution to the cardioplegia administration tube 44. Because the flow rate is constant, the composition of the cardioplegia solution delivered to the cardioplegia administration tube 44 is in direct proportion to the periods t A and t B .
Of course, a heat exchanger and a debubbler can be incorporated into the systems 20 and 22' to control the temperature of the cardioplegia fluid, and to remove gas bubbles entrained in the fluid.
The system 100 of the second embodiment is quickly and easily set up for the administration of cardioplegia to a patient undergoing cardiac surgery. The cassette 200 containing part of the tubing set 102 is first connected to the sources of cardioplegia medication and blood or blood substitute. The end 110 of the cardioplegia supply tube 108 is connected to a source 114 of cardioplegia medication, which may be, for example, a flexible bag. The end 118 of the blood supply tube 116 is connected to a source 122 of blood or blood substitute, which may be, for example, a flexible bag. The cassette 200 is then inserted into slot 202 on the mixing device 204, which aligns the cardioplegia supply tube 108, the blood supply the 116, and the recirculation tube 126, with the plungers 142, 144, and 146, of solenoids 136, 138, and 140 of the mixing system device 204. The contact 208 on the pressure transducer line in the cassette 200 is also aligned with a pressure transducer contact 210 on the mixing system device 204. A portion of the cardioplegia administration line 124 that parallels the recirculation tube 126 is installed in the track 128 of the roller pump 104. The tubing set 102 in the cassette 200 provides a sterile containment, mixing, and delivery for the cardioplegia solution and blood or blood substitute. The tubing set 102 is designed to minimize the internal volume, and thus the amount of cardioplegia medication and blood or blood substitute used.
The system 100 is then ready for use. The end of the cardioplegia administration tube 124 is connected to the patient's heart, and the controller 148 is programmed via the selection module 162 with the desired composition of the cardioplegia solution to be delivered to the patient's heart. In system 100, the controller 148 alternately energizes solenoid 136 while de-energizing solenoid 138 (see FIG. 10), and energizes solenoid 138 while de-energizing solenoid 136 (see FIG. 11), so that the plunger 142 of solenoid 136 opens the cardioplegia supply tube 108 for a period t A while the plunger 144 of solenoid 138 pinches the blood supply tube 116 closed, and so that the plunger 144 of the solenoid 138 opens the blood supply tube 116 for a period t B while the plunger 142 of the solenoid 136 pinches the cardioplegia supply tube 108 closed.
The periods t A and t B are automatically determined by the controller 148, taking into account the opening and closing properties of the pinch valves, to provide the selected composition of the cardioplegia solution to the cardioplegia administration tube 124. Because the flow rate is constant, the composition of the cardioplegia solution delivered to the cardioplegia administration tube 124 is in direct proportion to the periods t A and t B .
The pressure transducer 150 monitors the pressure in the cardioplegia administration tube 124, and if the pressure exceeds a predetermined threshold that may be set with the selection module 162, the controller 148 causes the plungers 142 and 144 of the solenoids 136 and 138 to close, closing the cardioplegia and blood supply tubes 108 and 116. The controller 148 also causes the plunger 146 of solenoid 140 to open the recirculation tube 126, allowing the cardioplegia solution to simply recirculate in a loop through tubes 124 and 126. See FIG. 12. The selection module 162 can also allow the user to enter the recirculation mode on command.
The limit stitches 154, 156, and 158 monitor the states of the solenoids 136, 138, and 140, and provide this information to the controller 148 via the safety module 152. If an error in a solenoid state is detected, the controller can take corrective action, shut down the system 100, or sound an alarm.
Of course, a heat exchanger and a debubbler can be incorporated into the systems 100 to control the temperature of the cardioplegia fluid, and to remove gas bubbles entrained in the fluid. Such heat exchangers (not shown) could be of the types described in U.S. Pat. No. 4,846,177 on Combination Fluid Path and Mount for Heat Exchanger, which is incorporated herein by reference, or in co-pending U.S. patent application Ser. No. 07/951,725; filed Sep. 25, 1992 by William G. O'Neill and Timothy P. Walker, on "Inline Heat Exchanger and Cardioplegia System", which is incorporated herein by reference.
As an alternative to solenoids, stepper motors could be provided to drive the pinch valves.
As various changes could be made in the above constructions and methods without departing from the scope of the invention as defined in the claims, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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A cardioplegia administration system includes a tubing set, a positive displacement pump and a mixing system. The tubing set has a cardioplegia supply tube; a blood supply tube; and a cardioplegia administration tube connected to the cardioplegia and blood supply tubes. The positive displacement pump engages the cardioplegia administration tube to pump fluid therethrough. The mixing system includes pinch valves for alternately-continually pinching the cardioplegia and blood supply tubes to close and open the cardioplegia and blood supply tubes such that only one of the cardioplegia and blood supply tubes is open at a time, and a controller that controls the intervals during which the pinch valves are open to control the ratio of the cardioplegia medication and blood or blood substitute administered through the cardioplegia administration tube. The method of this invention includes the step, among others, of operating the pinch valves to close and open the cardioplegia and blood supply tubes so that only one of the cardioplegia and blood supply tubes is open at a time while controlling the intervals during which the pinch valves are open to control the ratio of the cardioplegia medication and blood or blood substitute administered through the cardioplegia administration tube.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit under 35 USC §119(e) of U.S. Provisional Patent Application No. 61/324,377, filed Apr. 15, 2010.
FIELD OF THE INVENTION
This invention relates to reels, and more particularly to a reel for storing and transporting cable, wire, flexible tubing or the like, which can be readily disassembled after the supply of cable or the like is exhausted to facilitate shipment to a location where the reel can be reassembled and replenished with a supply of cable or the like.
BACKGROUND OF THE INVENTION
In the wire and cable industry, it is conventional practice to ship wire or cable wound on reels to a user. After unwinding the wire or cable from the reel, the user either disposes of the reel, or returns the reel for re-use.
A reel is composed of a cylindrical drum or core having flanges at its opposite ends for retaining cable, wire, or the like wound around the drum. To facilitate shipment of exhausted reels, various knockdown or collapsible reels have been designed. In a typical knockdown reel, the core is composed of two complementary, interlocking, semi-cylindrical parts which, when together, provide a circular, cylindrical outer surface. The two semi-cylindrical parts interlock with a pair of flanges to form a complete reel.
One such knockdown reel is described in U.S. Pat. No. 3,940,085, granted Feb. 24, 1976 to Kenneth E. Campbell. In the reel described in the Campbell patent, each of two semi-cylindrical core halves is formed with an arcuate ridge at both of its ends. The ridges are received in annular grooves formed in bosses on a pair of flanges. The core halves are secured to each other by bolts, and when they are secured together, the arcuate ridges are locked in the annular grooves, and the core and flanges are rigidly held together.
Another knockdown reel is described in U.S. Pat. No. 5,575,437, granted Nov. 19, 1997 to Kenneth E. Campbell. In this reel, semi-cylindrical core halves are connected to circular recesses in specially formed flanges by means of resilient, axially extending, latching fingers.
In still another knockdown reel, described in U.S. Pat. No. 5,806,788, granted on Sep. 15, 1998 to Richard P. Witwer and Kenneth E. Campbell, core halves are formed with locking fingers that engage notches formed on the peripheries of core-supporting hubs fastened to flanges.
Although the knock-down reels described in these patents have served reliably in the cable industry for many years, there remains a need for a more robust reel that can withstand impact, temperature variations and other forms of stress more reliably. For example, it is important for a reel to be able to withstand the impact that results when it is dropped from a fork lift or from the bed of a flat bed trailer.
SUMMARY OF THE INVENTION
The reel according to the invention comprises a cylindrical core composed of two complementary arcuate core segments, a pair of flanges disposed respectively at axially spaced opposite ends of the core, and a pair of rings for connecting the core to the flanges. The rings are fixed respectively to mutually facing inner sides of the flanges. Cooperating slots and tongues on the rings and core elements prevent the flanges from moving relative to the core in the direction of the axis of the core. The tongues enter the slots when the core segments are brought together. Resiliently bendable locking arms protrude radially inward from both ends of each core segment, and each locking arm is engageable by a snap fit with one of the rings when the core segments are brought together.
Preferably, access openings are provided in the flanges adjacent each of the locking arms to allow access to the locking arms for disengagement from the rings.
More particularly, a preferred embodiment of the reel comprises a core having a substantially circular cylindrical outer surface symmetrical about a core axis. The core is composed of a plurality of complementary, connected, arcuate core segments, and has two axially spaced opposite ends. Flanges are disposed respectively at the axially spaced opposite ends of the core, and have inner sides facing each other. Rings for connecting the core to the flanges, are fixed to the inner sides of the flanges whereby the rings are located opposite to each other.
Arc-shaped connecting are elements formed on the core segments at the opposite ends of the core, and arc-shaped connecting elements are also formed on the rings. The arc-shaped connecting elements of the core segments are engageable with the arc-shaped connecting elements formed on the rings and are fully engaged when the arcuate core segments are in complementary relationship to form a core having a circular cylindrical outer surface. The cooperation of the arc-shaped connecting elements locks the flanges against axial movement relative to the core. The arc-shaped connecting elements of the core segments are movable radially outward relative to the core axis for disengagement from the arc-shaped connecting elements formed on the rings.
Locking arms are connected to, and extend radially inward from, both ends of each core segment. The locking arms have end portions with radially outward facing locking surfaces. These locking arms are resiliently bendable so that their end portions can move through a limited range in a direction substantially parallel to the core axis. Each ring has radially extending slots for receiving the locking arms, so that the locking arms can move radially inward in the slots when the arc-shaped connecting elements of the core segments are engaged with the arc-shaped connecting elements formed on the rings. Each slot of each ring has a wall facing the opposite ring, the wall being positioned for sliding engagement with a locking arm and for bending the locking arm toward the opposite ring as the locking arm moves radially inward. Each wall also has a radially inward facing surface for locking engagement with a radially outward facing surface of a locking arm. The inwardly facing surfaces of the walls and the outwardly facing surfaces of the locking arms are positioned for automatic engagement with each other by resilient movement of the arms when the arc-shaped connecting elements of the core segments are fully engaged with the arc-shaped connecting elements formed on the rings. The end portion of each locking arm that has a radially outward facing surface engaged with a radially inward facing surface of a wall of a ring, is movable toward the opposite ring for disengagement of the engaged surfaces.
Preferably, the flanges have access apertures in register with the end portions of the locking arms, whereby axial pressure can be applied to the end portions of the locking arms to disengage the radially outward facing surfaces of the locking arms from the radially inward facing surfaces of the walls of the rings.
The resiliently bendable locking arms can be unitary parts of the cores segments. Alternatively, each of the locking arms can comprise a resilient metal sheet fastened to one of the core segments, and a resin block secured to the metal sheet and engageable by a snap fit with one of the rings.
In a preferred embodiment, the arc-shaped connecting elements formed on the core segments are radially inward facing slots, and the arc-shaped connecting elements formed on the rings are annular elements protruding radially outward. Each said annular element extends into one of the radially inward facing slots.
In the preferred embodiment, each of the radially extending slots of each ring is defined by the wall thereof and a pair of opposed sides protruding from the wall in spaced relationship to each other toward the opposite ring. The opposed sides are progressively closer to each other proceeding radially inward toward the core axis so that each slot is tapered. Each core segment includes a pair of rigid elements adjacent each of its locking arms. These rigid elements protrude substantially radially inward, and are circumferentially spaced from each other on opposite sides of the adjacent locking arm. The rigid elements have circumferentially facing outer sides that are also progressively closer to each other proceeding radially inward. These outer sides conform to and engage the opposed sides of a radially extending slot when the outwardly facing surface of the adjacent locking arm is engaged with the inwardly facing surface of the wall of the last-mentioned slot.
In the embodiment having rigid elements adjacent the locking arms, a rib extending axially along each core element is preferably provided to connects the rigid elements adjacent the locking arm at one end of each core segment to the rigid elements adjacent the locking arm at the other end thereof, thereby ensuring that the rigid elements are firmly supported in fixed relationship to the core segment.
The rigid elements adjacent each locking arm also preferably extend substantially radially inward beyond the innermost end of the adjacent locking arm to protect the locking arm from damage, especially when the core segments are stacked for shipment or storage.
The reel according to the invention is highly robust. Its overall strength, and the strength of the connections of the core components to the rings, are sufficiently high that the reel can withstand impact, temperature changes, and other stresses with a very low incidence of failure. At least the core and ring portions, and often the entire reel including the flanges, can be disassembled and re-used repeatedly without failure. Moreover, the reel can be assembled and disassembled quickly and easily by an individual worker without the use of tools.
Further objects and advantages of the invention will be apparent from the following description when read in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a reel in accordance with the invention;
FIG. 2 is a broken-away end view of the reel;
FIG. 3 is a sectional view taken on plane 3 - 3 in FIG. 2 ;
FIG. 4 is a sectional view taken on plane 4 - 4 in FIG. 2 ;
FIG. 5 is a sectional view taken on plane 5 - 5 in FIG. 2 ;
FIG. 6 is a perspective view showing details of the inside of one of the two core halves 10 and 12 ;
FIG. 7 is a fragmentary elevational view of a part of an attachment ring;
FIG. 8 is an exploded view showing an alternative locking arm composed of a resilient strip of sheet metal and a resin block; and
FIG. 9 is a sectional view corresponding to FIG. 4 but showing the alternative locking arm engaged with a wall 56 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 , a preferred embodiment of the reel according to the invention comprises two complementary arc-shaped segments 10 and 12 , which can be connected together to form a core 14 having a substantially circular, cylindrical outer surface symmetrical about a core axis. Each segment has two opposite edges, each having a row of tabs 16 and a row of slots 18 ( FIG. 6 ), the tabs and slots being arranged in alternating relationship. When the segments are joined, the tabs of each segment fit into the slots of the other segment.
Although the core is preferably composed of two complementary arc-shaped segments, it is possible to form the core from three or more complementary arc-shaped segments whose arcs subtend angles totalling 360 degrees.
Flanges 20 and 22 are disposed respectively at axially spaced opposite ends of the core. The flanges, which are typically composed of wood, although other suitable materials can be used, can be identical, and have inner sides facing each other. The inner side 24 of flange 20 is visible in FIG. 1 .
Rings are fixed respectively to the inner sides of flanges 20 and 22 , one such ring is ring 26 in FIG. 1 . The rings are preferably identical and can be fastened to the flanges by means of bolts 28 ( FIGS. 2 and 3 ). The bolts extend through holes 30 in the rings, and through corresponding holes 32 ( FIG. 3 ) in the flanges 20 and 22 , holes 32 being aligned with holes 30 . As shown in FIG. 3 , the heads 34 of the bolts are disposed in recesses 36 in the flanges. The bolts are secured to the rings by nuts 38 . For added strength, the recesses in the flanges can be lined with metal cup washers (not shown).
Each ring has a series of radially outward protruding annular parts, one such part 40 being seen in FIG. 3 . Part 40 is spaced from the inner side 24 of the adjacent flange 22 to provide a space 42 for receiving an inwardly protruding part 44 of an arc-shaped segment 12 .
A wall 46 extends inwardly from the outer part of the arc-shaped segment 12 as a unitary part thereof, and is reinforced by longitudinally extending ribs, which are also formed as unitary parts of the arc-shaped segment, one such rib being rib 47 in FIG. 3 . The wall 46 , which is in spaced relationship with inwardly protruding part 44 , cooperates with part 44 to form and annular slot 48 which receives outwardly protruding annular part 40 of the ring 26 . Slot 48 , and corresponding similar slots (not shown) are disposed around the circumference of the core 14 at both ends thereof and fit the outwardly protruding annular parts 40 of the rings closely in order to secure the arc-shaped segments of the core firmly to the rings. Movement of annular parts 40 into the slots is limited by engagement between the outer perimeters of the annular parts with the bottoms of slots 48 .
As seen in FIG. 1 , the protruding annular parts 40 of the ring are interrupted by two outwardly extending protrusions 50 located opposite each other on opposite sides of the ring. These protrusions extend into slots formed by notches 52 when the two parts of the core are brought together. The annular parts 40 of each ring are also interrupted by slots 54 , which receive locking parts 55 formed at both ends of each of the arc-shaped core segments 10 and 12 .
In the process of assembly of the reel, the wooden flanges, with rings 26 attached to them, are positioned so that their protruding annular parts 40 enter the slots 48 of the core parts 10 and 12 are brought together. The locking parts 55 on the core segments enter the slots 54 of the rings and secure the core parts to the rings in the manner depicted in FIGS. 4 and 5 .
As shown in FIG. 4 , a slot 54 of a ring includes a wall 56 , which is in abutting relationship with a wooden flange when the ring is attached to the flange. The locking member includes a hook-shaped arm 58 connected at one end 60 to an end of an outer wall of a core part 12 , and having an enlargement 62 at its opposite end that extends underneath wall 56 to lock the core part to the ring. The position of the part 64 of the enlargement 62 that extends underneath the inner end 64 of wall 56 is preferably such that, when the annular ring element 40 is in full engagement with the bottom of a slot 48 as shown in FIG. 3 , only a very small clearance, e.g., around 1 mm, exists between part 62 and the inner end 64 of wall 56 . Preferably, the inner end 64 of wall 56 and the surface of the enlarged part 62 of the arm that engages the end of the wall are both disposed at an angle of about 10 E as shown in FIGS. 4 and 5 so that the edge of the inner end of the wall closest to the flange 22 is slightly radially outward from the edge remote from the flange. These angled parts of the wall and the arm aid in preventing accidental unlatching.
The arm 58 is resilient, so that its enlarged part 62 snaps into place underneath the inner end 64 of the wall, thereby securely holding the core part and the ring in engagement with each other. A spacer 67 is formed on wall 56 adjacent the outer end thereof to maintain a spacing between the wall and the locking arm 58 . The enlarged part 62 of the locking arm is deflected by a ramp 66 on the front part of wall 56 as the core parts are brought out of engagement with the rings, so that the enlarged part 62 can clear spacer 67 .
As shown in FIG. 5 , a hole 68 is provided in the flange, adjacent the inner end 64 of wall 56 and in register with the enlarged part 62 of the resilient arm 58 , to allow access to the arm so that the arm can be disengaged from the wall by pushing it manually, or by means of a tool. Thus, the core parts can be readily and easily disconnected from the rings and from each other for disassembly of the reel.
As shown in FIG. 6 , the arc-shaped segment 12 has rows of tabs 16 , the tabs being in alternating relationship with slots 18 . The two core segments are preferably identical, and therefore capable of being produced in the same mold.
Each core segment is reinforced by an array 70 of ribs formed as parts of the inner surface of the core. Included in the reinforcing ribs is a central rib 72 which rigidly connect U-shaped parts 74 and 76 of the locking members at opposite ends of the core parts. The legs of part 74 are formed with rigid protrusions 78 and 80 , which are located in circumferentially spaced relationship to each other on opposite sides of locking arm 58 . These rigid protrusions extend beyond the inner end of locking arm 58 , and protect the locking arm from damage when the core segments are stacked one upon another for shipment after disassembly of the reel. The rigid protrusions 78 and 80 have outer edges 82 and 84 , which gradually become closer together proceeding radially inward toward the core axis. As shown in FIG. 7 , a slot 54 in ring 26 has opposed sides 86 and 88 , which protrude from the wall 56 in spaced relationship to each other toward the opposite ring. These opposed sides are progressively closer to each other proceeding radially inward toward the axis, causing the slot to be tapered. The tapered relationship of sides 86 and 88 correspond to the tapered relationship between the outer edges of protrusions 78 and 80 , and the outer edges of the protrusions conform to and engage the opposed sides 86 and 88 of slot 54 when the outwardly facing surface of the locking arm 58 adjacent and between protrusions 78 and 80 is engaged with the inwardly facing end surface 64 of wall 56 . The matching tapered relationship of the protrusions and the sides of slot 54 helps to ensure that the core segments remain firmly attached to the rings when the locking elements are engaged.
The core segments and rings can be molded from any of a variety of materials. Suitable materials include polycarbonate resin, e.g., Sabic FL910 polycarbonate, and various glass fiber-reinforced polycarbonate resins.
In the alternative embodiment illustrated in FIGS. 8 and 9 , the locking arm is composed of a rectangular strip 90 of sheet metal and a resin block 92 secured together by fasteners 94 . The sheet metal strip is sufficiently thin that it can be bent manually, and resilient so that it returns to its original condition when released after being bent. Any of a various kinds of sheet steel, suitably heat-treated, can be used for the sheet metal strip 90 , as can other metals having suitable spring characteristics. The resin block 92 can be molded from any suitable polymeric resin, including the resins mentioned above, and preferably has a shape similar to that of enlarged part 62 of arm 58 as shown in FIGS. 4 and 5 .
As shown in FIG. 9 , metal strip 90 is secured by fasteners 96 to an inwardly protruding flange 98 formed on arc-shaped core segment 12 a . If the metal strip is normally flat in its relaxed condition, the outer wall 100 of flange 98 should have a slight slope so that block 92 is positioned underneath wall 56 a when the metal strip is relaxed.
The locking arm operates in the same manner as the integral locking arm in the previously described embodiment. The arm snaps into place when the core segment to which it is attached is slid into engagement with the ring fastened to a wood reel flange, and can be disengaged manually by being by a tool inserted through an access hole (not shown) in the reel flange.
An advantage of the alternative locking arm is that it avoids difficulties encountered in molding the locking arm as a unitary part of a core segment. Another advantage is that it can be stronger than the unitary resin arm, and yet easier to bend both in assembly and disassembly of the reel.
Still another alternative, not illustrated, is the use of a locking arm that is entirely composed of sheet metal, wherein the block for engaging the inner end of a locking wall on the ring consists of an extension of the metal strip suitably bent into the form of a latching block corresponding to block 92 in FIGS. 8 and 9 .
Still other variations of the invention will become apparent to those skilled in the art, and can be adopted without departing from the scope of the invention as defined in the following claims.
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A reel comprises a cylindrical core composed of two complementary arcuate core segments, a pair of flanges disposed respectively at axially spaced opposite ends of the core, and a pair of rings for connecting the core to the flanges. The rings are fixed respectively to facing inner sides of the flanges. Cooperating slots and tongues on the rings and core elements prevent the flanges from moving relative to the core in the direction of the axis of the core. The tongues enter the slots when the core segments are brought together. Resiliently bendable locking arms protrude radially inward from both ends of each core segment, and each locking arm is engageable by a snap fit with one of the rings when the core segments are brought together. Access openings in the flanges adjacent each of the locking arms allow access to the locking arms for disengagement from the rings.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. provisional application No. 61/237,769, filed Aug. 28, 2009, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Large scale solar power plants utilizing concentrating solar power (“CSP”) technology have been in production for over twenty years. The Solar Electric Generating Systems (“SEGS”) facilities in the Mojave Desert of California are a well-known example of solar power plants using such CSP technology. Concentrating solar power utilizes solar collectors comprising large mirrors or lenses which concentrate solar energy upon an unpressurized pipe or tube that contains a heat transfer fluid. Typically, a synthetic oil having a high boiling point is used as the heat transfer fluid. For example, the SEGS facilities utilize Therminol® from Solutia, Inc. as the heat transfer fluid.
As the heat transfer fluid flows through the unpressurized pipe inside the solar collectors, it is heated by the incident sunlight. One or more pumps are situated along the pipe to pump the fluid through the solar collectors and towards a boiler or heat exchanger. There, the transfer fluid is used to heat water in the boiler to produce steam. The steam is then used for powering a conventional steam turbine to produce electricity. After the heat transfer fluid releases its thermal energy in the boiler/heat exchanger, the heat transfer fluid is pumped back to the solar collectors to be heated once again.
One disadvantage of the use of a synthetic heat transfer fluid is that the fluid has a relatively low energy density. For example, Therminol® has an energy density of approximately 2100 J/kg° C. whereas ordinary water has an energy density of approximately 4200 J/kg° C. This relatively low energy density for Therminol® means that it can carry relatively less thermal energy from the solar collectors to the heat exchanger than water.
Another disadvantage of synthetic heat transfer fluids is that they are often flammable. As a result, care must be taken in handling the fluids and they must be prevented from overheating.
For these and other reasons, a number of solar power systems have recently been developed to produce steam directly from water rather than using a synthetic heat transfer fluid. Such systems—dubbed Direct Solar Steam generation (“DISS”) or Direct Steam Generation (“DSG”)—distribute water through the unpressurized pipes in the solar collectors rather than distributing a synthetic heat transfer fluid. Because water has a much lower boiling point than a synthetic heat transfer fluid, the water will eventually turn to steam after being heated a sufficient amount. Thereafter, the steam is directed to a steam turbine for generating electricity.
Such DSG systems have their own drawbacks, however. First, the presence of steam in the pipes of the solar collectors reduces the efficiency of the collectors because steam has a significantly lower heat capacity than water. Thus, the steam can carry less thermal energy towards the turbine than can pressurized water. Second, the use of a two-phase (water/steam) flow within the pipes of the solar collectors creates a condition known as the Ledinegg Instability. This phenomenon results in a boiling front as the water moves through the pipes and flashes over to steam. To compensate for this instability, an undesirable pressure drop must be introduced into the system. Finally, DSG systems are more sensitive to variations in solar flux density and changes in atmospheric conditions because the systems will not function properly unless the water in the solar collectors is sufficiently heated to flash over to steam. Taken together, these drawbacks necessitate the use of larger, more expensive solar collectors to produce a given amount of electricity. Therefore, such DSG systems may have little or no cost savings in comparison to traditional CSP systems containing synthetic heat transfer fluid.
SUMMARY OF THE INVENTION
Disclosed herein are systems and methods for generating electrical power using a solar power system comprising pressurized pipes for transporting liquid water. The pressurized pipes flow through solar collectors which concentrate sunlight on the water flowing through said pipes. Because the pipes inside the solar collectors are pressurized, the water flowing therethrough can be heated well above the ordinary boiling point of water (100° C.). Advantageously, the systems and methods described herein rely upon the superior heat transfer capabilities of water in comparison to synthetic heat transfer fluids. Furthermore, the lack of synthetic heat transfer fluid minimizes the added costs and safety concerns associated with the use of such fluids.
Finally, the pressurized pipes described herein prevent the water flowing therethrough from flashing over to steam when heated to a high temperature. Accordingly, the instabilities and unwanted pressure drops associated with two-phase (water/steam) flow are eliminated. Furthermore, the use of water rather than steam for transporting thermal energy takes advantage of water's superior energy carrying capacity in comparison to steam.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a detailed view of a pressurized solar power system according to one embodiment of the present invention.
FIG. 2 shows a view of the embodiment of FIG. 1 including the steam turbine and power generation portion of the system.
FIG. 3 shows a view of a second embodiment of a pressurized solar power system.
FIG. 4 shows the heat exchanger of FIG. 3 and a plurality of thermal storage tanks for use with the embodiment shown in FIG. 3 .
FIG. 5 shows a view of a third embodiment of a pressurized solar power system.
DETAILED DESCRIPTION
FIGS. 1-4 show various embodiments and aspects of the present invention, with like reference numerals indicating like parts throughout the several views.
FIG. 1 shows a detailed view of a pressurized solar power system 100 in accordance with one embodiment of the present invention. A pressurized solar loop 1 comprising a hollow pipe or tube is present. A portion of the pressurized solar loop 1 is positioned within a solar collector receiver array (not pictured). The solar collector receiver array may comprise any suitable means of concentrating solar energy on the pressurized solar loop 1 including, but not limited to, parabolic troughs, parabolic dishes, compact linear Fresnel reflectors, linear Fresnel reflectors, compound parabolic collectors, two axis tracking systems that focus solar energy on a tower or other structure, and any other solar energy concentration system.
The pressurized solar loop 1 forms a closed loop and preferably contains water within the loop. Other suitable heat transfer fluids known to those skilled in the art may be used instead of water, however. A pressurizer 3 is attached to the pressurized solar loop 1 to pressurize the solar loop 1 above normal atmospheric pressure.
Preferably, pressurizer 3 is a steam bubble pressurizer comprising a large internal chamber where steam can form in the upper section of the chamber but cannot be released. As the water in the solar loop 1 is heated due to the concentrated sunlight directed towards solar loop 1 , a steam bubble will form in the upper portion of steam bubble pressurizer 3 . The steam bubble can also be formed by pre-heating the water in solar loop 1 . After forming, the steam bubble in the upper section of the pressurizer 3 keeps pressure on the water in the pressurized solar loop 1 . Advantageously, this pressure increases the boiling point of the water in the pressurized solar loop 1 , thus preventing the water from flashing over to steam. As solar energy increases the temperature of water circulating in solar loop 1 , the steam bubble in the pressurizer 3 increases in pressure thereby creating a self-regulating pressure control system.
As described above, the use of a single-phase (water only) pressurized solar loop 1 prevents Ledinegg Instability and unwanted pressure drop. Water also has an increased energy carrying capacity in comparison to steam. Thus, the pressurized water in pressurized solar loop 1 can carry more energy than a comparable DSG system with a two-phase (water/steam) energy transport mechanism.
One or more pumps 8 are present along the pressurized solar loop 1 . These pumps 8 act to circulate water through the solar collector receiver array and to the heat exchanger 4 . Control mechanisms known to those skilled in the art operate to control the pumps 8 and the flow rate of water flowing through pressurized solar loop 1 .
An auxiliary heating device 9 can be attached to pressurized solar loop 1 , preferably near the point where the pressurized solar loop 1 enters the heat exchanger 4 . One or more pumps 10 can be provided to pump water from the solar loop 1 into the auxiliary heating device 9 . The auxiliary heating device 9 can be used to heat the water in the solar loop 1 if there is insufficient solar energy to heat the water to an appropriate operating temperature such as on cloudy days or during the nighttime hours.
In some embodiments, an optional distillation unit 5 , condenser 6 , and water collector 7 can be connected to the pressurized solar loop 1 . The distillation unit 5 can use the hot water from the pressurized solar loop 1 to boil water to create steam. This steam can then be transferred to condenser 6 where it will be cooled and condensed into clean distilled water. Such distilled water can be collected in water collector 7 . The distilled water can later be used for any number of purposes including, but not limited to, providing makeup water for the heat exchanger 4 or the pressurized solar loop 1 .
After the water is heated in the portion of pressurized solar loop 1 that lies inside the solar collectors, the water travels to the heat exchanger 4 . The heat exchanger 4 preferably comprises a pressurized steam generator vessel 2 with liquid water in the lower portion of the steam generator vessel 2 . Preferably, the pressurized solar loop 1 will enter the lower portion of the steam generator vessel 2 . A sizeable length of solar loop 1 will be present within the lower portion of the steam generator vessel 2 , preferably in a coil, loop, or other configuration so as to expose a substantial surface area of the solar loop 1 to the water contained in the lower portion of heat exchanger 4 . The hot water contained in solar loop 1 will transfer its heat to the water in the bottom of heat exchanger 4 thus causing the water in the heat exchanger 4 to boil and produce steam. The steam generator vessel 2 of heat exchanger 4 preferably comprises suitable ports or openings for releasing steam and for introducing makeup water into the heat exchanger 4 . Preferably, the makeup water is cooler than the water present in the pressurized solar loop 1 so as to facilitate the transfer of thermal energy inside the heat exchanger 4 . As described in more detail below, cooling towers or other means for cooling water can be used to sufficiently cool water for use as makeup water.
After the hot water in the pressurized solar loop 1 transfers its thermal energy to create steam inside the heat exchanger 4 , the cooled water exits the heat exchanger 4 and returns to the solar collectors. In such a manner, the water inside pressurized solar loop 1 continuously circulates through solar loop 1 , absorbing thermal energy from the sunlight at the solar collectors and releasing thermal energy inside the heat exchanger 4 .
With reference to FIGS. 1 and 2 , the steam produced inside heat exchanger 4 exits the steam generator vessel 2 and proceeds through steam piping 11 towards a steam turbine 16 . As known to those skilled in the art, the steam turbine 16 utilizes the energy contained in the steam to generate rotary motion. This motion, in turn, is used by generator 15 to produce electricity.
As shown in FIG. 1 , an optional superheater 12 may be attached to steam piping 11 prior to entry into steam turbine 16 . The superheater 12 can be used to add additional heat to the steam from any external heat source 14 including, but not limited to, additional solar heating sources. An optional moisture separator 13 can also be attached to steam piping 11 .
Returning to FIG. 2 , after powering the steam turbine 16 , the steam will exit the turbine 16 and enter a condenser 17 where it will be condensed back into water. The water then is transferred to a heat rejection device 18 such as a cooling tower. The cooled water will then flow back into the steam generator vessel 2 of heat exchanger 4 . One or more pumps 19 may act to pump the water back to the heat exchanger 4 . In such a manner, the water is ready to again be heated by the pressurized solar loop 1 to form steam inside the heat exchanger 4 .
As described above, the pressurized water in pressurized solar loop 1 allows for the water to absorb substantial energy and rise to a temperature well above 100° C. without flashing over to steam. Advantageously, this allows the pressurized solar power system 100 to carry more energy than a two-phase (water/steam) DSG system or a system using a synthetic heat transfer fluid in a non-pressurized solar loop. The enhanced efficiency of the pressurized solar power system 100 described herein also allows for the use of smaller and/or fewer solar collectors than in prior art systems. The efficiency of the pressurized solar power system 100 can be further increased by placing the steam turbine 16 and the heat exchanger 4 in the center of the array of solar collectors, thus reducing the length of piping between the solar collectors and the heat exchanger 4 as well as the length of piping 11 between the heat exchanger 4 and the steam turbine 16 .
Turning to FIG. 3 , a second embodiment of a pressurized solar power system 200 is shown. The embodiment shown in FIG. 3 is similar in many respects to the embodiment shown in FIGS. 1-2 , with like reference numerals indicating like parts between the two embodiments. The pressurized solar power system 200 of FIG. 3 generally comprises a pressurized solar loop 1 that preferably contains pressurized water. The pressurized water in solar loop 1 absorbs thermal energy from the concentrated solar energy produced by one or more solar collectors and transports said thermal energy to a heat exchanger 104 .
Heat exchanger 104 preferably comprises two vessels: a pressurized steam generator vessel 102 and a non-pressurized storage media vessel 101 . The storage media vessel 101 contains a substance suitable for storing and transporting thermal energy such as molten salt. The steam generator vessel 102 contains water in the lower portion of the vessel which, when heated sufficiently, will boil and produce steam in the upper portion of steam generator vessel 102 .
A portion of the pressurized solar loop 1 preferably enters the storage media vessel 101 near the lower end of the storage media vessel 101 and forms a coil, loop, or other shape to expose a substantial surface are of the solar loop 1 to the surrounding salt inside the storage media vessel 101 . The hot water in the pressurized solar loop 1 advantageously heats the molten salt contained in the storage media vessel 101 . In turn, the molten salt is in contact with the exterior portion of steam generator vessel 102 and transfers heat from the molten salt to the steam generator vessel 102 . This causes the water inside steam generator vessel 102 to heat up and eventually turn to steam. As described above with respect to FIGS. 1 and 2 , the steam can be used to drive a steam turbine 16 and produce electrical energy at an electrical generator 15 .
Turning to FIG. 4 , a plurality of thermal storage tanks 105 b - 105 e are shown. One or more of such thermal storage tanks 105 may optionally be used in conjunction with the pressurized solar power system 200 of FIG. 3 . Advantageously, the thermal storage tanks 105 can be used to store heat energy during the day for use during the night or on cloudy days.
The thermal storage tanks 105 preferably contain molten salt or any other substance suitable for storing heat including, but not limited to, eutectic salts, brines, and graphite. Each storage tank 105 b - 105 e also has disposed therein a portion of a pressurized solar loop 1 b - 1 e . Similar to the pressurized solar loop 1 that heats the molten salt in the heat exchanger 104 , the pressurized solar loops 1 b - 1 e are utilized to absorb solar energy as thermal energy, transport that thermal energy to a storage tank 105 , and heat the molten salt contained in the storage tank 105 . That is, each of the pressurized solar loops 1 b - 1 e are connected at one end of the loop to one or more solar collectors and are connected at the other end of the loop to a storage tank 105 . In such a manner, solar energy can be absorbed during a sunny day, converted to thermal energy, and stored in a storage tank 105 for use during the night or on cloudy days.
As shown in FIG. 4 , a storage media loop 103 travels from the storage media vessel 101 of heat exchanger 104 to the storage tanks 105 . The storage media loop 103 continues from the storage tanks 105 back to the storage media vessel 101 . One or more pumps 106 are present along the storage media loop 103 to pump the molten salt. On cloudy days or during the night, hot molten salt from the storage tanks 105 can be pumped into the storage media vessel 101 of heat exchanger 104 to produce steam in steam generator vessel 102 . As such, the pressurized solar power system 200 can continue to produce electricity even when there is little or no sunlight.
Returning to FIG. 3 , an optional co-generation or combined cycle power generation aspect of the present invention is shown. Specifically, the pressurized solar power systems 100 , 200 described herein may be used in conjunction with conventional power generation systems (such as natural gas or coal fired power generation plants) to supplement the power produced by the pressurized solar power system 100 , 200 . As shown in FIG. 3 , hydrocarbon fuel such as natural gas can be used with a conventional gas turbine 112 to power an electrical generator 111 . One or more heat recovery coils 113 can advantageously be used to recover waste heat from the gas turbine 112 to heat water in the pressurized solar loop 1 . Similarly, one or more heat recovery coils 114 may be used to pre-heat the water before it enters the steam generator vessel 102 of heat exchanger 104 .
Turning to FIG. 5 , a third embodiment of a pressurized solar power system 300 is shown. The embodiment shown in FIG. 5 is similar to the embodiment shown in FIG. 3 , with like reference numerals indicating like parts between the two embodiments. The pressurized solar power system 300 comprises an array of solar collectors (solar array), a pressurized solar loop 1 , a heat exchanger 104 , a steam turbine 16 , and an electric generator 15 . The heat exchanger 104 comprises a steam generator vessel 102 and a storage media vessel 101 and functions in a manner similar to the heat exchanger 104 of FIG. 3 .
The pressurized solar power system 300 in FIG. 5 is shown operating in conjunction with a geothermal power source 301 and a natural gas source 311 . Hot water, steam, natural gas, and/or other carriers from the geothermal power source 301 are directed to a separation tank 302 where natural gas can be separated from the hot water generated by the geothermal power source 301 . The natural gas can be directed through pipe 305 to a natural gas pipeline or natural gas storage tank for suitable use, including as a fuel for a conventional gas turbine for use in combined cycle power operations.
After separating the natural gas from the hot water inside separation tank 302 , the hot water can be directed through pipe 303 to heat exchanger 104 . There, the hot water can supplement the thermal energy produced by the pressurized solar power system 300 . After the hot water from the geothermal source 301 has released much of its heat in heat exchanger 104 , the water can be injected into the ground through pipe 304 .
Advantageously, this injection of water into the ground can be used to bring natural gas to the surface from natural gas source 311 . A natural gas well 312 can collect the natural gas and transport it to a separation tank 313 . Any water mixed with the natural gas can be removed through pipe 314 and injected into the ground through pipe 304 . The recovered natural gas can be collected through pipe 305 and used in any suitable manner, including for combined cycle power operations.
Accordingly, while the invention has been described with reference to the structures and processes disclosed, it is not confined to the details set forth, but is intended to cover such modifications or changes as may fall within the scope of the following claims.
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Systems and methods for generating electrical power using a solar power system comprising pressurized pipes for transporting liquid water. The pressurized pipes flow through solar collectors which concentrate sunlight on the water flowing through the pipes. The pressurization in the pipes allows for the water flowing therethrough to absorb large quantities of energy. The pressurized and heated water is then pumped to a heat exchanger where the thermal energy is released to produce steam for powering a steam turbine electrical generator. Thereafter, the water is returned to the solar collectors in a closed loop to repeat the process.
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BACKGROUND OF THE INVENTION
The present invention relates to multifunctional projection equipment, and more particularly to a portable video projector frame system.
Conventional front video projector systems permanently mount the projector to the ceiling or some other fixed structure. This severely limits the options for locating the screen or substrate onto which the image from the projector is to be projected, as the screen must be placed a predetermined and specific distance from the projector to obtain an acceptable focused video image. Moreover, the permanently mounted projector eliminates the portability of the system.
It is therefore an object of the present invention to provide a video projector frame system which is easy to install, and which eliminates the requirement of permanently mounting the projector to a fixed structure such as a ceiling.
It is a further object of the present invention to provide a portable video projector frame system which houses and supports the projector, screen, and audio/video equipment and which can be readily assembled and disassembled for ease of transport.
It is a still further object of the present invention to provide a video projector frame system which can be semi-permanently installed if desired.
SUMMARY OF THE INVENTION
The problems of the prior art have been overcome by the present invention, which provides a portable video frame system. More specifically, a projector such as an LCD lightweight projector is removably mounted to a triangular top frame portion. Support brackets are removably mounted to this top frame portion and to a rear frame portion. The rear frame portion is itself supported on a base having sufficient weight to support the entire assembly. Optionally, at least a portion of the weight is provided by necessary ancillary equipment, such as speakers. A conventional snap screen snaps onto the rear frame portion, and is always the same distance from the projector. The entire assembly can be readily disassembled and moved to a different location.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the video frame in accordance with the present invention;
FIG. 2 is a side view of the video frame in accordance with the present invention;
FIG. 3 is a front view of the video frame in accordance with the present invention;
FIG. 4 is a perspective view of the base of the video frame in accordance with the present invention;
FIG. 5 is a front view of a portion of the frame system in accordance with the present invention;
FIG. 6 is a perspective view of the top portion of the frame system in accordance with the present invention;
FIG. 6A is a perspective view of the side portion of the frame system in accordance with the present invention;
FIG. 7 is a schematic view detailing the eye-bolts used to assemble the frame system of the present invention;
FIG. 8 is an alternative preferred embodiment of the video projector support in accordance with the present invention;
FIG. 9 is a schematic view of a stabilization mechanism in accordance with the present invention; and
FIG. 10 is a perspective view of the hinge for the V-support in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Turning first to FIG. 1, there is shown a frame system generally at 30. The frame system 10 includes a rear wall 12 which provides a surface for the image from a projector to be projected. For example, a conventional video screen suitable for supporting either front or rear projection can be mounted on rear wall 12, the screen preferably being a commercially available "snap screen", which allows for ease in assembly and disassembly of the system. In the embodiment shown, the rear wall 12 has a diagonal of sixty inches, although it should be understood by those skilled in the art that other sizes can be used, depending upon the image size desired. The rear wall 12 is generally rectangular in shape, and includes a top bar 13, side bars 14 and 14' extending downwardly and orthagonally from the top bar 13, and base bar 15 (FIG. 3). Preferably the frame system is constructed of 1"×1" aluminum square tubing, and is welded at the non-movable joints.
Assembly of the frame system is accomplished as follows. Each end of top bar 13 terminates in a right-angled welded angle, as shown in FIG. 6. An intermediate member 5 extends from each end of the welded angle, the intermediate member being smaller in cross-section than either top bar 13 or side bars 14, 14'. The intermediate member is then received by the side bars 14, 14' and is locked in place by aligning apertures 5a, 5b in the intermediate member 5 with apertures 14a, 14b in side bars 14, 14' (FIG. 6A), and by inserting a pip-pin, bolt, or the like through the apertures. In the case of assembly top bar 13 to side bars 14, 14', gravity acts to retain top bar 13 in place, and thus the aforementioned locking system is optional, though preferable, in order to ensure a stable frame.
In addition, bars 13 and 15 optionally can be halved, preferably at their respective centers, and the respective halves can be assembled using smaller-dimensioned intermediate members in a manner similar to the assembly of bars 13 and 14 above. This construction allows for disassembly of the unit into smaller parts.
Turning now to FIG. 4, there is shown the base 30 of the frame assembly. Preferably the base 30 is configured so as to house ancillary equipment, such as speakers and source equipment. Such equipment also serves to add weight to the base 30, which supports the frame assembly. In addition, a ballast compartment 31 can be formed in the base unit 30, such as with aluminum tubing, and can be filled with suitable weights. Extending from the top of the base 30 are feet 32, 33. The feet 32, 33 are hollow, and have a cross-section sufficient to slidingly receive the respective side bars 14, 14' of the frame 10 in a manner similar to the assembly of top bar 13 into side bars 14, 14'. Specifically, with reference to FIG. 5, an intermediate member 35 extends from the bottom of each side bar 14, 14', the intermediate member being smaller in cross-section than either the side bars 14, 14' or the feet 32, 33. To assemble the frame 10 onto the base 30, the intermediate members 35 are slid into the feet 32, 33. The frame assembly 10 can then be adjusted to an appropriate vertical height by aligning apertures 36a-36n formed in the intermediate members 35 with the apertures 37, 37' formed in the feet 32, 33, respectively, and inserting a pip-pin, bolt or the like to lock the side bars in place. Alternatively, where the vertical height so dictates, the side bars 14, 14' can simply sit at the bottom of feet 32, 33, respectively, requiring no aperture alignment, although preferably they are locked in place in the manner discussed above.
Extending outwardly from the rear wall 12 is video projector support frame 20. The support frame 20 includes a first arm 21 and a second arm 22, preferably of equal length and constructed of 1"×1" aluminum tubing. One end of each arm 21, 22 is removably secured to the frame 12, such as to side bars 14, 14', in a manner similar to the manner in which top bar 13 is secured to side bars 14, 14'. Thus, each such end of arms 21, 22 terminates in a right-angled welded angle, and has an intermediate section of lesser cross-section extending therefrom that is received by side bars 14, 14'. The opposite ends of each arm 21, 22 are joined together at a hinged joint 25 (FIG. 10). A pair of support brackets 26, 26' (FIG. 2, only one shown) are removably secured at one end to each arm 21, 22, and at the other end to respective side bars 14, 14'. Preferably each bracket 26, 26' terminates at each end in an eyebolt (FIG. 7), which can then be aligned with corresponding eyebolts located on the underside of each arm 21, 22 and on each side bar 14, 14' to secure the brackets 26, 26' thereto. A horizontal cross bar 40 (FIG. 1), preferably made of 1"×1" square tubing, is coupled at each end to arms 21, 22 by suitable bolting to the V-frame (21, 22), and is used to provide additional support. The horizontal cross bar 40 is itself coupled to legs 41, 42 at its opposite ends, which legs terminate at the rear wall 12 by fastening to bars 14, 14', respectively. A suitable video projector 60 is mounted to the support frame 20 at a predetermined position using suitable mounting brackets well known to those skilled in the art. Preferably the video projector weighs less than about 50 pounds.
FIG. 8 shows an alternative, preferred embodiment of the arms 21, 22 of support frame 20. This embodiment is similar to the embodiment of FIG. 1, except that the arms when assembled are configured so as to form a Y-frame. Thus, welded angles 40, 40' (only one shown) are formed beyond the projector mount, and are apertured as shown. Welded angles 40, 40' can thus be aligned and locked in place by inserting pins or the like through the apertures, which provides for ease of assembly and disassembly of the frame system.
FIG. 9 depicts a further embodiment of the present invention used to provide additional stability to the frame system. A plate 50 is coupled to the top of one of the Y-frames, preferably where the Y-frame inserts into the side bar 14 or 14'. A nut 51 is coupled to the underside of the plate and inside the Y-frame, and is adapted to receive a threaded stem 52 which terminates in a knob 53 having a rubber pad 54 or the like on its upper surface. Once the frame system 10 is assembled, the height of the knob 53 can be adjusted by rotation so that the rubber pad 54 engages the ceiling or other fixed structure and stabilizes the system.
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A portable video frame system. A projector such as an LCD lightweight projector is removably mounted to a triangular top frame portion. Support brackets are removably mounted to this top frame portion and to a rear frame portion. The rear frame portion is itself supported on a base having sufficient weight to support the entire assembly. Optionally, at least a portion of the weight is provided by necessary ancillary equipment, such as speakers. A conventional snap screen snaps onto the rear frame portion, and is always the same distance from the projector. The entire assembly can be readily disassembled and moved to a different location.
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CROSS-REFERENCE TO PRIOR APPLICATION
This application is a continuation-in-part of application Ser. No. 647,563, filed Sept. 5, 1984, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a weft straightener attached to various machines which are used for dyeing, printing and finishing of natural and synthetic fiber cloths. Particularly, this invention relates to a pin wheel type weft straightener which is attached to various machines for use in dyeing, printing and finishing of natural and synthetic fiber cloths and which straightens the skewing or the bowing of a travelling cloth.
2. Description of the Prior Art
As a weft straightener using pin wheels, the weft straightener disclosed in Japanese Utility Model Publication No. 015056/1980 has been already known. In this straightener, a pair of pin wheels are provided along both selvages divergently and in a weft direction, and a group of pins are projectingly implanted in the outer peripheral parts of these pin wheels. The skewing or the bowing of the cloth is straightened by subsequent pinning of both selvages of the cloth and by the difference of rotation speed of both pin wheels, namely by the difference in the rate of over feed of the cloth.
In Japanese Utility Model Publication No. 004700/1983, an improved weft straightener is disclosed. In this straightener are provided a pair of pin wheels for pinning both selvages of a travelling cloth with a group of pins projectingly implanted on the outher peripheral parts of the pin wheels; a pair of pin wheel stands which support the pin wheels inclinably in relation to the tangent or the neighborhood of the pinning starting position, and which are movable in the weft direction; an inclination controlling means which adjusts the inclination angle of each pin wheel to a desired divergent angle; and position controlling means which adjust each pin wheel stand to a desired position.
In this improved weft straightener, control of an inclination controlling means which adjusts the inclination angle of each pin wheel to a desired divergent angle; and position controlling means which adjust each pin wheel stand to a desired position.
In this improved weft straightener, control of an inclination angle keeps the rockable central axial line straight, and scarcely changes the pinning starting position on the outer peripheral part of the pin wheels, which dispenses with the needs for adjustment of cloth racking when the inclination angle of each pin wheel is adjusted, or adjustment of the location of a brush roll or other attachments. In addition, this type of straightener, wherein each pin wheel stand is locked to each feed screw shaft, and which is disposed across the weft independently of other pin wheel stands, and in which each pin wheel is moved to a desired position in the weft direction by a forward or backward turn of the feed screw shafts, enables, to a certain degree, the control of the intervals between both pin wheels in accordance with the width of a cloth, and also enables automatic follow up of the pin wheels to the selvages of a running cloth.
However, the convention pin wheel type weft straighteners, including the one disclosed in Japanese Utility Model Publication No. 04700/1983, had the problem that they induced deformation or rupture of a travelling cloth under abnormal tension in the weft direction while being pinned by each pin wheel.
Furthermore, in the conventional weft straightener, when movement of the travelling cloth on the pin wheels is stopped while the cloth is being pinned, the cloth on the pin wheels is stretched. If the intervening period is prolonged, deformation or rupture of the cloth is unavoidable, which leads to deterioration in quality and the production of inferior articles.
SUMMARY OF THE INVENTION
Accordingly, it is an object to provide a pin wheel type weft straightener which prevents deformation and rupture of cloth under abnormal tension in the weft direction while a travelling cloth is pinned to the pin wheels, and contributes to an improvement in quality and an increase in productivity.
It is another object to provide a pin wheel type weft straightener which lessens the stretching of a travelling cloth on pin wheels when the cloth on the pin wheels is stopped while the cloth is pinned, and prevents deformation and rupture of cloth as well as contributing to an improvement in quality and an increase in productivity. These and other objects as well as advantages of the present invention will become clear from the following description of a preferred embodiment of the present invention and from the claims.
DESCRIPTION OF THE PREFERRED EMBODIMENT
According to this invention, there is provided a weft straightener which comprises a pair of pin wheels divergently disposed in the weft direction and independently free to rotate, for pinning both selvages of a travelling cloth with a group of pins projectingly implanted on the outer peripheral part of each pin wheel, a pair of pin wheel stands movably disposed in the weft direction, for supporting each pin wheel inclinably in relation to a tangent extending from, or in the vicinity of, the pinning starting position on the circumference of each pin wheel, inclination controlling means for adjusting the inclination angle of each pin wheel to a desired divergent angle, and position controlling means for adjusting each pin wheel stand to a desired position in the weft direction, characterized in that there is provided a spring mechanism for urging each pin wheel in the divergent direction in such a manner that each pin wheel can be inclined in the convergent direction by the travelling cloth being over-tensioned in the weft direction. The invention counteracts any abnormal tension in the weft direction while the travelling cloth is pinned by the pin wheels, that is, the inclination angle of the pin wheel can be reduced when the cloth is over-tensioned in the weft direction because the pin wheels are convergently inclined against the spring mechanism by the pinned cloth being over-tensioned in the weft direction and it can prevent deformation and rupture of cloth as well as contributing to an improvement in quality and an increase in productivity.
Further, the above weft straightener may have a structure in which there are provided interruption detrecting means for detecting the interruption of the travel of the cloth on each pin wheel and inclination reducing means for actuating the inclination controlling meansso as to reduce the inclination angle of each pin wheel, on the basis of the output signal of the interruption detrecting means. This prevents the generation of abnormal tension in the weft direction and when the cloth on the pin wheels stops travelling while pinned by the pin wheels, the stretching of the cloth is quickly mitigated, preventing deformation and rupture of the cloth and contributing to an improvement in quality and an increase in productivity. The principle of this weft straightening is that when both selvages of the travelling cloth having skewed or bowed wefts are fixed by the pins on the pin wheels and the cloth turns with the pin wheels, a widthwise tension gradually increases on the cloth because of the pin wheels being divergent and the stretched wefts obliquely spanning the two pin wheels will naturally act to take the shortest length between the two pin wheels and, thus, to differentially rotate each pin wheel to the position where the wefts take the shortest length, namely to the position where the wefts become straightened at right angles to warps.
In this invention, the means by which the pin wheel stand is supported and the inclination control means of a pin wheel are not specifically restricted. For example, the structure can be adopted, in which each pin wheel is rotatably connected to a varied-angle shaft on the tangent extending from, or in the vicinity of, the pinning starting position on the circumference of the pin wheel, each varied-angle shaft is rotatably supported by the pin wheel stand, a worm wheel is attached to each varied-angle shaft, each worm wheel is meshed with a worm, each worm is axially-slidably and interlockingly-rotatably mounted on a worm shaft and is axially urged by a spring mechanism in such a manner that each pin wheel can be urged in the divergent direction, the worm shaft is disposed across the cloth width, and the inclination angle of each pin wheel is adjusted to desired divergent degrees by controlling the rotation angle of the worm shaft. In this invention, when the worm shaft is rotated by desired degrees, the worm, the worm wheel and the varied-angle shaft are rotated successively, and the pin wheel rocks about the pinning starting position and forms a desired inclination angle.
Position controlling means for each pin wheel stand of this invention may have a structure, for example in which each pin wheel stand can be adjusted to the cloth width by the driving force of an actuator mounted on the wheel stand.
The structure as described above, in which each pin wheel stand is adjusted to the widthwise length of the cloth by the driving force of the actuator carried in the pin wheel stand, is superior in various points to the structure in which the pin wheel stand is engaged with a screw shaft arranged across the weft, and is fed in the widthwise direction of the cloth by the turn of the screw. For example, the apparatus can be miniaturized; the selection of the centering position of the travelling cloth in the widthwise direction of the cloth and the adjustment of the intervals of both pin wheels can be freely conducted; the adaptability to the width of the cloth is superior; and the weft straightening of more than two cloths very different in width can be executed with this weft straightener alone.
In this invention, when the widthwise tension of the cloth on the pin wheels is low, the spring system is not activated nor does it change its position, which maintains the inclination angle of the pin wheels at a predetermined angle, but when the tension of the cloth exceeds a predetermined value, the spring system is actuated or changes its position, which reduces the inclination angle of the pin wheels and mitigates the stretching of the cloth in the weft direction. The spring mechanism is preferably adjustable in resilience depending on the type of cloth and other factors.
The automatic reducing mechanisms for adjustment of the inclination angle of each pin wheel when the cloth is over-tensioned and for adjustment of the inclination angle of each pin wheel when the cloth movement is interrupted should be properly selected in accordance with the structure and type of a particular pin wheel and is not specified in this invention. The adjustment of the inclination angle of each pin wheel can be made by manually or automatically driving an inclination angle control motor which actuates the inclination controlling means, while detecting the inclination angle of each pin wheel. In the structure wherein the worm wheel and worm are intermeshed, each pin wheel may be inclined in the opposite direction by an equal angle of adjustment by a forward or backward rotation of the worm shaft in such a manner that each pin wheel can be constantly symmetrically inclined about the center line of a travelling cloth.
The automatic reducing mechanism of the inclination angle of each pin wheel may have a structure in which a dancer roll rocking in accordance with the lengthwise tension of the travelling cloth is also used for the interruption detecting means, a limit switch actuated by the rocking motion of the dancer roll feeds an interruption signal to the inclination reducing means, and the inclination controlling means actuated by the inclination reducing means incline each pin wheel in the convergent direction.
Furthermore, in this invention, it is important for effective weft straightening that the cloth should be pinned in a sufficiently overfed state. To this end, brush rolls are arranged across the weft so that they may engage with the group of pins projectingly implanted on the outer peripheral part of the pin wheels at the pinning starting position, and both selvages of the cloth are pinned with the group of pins while being pushed with the brush rolls.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the main part of a preferred weft straightener according to this invention;
FIG. 2 is a front view of the main part of a pin wheel operation mechanism of the weft straightener shown in FIG. 1;
FIG. 3 is a side view of the main part of a cam board in the pin wheel operation mechanism shown in FIG. 2;
FIG. 4 is a sectional view of the weft straightener taken along the line I--I of FIG. 1; and
FIGS. 5 and 6 are sectional views vertical to the axial line of preferred brush rolls which can be used for this invention.
DETAILED DESCRIPTION OF THE INVENTION
In order to make the invention clearer, hereinunder it will be described in detail with reference to the attached drawings.
Referring first to FIGS. 1 to 4, the pin wheel mechanism will be explained. Two guide shafts 1, 2 are disposed across the weft and a worm shaft 3 and a rack 4 are disposed linking frames 5, 5 in parallel with the guide shafts 1, 2. Into the two guide shafts 1, 2, a pair of pin wheel stands 6, 6 having the same mechanism are slidably inserted. Since these pin wheel stands 6, 6 each have the same pin wheel mechanism, hereinunder a pin wheel mechanism of a single pin wheel stand 6 only will be explained. In the pin wheel stand 6, a varied-angle shaft 7 is rotatably supported perpendicular or substantially vertically in relation to the weft. In the middle part of the varied-angle shaft 7, a worm wheel 8 is attached coaxially, and on the end portion of the varied-angle shaft 7 a forked arm 9 is attached extending obliquely downwardly. On the arm 9, a pin wheel 10 is divergently and rotatably mounted in such a way that an extended axial line of the varied-angle shaft 7 forms, or is in the vicinity of a tangent to the pin wheel at the pinning starting position P on the circumference of the pin wheel. On the outer peripheral part of the pin wheel 10 a plurality of pins 11 are projectingly implanted at a desired pitch.
On the pin wheel stand 6, a worm 12 is rotatably carried in the widthwise direction of the cloth through a compressing coiled spring 13 whch is arranged in series in the inside end of the worm 12, in the state of intermeshing with the worm wheel 8, and is inserted into the worm shaft 3 slidably and rotatably interlocking with it in such a conventional manner that bosses on the inside hole of the worm 12 can be slidably engaged with splined channels on the worm shaft 3. On the pin wheel stand 6, the worm shaft 3 is movably inserted into an adjust bolt 14, in such a manner that the adjust bolt 14 will press the inside end of the compressing coiled spring 13 through a bearing 15.
Further, on the pin wheel stand 6 are carried a position control motor 16, its speed regulator 17, a selvage sensor (shown later as 32) the output signal of which is fed to the control circuit (not shown) of the position control motor 16 for automatic follow up of the pin wheel 10 to the selvage of the cloth C and a pinion 18 which is rotated by the position control motor 16 and the pinion 18 is engaged with the rack 4. The position control motor 16 can be manually driven in a conventional manner for moving the pin wheel stand 6 along the guide shafts 1, 2 to a desired position in the weft direction and also automatically driven in a conventional manner for moving the pin wheel stand 6 along the guide shafts 1, 2 to the selvage of the cloth C which is apt to be laterally shifted so that the pin wheel 10 can automatically follow up the selvage of the cloth C.
The worm shaft 3 is connected at one end to the inclination angle control motor 20 through a gear 19 and at the other end is connected to one end of the rotary shaft of a detection potentiometer 22 through a speed regulator 21, while on the other end of the rotary shaft of the direction potentiometer 22 is mounted a cam board 23. The detection potentiometer 22 which may have a conventional structure of a variable resistor, detects the rotation angle of the worm shaft 3 and outputs the voltage corresponding to the inclination angle of the pin wheel 10, and is connected in parallel to an angle set potentiometer (not shown) which may also have a conventional structure of a variable resistor and which outputs the voltage corresponding to a desired inclination angle of the pin wheel 10.
The above parallel circuit which outputs the voltage deviation between the two potentiometers and which is generally known as a conventional circuit for a servo system, is connected to the control circuit (not shown) of the inclination angle control motor 20. A notch 24 is cut out of the cam board 23, in the vicinity of which, at the portion of the upper limit 60 degrees of the inclination angle (divergent angle 120 degrees) and the lower limit 0 degrees of the inclination angle (divergent angle 0 degrees) an upper limit switch 25 and a lower limit switch 26, respectively, are disposed and they are connected to the control circuit (not shown) of the inclination angle control motor 20. The notch 24 indirectly denotes the inclination angle of the pin wheel. The limit switch (not shown) which is actuated by the rocking motion of a dancer roll (shown later as 31) and detects the interruption of the travelling of the cloth C on the pin wheel 10 is mounted at a proper position and is connected to the control circuit of the inclination angle control motor 20.
In the structure above mentioned, by controlling the rotation angle of the worm shaft 3 adjustment of the degree of stretching the cloth, namely adjustment of the inclination angle of the pin wheel, can be achieved. The rotation of the inclination angle control motor 20 is transmitted to the gear 19, the worm shaft 3, the worm 12, the worm wheel 8 and the varied-angle shaft 7, which rocks the arm 9, and thus the pin wheel 10, and inclines the pin wheels 10, 10 on both sides in the opposite direction and by an equal angle of adjustment. On the other hand, the rotation of the worm shaft 3 rotates the speed regulator 21, the rotary shaft of the detection potentiometer 22 and the cam board 23, and when the inclination angle of the pin wheel reaches the divergent angle 120 degrees or 0 degrees, the notch 24 of the cam board 23 activates the upper limit switch 25 or the lower limit switch 26, respectively, thus immediately stopping the inclination angle control motor 20. The inclination angle control motor 20 can be driven in a forward or backward direction for adjusting of the inclination angle of the pin wheel 10 to predetermined degrees, manually in a conventional manner on the basis of that indication of the output of the detection potentiometer 22 which shows the inclination angle of the pin wheel 10, or also automatically in a conventional manner on the basis of the output deviation between the detection potentiometer 22 and the angle set potentiometer so that the output deviation may be reduced to zero.
When the travel of the cloth C is stopped while pinned by the pin wheel 10, the dancer roll rocks to the limit and the limit switch for detecting interruption described above starts the inclination angle control motor 20 in the direction of reducing the inclination angle of the pin wheel, and subsequently the lower limit switch 26 is actuated as described above to stop the motor 20 at the position where the inclination angle of the pin wheel is the divergent angle 0 degrees.
When the cloth C is subject to abnormal tension in the weft direction while being pinned by the pin wheel 10, the pin wheel 10 is convergently stressed, the worm wheel 8 is rotated, the worm 12 is axially shifted along the worm shaft 3 and the compressing coiled spring 13 is compressed successively, and thus the inclination angle of the pin wheel 10 is reduced so that the cloth C is prevented from rupture and breakage. In the above case, with the rotation of the worm wheel 8, the worm 12 is not rotated with the worm shaft 3 but axially shifted along the worm shaft 3 because the worm shaft 3 slidably engaged with the worm 12 cannot be freely rotated. The resilience of the compressing coiled spring 13 can be adjusted by the turn of an adjust bolt 14 in accordance with the permissible tension of the cloth C and other factors.
When the position control motor 16 carried on the pin wheel stand 6 starts, the pinion 18 is rotated through the speed regulator 17 and moves straight on the rack 4 in the engaged state, and thus, the pin wheel stand 6 itself moves straight on the rack 4. Therefore, each pin wheel 10 is freely movable in the widthwise direction of the cloth, by control of the position control motor 16, and it is thus made easily possible to introduce the system of the adjustment of the interval of the pin wheels 10, 10, the selection of the central position of the travelling cloth C and automatic follow up of the pin wheel 10 to the selvage of the cloth C, where the pin wheel stand 6 is moved in the weft direction along the guide shafts 1, 2 to a desired position in a conventional manner by the automatic control of the position control motor 16.
Next, the whole structure of the weft straightener having the above pin wheel mechanism will be explained. In FIG. 1, the cloth C is fed to, for example, an endless belt (not shown) of an auto-screen printing machine successively through a centering roll 27 which may have a conventional structure of a roll cloth guider or a slat cloth guider, the roll cloth guider having guide rolls inclinably and rotatably disposed in the weft direction, the slat cloth guider having many slats axially-slidably mounted in parallel in the weft direction on the surface of a cylinder which is rotated, a selvage sensor 28, feed rolls 29, 30, a dancer roll 31, selvage sensors 32, 32, brush rolls 33, 33, pin wheels 10, 10, a bar expander 34 and so on.
The centering roll 27 automatically amends the travelling of the cloth C so as to pass the cloth C along the widthwise center of the inlet of the weft straightener, contributing to effective weft straightening. The selvage sensor 28 detects the selvage of the cloth C in the weft direction and feeds its output signal to the control circuit (not shown) of the centering roll 27 for the automatic amendment of the travelling of the cloth C. The feed rolls 29, 30 feed the cloth C by a motor (not shown), and the dancer roll 31 feeds the cloth C to pin wheels 10, 10, with a constantly low tension while rocking in accordance with the difference between the feeding amount of the cloth C supplied by the feed rolls 29, 30, and the drawing amount of the cloth C produced by the endless belt (not shown) above mentioned. The dancer roll 31 is also used for detecting the interruption of the travel of the cloth C. The brush rolls 33, 33 push the cloth C on the outer peripheral part of the pin wheels 10, 10 in the overfed state, and the pin wheels 10, 10 automtically follow the selvages of the cloth C, pin the pushed cloth C in the overfed state and straighten the weft. The selvage sensors 32, 32 detect the selvages of the cloth C for the automatic follow up. For the feeding of the stretched cloth C to the following endless belt (not shown), the bar expander 34 stretches the cloth C after weft straightening. The brush rolls 33, 33 may be made of a short and long brush 35 in such a manner that the periphery of their section may have the configuration of continuous square waves, as is shown in FIG. 5, or continuous sine waves or triangle waves, as is shown in FIG. 6. The brush rolls 33, 33 have the cloth c supplied in a regular and stable overfed state and with a sufficient maount of overfeed because the group of pins 11 pin the cloth C while the rotating brush rolls 33, 33 push the cloth C into the movable group of pins 11 substantially in the configuration of continuous waves corresponding to a wave-patterned surface of the brush rolls 33, 33. In addition, these wave-patterned brush rolls 33, 33 contribute to mitigating any skewing or bowing of the cloth C by relatively slowing the speed of trhe wefts travelling forward, because the brush roll 33 has its diameter partially reduced by contacting that portion of the cloth C in whcih the wefts are travelling forward, namely to which the tension applied is larger and the circumferential speed of the brush roll 33 is partially lowered.
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A pin wheel type weft straightener attached to various machines which are used for dyeing, printing, finishing of natural and synthetic fiber cloths, in which a pair of pin wheels straightens the skewing or the bowing of a travelling cloth while pinning both selvages of the cloth successively and the inclination angle of each pin wheel can be adjusted without changing the pinning starting position.
Each pin wheel is supported by a pin wheel stand which is movable in the widthwise direction of the cloth by the driving force of a motor or other actuators carried thereon.
Each pin wheel is urged in the divergent direction by a spring mechanism and the inclination angle is reduced when the cloth on each pin wheel is over-tensioned, and also the inclination angle is automatically reduced when the cloth on each pin wheel is interrupted travelling. They can mitigate an abnormal tension of the cloth and prevent the distortion, rupture or breakage of the cloth by automatically reducing the inclination angle to lessen the stretching of the cloth.
In order to obtain a sufficient overfed state preferable for the weft straightening, the travelling cloth is pushed by brush rolls, particularly brush rolls the peripheries of the section of which form the configuration of continuous waves, while pinned with a group of pins on the outer peripheral part of the pin wheels.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority from Provisional Application Ser. No. 62/039,495 filed on Aug. 20, 2014 which is incorporated by reference herein in its entirety.
FIELD OF INVENTION
The present invention describes methodology for the permanent elimination of tritiated water from the environment by fixing radioactive tritiated water into an organic insoluble substances into a polystyrene or its derivatives.
BACKGROUND OF INVENTION
Tritium (T) is a hydrogen atom that has two neutrons in the nucleus and a single proton, giving it an atomic weight near three. Tritium has a half-life of 12.3 years and emits a very weak beta particle. Tritium replaces one of the stable hydrogens in the water molecule to form tritiated water. Apart of its natural formations in the upper atmosphere when cosmic rays strike nitrogen molecules in the air, tritium is produced during nuclear weapons explosions as a byproduct as well as in commercial reactors producing electricity and in special production reactors like in the government weapons production plants. Although tritium can be a gas, its most common form is in water which is formed when it reacts with oxygen to form tritiated (radioactive) water.
Tritiated water is concentrated in respect to tritium by isotopic separation. This allows the dispersion of a large quantity of very low activity water to the environment and the required fixation of a small quantity of relatively high activity tritiated water. It also allows the recovery of deuterium for tritiated heavy water wastes from certain types of fission reactors.
Tritium is considered one of the most innocuous of fission products. Tritiated water and its vapor can be taken into the body by skin penetration. The retention of tritium in the body is dependent on the chemical form in which it enters. The probability of genetic and somatic damage from tritium exposure is enhanced when tritium is ingested,
The most common documented sources of tritium in the environment are (a) from improper disposal of this isotope in municipal landfills, and (b) from leakages occurring from commercial reactors. If improperly stored, it seeps through landfills and passes into waterways, carrying the radioactive tritium with it.
As with all ionizing radiation, exposure of humans to tritium increases the risk of developing cancer. This is the reason why the Environmental Protection Agency (EPA) has established standards for the maximum amount of tritium that may be released by nuclear facilities or quantity that may be found in drinking water.
The present methods of eliminating tritiated water (water contaminated with radioactive tritium) involve compounds with liquids and solids or absorption of the contaminated water with organic molecules through non-covalent binding during storage. This method of elimination, by a “reversible” chemical entrapment represents a temporary solution to the problem of protecting the environment. Being reversibly bound, tritiated water would ultimately seep out of its usual underground storage and ultimately contaminate waterways.
DESCRIPTION OF THE PRIOR ART
Patents relating to the present invention are as follows: US 20120106692 for SYSTEMS AND METHOD FOR REDUCING TRITIUM MIGRATION by Keenan, US 20130336870 for Advanced Tritium System for Separation of Tritium from Radioactive Wastes and Reactor Water in Light Water Systems by Denton, U.S. Pat. No. 4,020,003 Fixation of Tritium in a Highly Stable Polymer Form by Steinberg, U.S. Pat. No. 4,085,061 for Tritiated Water Treatment Process by O'Brien, U.S. Pat. No. 4,173,620 Extraction Method of Titium by Shimizu, U.S. Pat. No. 4,190,515 Apparatus for Removal and Recovery of Tritium from Light and Heavy Water by Butler, U.S. Pat. No. 5,854,080 for a Process for Separating Tritiated Water by Harvey, U.S. Pat. No. 6,110,373 for Method for Separating Heavy Isotopes of Hydrogen from Water by Patterson, U.S. Pat. No. 6,416,671 Methods for Removing Hazardous Organic Molecules from Liquid Waste by Pourfarzaneh, U.S. Pat. No. 6,632,367 for Method for Separating Heavy Isotopes of Hydrogen from Water by Furlong, U.S. Pat. No. 6,984,327 for System and Method for Separating Heavy Isotopes of Hydrogen Oxide from Water by Patterson, U.S. Pat. No. 7,470,350 for a Process for tritium removal from light water by Bonnett, U.S. Pat. No. 8,889,582 Hydrogen Combustion Catalyst and Method for Producing Thereof, and Method for Combusting Hydrogen by Noguchi, and U.S. Pat. No. 9,040,768 for a Method for Limiting the Degassing of Tritiated Waste Issued from the Nuclear Industry by Lefebvre.
The conventional methods utilize a process of complexing or absorbing the tritiated water with organic molecules through non-covalent bonding. This type of non-covalent association represents a temporary and reversible type of association that does not constitute a permanent removal of radioactivity due to the tritium (long lived radio nuclide with a half-life of 12.3 years). With passage of time, the radioactivity from non-covalently bonded tritium atom infiltrated water will ultimately be released into the environment.
SUMMARY OF THE INVENTION
The present invention describes methodology for the permanent elimination of tritiated water from the environment. The salient principle of the method is the incorporation of the tritium, existing in the radioactive tritiated water, into organic insoluble substances through a covalent bond. The incorporation of the tritium occurs into such inert substances as polystyrene or its derivatives.
Calcium carbide (CaC2) is reacted with tritiated water to produce tritiated acetylene. This is an exothermic reaction represented by the following equation:
When tritiated acetylene is passed through a red hot copper tube, it polymerizes to form tritiated benzene (cyclotrimerization step). The tritiated benzene is converted to tritiated ethyl benzene by its reaction with ethyl chloride in an acid-catalyzed chemical reaction represented by the following mechanism. The hydrochloric acid produced is channeled into a solution of concentrated sodium hydroxide (NaOH). The latter produces sodium chloride (NaCl) and tritiated water. The latter is collected and is recycled to react with calcium carbide to produce tritiated acetylene. The tritiated acetylene is subject to a heat and a copper catalyst to form a tritiated ethyl benzene by-product. The tritiated ethyl benzene is converted in the presence of steam over iron oxide-based catalyst to tritiated styrene as represented by the catalytic dehydrogenation. The polymerization or copolymerization of the tritiated styrene with variable amounts of divinyl benzene (0.2-1%), as a cross-linking agent, produces the tritiated polystyrene. The latter can be micronized into particles with a desired radius (size) or can be converted in a form of solid sheaths of plastic. The tritium atom by being covalently bonded into the benzene moieties of the water-insoluble and unreactive polystyrene molecule is securely eliminated from the environments, i.e. it is not allowed to leach out from its storage.
The present invention provides for the permanent storage of tritiated water in solid form which is virtually free of leaching when in contact with water.
More particularly, the present invention comprises, consists of and/or consists essentially of a method of producing an insoluble tritiated polystyrene, comprising the steps of reacting tritiated water with calcium carbide to produce a tritiated acetylene by-product; reacting said tritiated acetylene by-product with heat and a first catalyst to form a tritiated ethyl benzene by-product; reacting said tritiated ethyl benzene in the presence of steam and an iron oxide based second catalyst via catalytic dehydrogenation form a tritiated styrene by-product; and polymerizing said tritiated styrene by-product with an effective amount of divinyl benzene cross-linking agent producing an insoluble tritiated polystyrene compound.
Polystyrene is a thermopolymer which melts at temperatures 100° C., and becomes rigid again when cooled. This temperature behavior is exploited for extrusion, molding, and vacuum forming, since it can be cast into molds with fine detail. Polystyrene is very slow to biodegrade. Polystyrene is a long chain hydrocarbon wherein alternating carbon centers are attached to phenyl groups (the name given to the aromatic ring benzene). Polystyrene's chemical formula is © 8H8)n; The material's properties are determined by short-range van der Waals attractions between polymers chains. Since the molecules are long hydrocarbon chains that consist of thousands of atoms, the total attractive force between the molecules is large. Polystyrene results when styrene monomers interconnect. In the polymerization, the carbon-carbon pi bond (in the vinyl group) is broken and a new carbon-carbon single (sigma) bond is formed, attaching another styrene monomer to the chain. The newly formed sigma bond is much stronger than the pi bond that was broken, thus it is very difficult to de-polymerize polystyrene. About a few thousand monomers typically comprise a chain of polystyrene, giving a molecular weight of 100,000-400,000. Pure polystyrene is brittle, but hard enough that a fairly high-performance product can be made by giving it some of the properties of a stretchier material, such as polybutadiene rubber. The materials can never normally be mixed because of the amplified effect of intermolecular forces on polymer insolubility, but if polybutadiene is added during polymerization it can become chemically bonded to the polystyrene, forming a graft copolymer, which helps to incorporate normal polybutadiene into the final mix, resulting in high-impact polystyrene. Several other copolymers are also used with styrene such as acrylonitrile butadiene styrene, a copolymer of acrylonitrile and styrene, toughened with polybutadiene. SAN is a copolymer of styrene with acrylonitrile, and SMA with maleic anhydride. Styrene can be copolymerized with other monomers; for example, divinylbenzene can be used for cross-linking the polystyrene chains.
In accordance with a preferred embodiment of this invention, tritiated water is reacted with calcium carbide to produce calcium hydroxide and acetylene, separating the final products, and polymerizing the acetylene to form a stable tritiated polystyrene compound. To improve the yield of the process, the calcium hydroxide may be calcinated to remove the tritiated water and the water-calcium carbide reaction is repeated.
It is an object of the present invention to provide for the fixation of tritiated water in such form as to minimize leachability.
It is an object of the present invention to provide a method for covalently bonding tritiated water with a polymer producing a tritiated polystyrene.
It is object of the present invention to react tritiated water with calcium carbide to produce a tritiated acetylene by-product.
It is an object of the present invention to process the tritiated acetylene by-product with heat and a catalyst to form a tritiated ethyl benzene by-product.
It is an object of the present invention to convert the tritiated ethyl benzene in the presence of steam and over iron oxide based catalyst to tritiated styrene by-product via catalytic dehydrogenation.
It is an object of the present invention to copolymerize the tritiated styrene by-product with an effective amount of divinyl benzene cross-linking agent to produce a fixed tritiated polystyrene and derivatives thereof.
Other objects, features, and advantages of the invention will be apparent with the following detailed description taken in conjunction with the accompanying drawings showing a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the views wherein:
FIG. 1 is a schematic depicting the chemical bonding of the radioactivity from tritiated after into an insoluble polystyrene matrix via covalent bonding; and
FIG. 2 is a flow diagram of the process for conversion of tritiated water to an insoluble polystyrene.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Tritium fixation by incorporation into a polymeric form results in both low leachability and tritium exchange rates due to the nature of the strong hydrogen-carbon covalent bond. The initial reaction is based on the polymerization of acetylene produced by the reaction of tritiated water with calcium carbide.
Step 1:
Calcium carbide (CaC2) is reacted with tritiated water to produce tritiated acetylene. This is an exothermic reaction.
The concentrated tritium waste is converted to Tritiated acetylene by reaction with calcium carbide, in accordance with the following reaction:
The reaction of tritiated water with calcium carbide partitions only a portion of the initial tritium as tritiated acetylene, the remainder is contained in tritiated calcium hydroxide.
The tritiated water can be removed from the calcium hydroxide by calcination at 350 to 400° C. and recycled to the tritiated water calcium carbide reaction. Alternately, the calcium hydroxide can be reacted with hydrochloric acid to yield calcium chloride and tritiated water.
Step 2
Tritiated acetylene is passed through a catalyst such as a red hot copper tube where it polymerizes to form a tritiated benzene (the cyclotrimerization step) as shown in FIG. 1 .
Step 3
The tritiated benzene is converted to tritiated ethyl benzene by its reaction with ethyl chloride in an acid-catalyzed (ferric chloride) chemical reaction. The hydrochloric acid produced is channeled into a solution of concentrated sodium hydroxide (NaOH). The latter produces ferric chloride ,sodium chloride (NaCl) and tritiated water. The latter is collected and is recycled to react with calcium carbide to produce tritiated acetylene as shown in Step 1 of FIG. 1 .
Step 4
The tritiated ethyl benzene is converted in the presence of steam over iron oxide-based catalyst (KFeO 2 /K 2 Fe 22 O 34 ) to a tritiated styrene as represented by the catalytic dehydrogenation reaction shown in Step 4 of FIG. 1 .
Step 5
The copolymerization of the tritiated styrene with variable amounts of divinyl benzene as a cross-linking agent, produces the insoluble tritiated polystyrene as shown in FIG. 1 . In a preferred embodiment, the amount to divinyl benzene is from 0.01 to 5.0% by weight, more preferably from 0.1 to 2% by weight, and more preferably from 0.2 to 1% by weight.
It is contemplated that additional materials such as polybutadiene can be added during polymerization to become chemically bonded to the polystyrene, forming a graft copolymer, which helps to incorporate normal polybutadiene into the final mix, resulting in high-impact polystyrene. Several other copolymers are also used with styrene such as acrylonitrile butadiene styrene, a copolymer of acrylonitrile and styrene, toughened with polybutadiene. SAN is a copolymer of styrene with acrylonitrile, and SMA with maleic anhydride. Styrene can also be copolymerized with other monomers; for example, divinylbenzene can be used for cross-linking the polystyrene chains.
Divinylbenzene consists of a benzene ring bonded to two vinyl groups. It is related to styrene (vinylbenzene) by the addition of a second vinyl group. Divinylbenzene is usually a 2:1 mixture of m and p-divinylbenzene, containing the corresponding ethylvinyl benzene isomers. When reacted with styrene, divinylbenzene can be used as a reactive monomer in polyester resins. Styrene and divinylbenzene react together to form the copolymer styrene-divinylbenzene, S-DVB or Styrene-DVB resulting in cross-linked polymer.
The tritiated polystyrene can be micronized into particles with a desired radius (size) or can be converted in a form of solid sheaths of plastic. The tritium atom by being covalently bonded into the benzene moieties of the water-insoluble and unreactive polystyrene molecule is securely eliminated from the environments, i.e. it is not allowed to leach out from its storage.
The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modification will become obvious to those skilled in the art upon reading this disclosure and may be made upon departing from the spirit of the invention and scope of the appended claims. Accordingly, this invention is not intended to be limited by the specific exemplifications presented herein above. Rather, what is intended to be covered is within the spirit and scope of the appended claims.
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The present invention relates to a method and covalent bonding process for fixing tritiated water into a polystyrene based product for the permanent elimination of tritiated water from the environment.
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RELATED APPLICATIONS
[0001] This Application is a CIP of U.S. patent application Ser. No. 11/735,131 filed Apr. 13, 2007; which is a CIP of U.S. patent application Ser. No. 10/699,565 filed Nov. 30, 2003 (issued as U.S. Pat. No. 7,226,133); which is a CIP of U.S. patent application Ser. No. 10/376,756 filed Feb. 28, 2003 (issued as U.S. Pat. No. 7,125,084).
FIELD OF THE INVENTION
[0002] This invention is related to the field of bearing protection and, in particular, to a system that permits the pressurization of a bearing chamber used in an industrial application to provide bearing chamber integrity, as well as provide visual and/or audible indication of bearing chamber integrity.
BACKGROUND OF THE INVENTION
[0003] The instant invention is an apparatus and method for maintaining bearing chamber integrity in structures commonly referred to as a hub. Of particular concern is the hubs found in most industrial machines used in pulverizing, grinding, sanding, deburring, grinding, polishing, or the like applications where the hub may be subjected to an adverse environment. Such hubs are subjected to an environment of water, lubricating oil, grinding dirt and dust which might be microscopic, or most any other abrasive material that is used in the process. The environment surrounding the hub can result in premature wear of metals due to the abrasive nature but is especially problematic to bearings once the abrasive materials contact the bearing. The same abrasive material that is used in the particular grindings, polishing or the like process can quickly destroy the bearings once the abrasive materials come in contact with the bearings.
[0004] The hub, as used throughout this disclosure, includes a bearing chamber that has roller bearings, races of the like assemblies to allow free rotation of the hub assembly in relation to the axle. As with any friction producing components, it is imperative that the bearings are lubricated in order to prevent premature wear. Typically, grease is used which liquefies during hub rotation for use in lubricating the bearings. The grease is sealed within the bearing chamber by use of a seals positioned along an inner side surface of the hub, and a bearing cap positioned along an outer side surface of the hub. The seals are used to prevent liquified grease from escaping the hub joint.
[0005] The integrity of the seals is critical to prevent loss of grease. Absence of a lubricant can quickly lead to catastrophic failure of the bearings causing hub disengagement of the axle, which can result in assembly loss and the associated dangerous scenario of property damage. For instance, a grinding device that fails can quickly damage the item being worked upon beyond salvage, damage the sanding grinding belts beyond salvage, place the operator at risk, and result in downtime for repair of the equipment.
[0006] A bearing that is used in grinding can carry a heavy load which will quickly heat up a bearing that is not properly lubricated. Should the bearing fail, the bearing and race will typically disintegrate with a likely result of the hub detaching from the axle. In certain operations, the bearing may be subject to external pressures that may include air, water, or lubrication fluid pressure. Should there be a failure of the hub seal, the pressured air or fluid is then forced into the hub carrying with it the materials removed during the grinding operation, the ideal material for immediate destruction of the bearings. In addition, should the materials that enter the hub include moisture, bearing disintegration is greatly enhanced since rust forming on the axles surface will operate to destroy the replacement bearings with very short use.
[0007] In light of the above numerous attempts have been made in order to prevent loss of bearing lubricant. Many prior art hub devices are designed to maintain a pressurized grease within the hub. U.S. Pat. No. 4,524,917 discloses the use of bearing assembly that operates under pressure to form air seals to keep out dust and abrasive material. However, the teaching is to place the air to the outside of the seals in an effort to push contaminants away from the seal. The disclosure maintains the use of a pressurize oil lubricant for the bearings.
[0008] U.S. Pat. No. 3,609,066 discloses the use of a lubricant pump to supply pressurized lubricant to bearings.
[0009] U.S. Pat. No. 4,981,182 discloses a sealed rotary drill bit having an inner seal and an outer seal with a circumferential seal gap there between which is filed with a lubricant. Pressurized gas is carried by passageways pass through a restrictor that has a controlled dissipation to wash away drilling debris.
[0010] Current pressurized systems can result in an excess amount of lubricant being injected into the hub which results in a waste of lubricant should a leak occur. A leaking seal can cause the entire work area to become contaminated and the lubricant can contaminate the work product. In a conventional lubricant pressurized system, lubricant may be pumped in on a continuous basis with the lubricant leaking through the seal breach. In a conventional non-pressurized system, lubricant may be pumped in only when the operator deems it necessary. For instance, an operator may check a hub before starting a work project and insert grease into the hub. Once the hub reaches its operating speed, the grease liquefies and may easily escape a breached seal. Should the operator introduce a cooling liquid, the lubricant may be drawn through the seal with the uneven temperatures and the cooling liquid can be contaminated.
[0011] The environmental impact of disposing a contaminated lubricant is well known. The operator must clean the cooling liquid of the lubricant for the expulsion of grease into a conventional drain that will have a cumulative negative impact on the environment. Should the water be expelled without cleaning, even a few drops of oil can result in extensive contamination.
[0012] Thus, what is lacking in the art is a pressurization system that verifies bearing chamber integrity.
SUMMARY OF THE INVENTION
[0013] Disclosed is an apparatus to provide a pressurized hub to provide a positive indication of bearing chamber integrity, provide an indication as to the presence of bearing lubricant within the hub, and prevent the release of bearing lubricant into the environment outside the bearing chamber. The applicant's system can be use to modify a conventional hub to provide an air-tight seal for receipt of pressurized air from a compressed air source. The compressed air provides continual hub, bearing chamber, pressurization despite temperature fluctuations. A pressure gauge can be mounted anywhere along the pressurized system providing a visual indication of the internal pressure and seal integrity.
[0014] It is an objective of the instant invention to provide a pressurization system for indicating bearing chamber integrity for hub assemblies used on commercial and industrial equipment in abrasive and corrosive environments.
[0015] Another objective of the instant invention to provide a apparatus for maintaining a predetermined amount of pressurized air in a hub assembly and to automatically adjust for fluctuations in pressure caused by temperature variations.
[0016] Still another objective of the instant invention is to provide a visual and/or audible indicator for shop personnel that hub integrity is intact thereby indicating proper lubrication in an environment that might otherwise be obscured due to the particular machining function.
[0017] Yet still another objective of the instant invention is to provide a positive pressure within a bearing chamber at all times to prevent the entrance of particles within the chamber including water thereby preventing premature destruction of the bearing assemblies.
[0018] In accordance with the above objectives, a pressurization system for hubs is provided utilizing compressed air having a pressure switch for use in series with a relief valve to prevent over-pressurization. The pressurization system is coupled to a hub having a bearing chamber that is rotatably securable to an axle; seals between the hub and the axle, the seals forming a closed air space around the bearings.
[0019] The hub comprises a sealing arrangement that provides an air-tight sealing arrangement for the bearings of a hub to form a closed air system. An aperture is formed through the axle to provide an air flow connection with a remotely mounted air compressor used to pressurize the closed air space. An air pressure gauge provides a visual indication of the level of air pressure in the closed air system whereby a breached seal condition within the hub can be detected by the inability to maintain a properly pressurized system. A hub cap may also be used to provide a seal wherein the degradation of the hub bearing outer seal will not result in air loss or grease leakage.
BRIEF DESCRIPTION OF THE FIGURES
[0020] FIG. 1 is a cross-sectional view of a pressurized hub shown mounted on a roller assembly;
[0021] FIG. 2 is a flow diagram of an air-compressor based pressurization system; and
[0022] FIG. 3 is a cross sectional pictorial of an industrial polisher, grinding, and deburring with liquid cooling/waste material collection.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Although the invention will be described in terms of a specific embodiment, it will be readily apparent to those skilled in this art that various modifications, rearrangements, and substitutions can be made without departing from the spirit of the invention. The scope of the invention is defined by the claims appended hereto.
[0024] FIG. 1 is a cross-sectional side view of a roller assembly 10 having a roller shell 12 with an axle 14 extending therethrough. The axle is rotatably supported by a first and second hub 17 , 18 . First hub 17 has a bearing 20 operatively associated with a bearing race 22 . A modified seal 24 is used in conjunction with a stainless steel bushing 26 , the combination capable of preventing air from passing. The stainless steel bushing 26 is secured to the axle with a bonding agent thereby eliminating the need for polishing of the axle and allowing for retrofit of existing systems that may have axle corrosion. An O-ring 25 may be positioned beneath the bearing so that a fully air tight seal can be achieved without bonding or the use of a liquid seal, thus creating a closed air system. The end caps have silicon sealant on the inside of the end cap and the outside of the roller where they are bolted together. The end cap 16 is secured to the hub 17 by use of mounting bolts 28 . The axle 14 has an aperture 32 extending along a longitudinal length of the axle with a cross aperture 34 allowing pressured air to be delivered through the aperture and into a outboard chamber 38 , inboard chamber 40 , and roller chamber 42 . Chambers 38 and 40 may be isolated from roller chamber 42 wherein lubrication is maintained within the hub only, without excess lubrication being placed in the roller chamber. Such installations would be used in instances where the hub is rotated at right rpm's which may cause liquefying of the lubricant. In lower speed operations, packing of the bearings is sufficient and the roller chamber can be coupled with the hub chambers.
[0025] Second hub 17 has a bearing 50 operatively associated with a bearing race 52 . A modified oil seal 54 operates in conjunction with a stainless steel bushing 56 , the combination is capable of preventing air from passing. The stainless steel bushing 56 is secured to the axle 14 with a bonding agent, not shown. The end cap in this embodiment is a belt housing end cap 19 , the bushing is mounted with the flange facing outwards, silicon sealant, not shown, is on the inside of the end cap 19 and the outside of the roller where they bolt together. The end cap 18 is secured to the hub 18 by use of mounting bolts 58 . The axle 14 has an aperture 62 extending along a longitudinal length of the axle 14 with a cross aperture 64 allowing pressured air delivered through the aperture to into a outboard chamber 68 , inboard chamber 70 , and roller chamber 42 . Chambers 38 and 40 may be isolated from roller chamber 42 in a conventional hub wherein lubrication is maintained within the hub only, without excess lubrication being placed in the roller chamber. In this embodiment, all chamber are fluidly connected thus an end plug 80 may be used to plug the aperture if drilled.
[0026] The hub is pressurized by use of compressed air, found in most any industrial plant. Alternatively a small air compressor, not shown, can be employed if a self contained pressurized system is desired. The air compressor is capable of maintaining a predetermined pressure in the chambers which is now a closed air space, typically between 1 psi and 30 psi. The actual pressure is determined by the type of seals to be employed since certain seals cannot handle the higher pressures. In the preferred embodiment, the air compressor will automatically compensate for differing loading characteristics which can change the pressure reading of the hub. For instance, if the hub is filled to 30 psi, operating the rollers at high rpm's will have a tendency to warm the air within the hub assembly and increase air pressure. Similarly, should the hub assembly be subjected to very cold temperatures, such as when the hub assembly is water or air cooled, the pressure can be changed.
[0027] The end plug 80 may be replaced by a pressure gauge, not shown, to provide a location for a specific visual indicator of seal integrity. An air gauge may also be remotely mounted by directly coupling into an air line.
[0028] An air pressure gauge of a conventional design would include a dial in the form of an annular disk having the standard numeric indicia thereon in the form of radial graduations. A pressure indicating needle moves relative to the annular disk in direct relation to the air pressure within the hub. The disk can also include alphanumeric indicia specific to the function of the present invention corresponding to the position of pressure indicator needle. For example, the disk can indicate an optimum air pressure fill level, and can include color coded regions to alert observers that the seal has been breached. For instance, a gauge indicator could show green if the hub integrity is proper, or red is no pressure is available so as to indicate seal breach
[0029] Now referring to FIG. 2 set forth is flow diagram of pressurization system 100 for use with a pressurized hub (rollers) 102 , 104 . The system 100 consists of an air source 106 that is preferably coupled to an air tank 108 to prevent compressor cycling. In this embodiment an air regulator 110 is set for a low pressure installation of 10 psi. The air regulator 110 may include a filter, may be adjustable, or may be fixed with an emergency relief valve. A control panel 112 is provided for ease of installation and includes an electric pressure switch 114 for control of solenoid valve 116 . In this embodiment the switch 114 turns on at 7 psi and off at 10 psi for controlling the electrically operated solenoid valve 116 directing the air through a pressure relief valve 118 which is set at 15 psi and may provide redundant back-up to the air regulator 110 . As the operation of this device is typically in an industrial application, the use of a visual indicator 120 provides a light indication that the bearing chamber integrity may be in breach. The indicator may also be an audible indicator in those instances where an alarm function may be heard.
[0030] From the control panel 112 the pressurized air produced may be directed to the hubs by low pressure tubing 121 such as polyethylene tubing. An in-line shut off valve 122 allows maintenance of the hubs without disabling of the air compressors. A pressure gauge 124 and audible and/or visible low pressure indicator 126 provides localized visualization of the bearing chamber integrity. As previously mentioned, a pressure gauge may also be mounted directly to the hub if convenient to the operator. The system can provide protection to an unlimited number of hubs by simply adding connections 128 within the piping system.
[0031] FIG. 3 is a cross sectional pictorial view depicting an industrial polishing unit have upper rollers 150 , lower rollers 152 and a polishing belt 154 placed there between. The polishing belt 154 is a continuous belt with work pieces carried along the conveyor belt 156 . As illustrated, the upper and lower rollers are placed in an environment having a continual bath of fluid 160 for use in cooling and waste material transfer. Excess waste 164 is collected on a drape 162 with the filtered water 166 available for recycling. In operation the filtered water remains loaded with waste material that passed through the filter, the smaller material is even better suited for breaching of a seals used in a conventional system for protecting of the bearing.
[0032] 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 and drawings. The instant invention can be used on any type of industrial equipment where integrity of the bearing housing is critical. It should be noted that proper seals also prevents grit, wood dust, or any other water or airborne contaminants from entering the bearing housing thereby enhancing bearing life.
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A system for pressurizing a hub having a bearing chamber formed from an air-tight sealing arrangement located on each end of a hub to form a closed air system in the interior of the hub or in combination with a second hub. The closed air system fluidly coupled to a pressurized air tank for receiving pressurized air. A pressure gauge provides a visual indication of the air pressure in the closed air system whereby a breached seal condition within the hub can be detected.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention disclosed and claimed herein generally pertains to a method and related apparatus for data transfer between multiple root nodes and PCI adapters, through an input/output (I/O) switched-fabric bus. More particularly, the invention pertains to a method of the above type wherein different root nodes may be routed through the I/O fabric to share the same adapter, and a single control, used to configure the routing for all root nodes, resides in one of the nodes. Even more particularly, the invention pertains to a method of the above type wherein a challenge procedure is provided, to resolve any uncertainty as to which node is serving as the control node.
2. Description of the Related Art
As is well known by those of skill in the art, PCI Express (PCI-E) is widely used in computer systems to interconnect host units to adapters or other components, by means of an I/O switched-fabric bus or the like. However, PCI-E currently does not permit sharing of PCI adapters in topologies where there are multiple hosts with multiple shared PCI buses. As a result, even though such sharing capability could be very valuable when using blade clusters or other clustered servers, adapters for PCI-E and secondary networks (e.g., FC, IB, Enet) are at present generally integrated into individual blades and server systems. Thus, such adapters cannot be shared between clustered blades, or even between multiple roots within a clustered system.
In an environment containing multiple blades or blade clusters, it can be very costly to dedicate a PCI adapter for use with only a single blade. For example, a 10 Gigabit Ethernet (10 GigE) adapter currently costs on the order of $6,000. The inability to share these expensive adapters between blades has, in fact, contributed to the slow adoption rate of certain new network technologies such as 10 GigE. Moreover, there is a constraint imposed by the limited space available in blades to accommodate PCI adapters. This problem of limited space could be overcome if a PC network was able to support attachment of multiple hosts to a single PCI adapter, so that virtual PCI I/O adapters could be shared between the multiple hosts.
In a distributed computer system comprising a multi-host environment or the like, the configuration of any portion of an I/O fabric that is shared between hosts, or other root nodes, cannot be controlled by multiple hosts. This is because one host might make changes that affect another host. Accordingly, to achieve the above goal of sharing a PCI adapter amongst different hosts, it is necessary to provide a central management mechanism of some type. This management mechanism is needed to configure the routings used by PCI switches of the I/O fabric, as well as by the root complexes, PCI adapters and other devices interconnected by the PCI switches.
It is to be understood that the term “root node” is used herein to generically describe an entity that may comprise a computer host CPU set or the like, and a root complex connected thereto. The host set could have one or multiple discrete CPU's. However, the term “root node” is not necessarily limited to host CPU sets. The term “root complex” is used herein to generically describe structure in a root node for connecting the root node and its host CPU set to the I/O fabric.
In one very useful approach, a particular designated root node includes a component which is the PCI Configuration Master (PCM) for the entire multi-host system. The PCM configures all routings through the I/O fabric, for all PCI switches, root complexes and adapters. However, in a PCI switched-fabric, multiple fabric managers are allowed. Moreover, any fabric manager can plug into any root switch port, that is, the port of a PCI switch that is directly connected to a root complex. As a result, when a PCM of the above type is engaged in configuring a route through a PCI fabric, it will sometimes encounter a switch that appears to be controlled by a fabric manager other than the PCM, residing at a root node other than the designated node. Accordingly, it is necessary to provide a challenge procedure, to determine or affirm which root node actually contains the controlling fabric configuration manager.
SUMMARY OF THE INVENTION
The invention generally provides a challenge procedure or protocol for determining the root node in which the PCI Configuration Master or Manager actually resides, in a multi-host system of the above type. This node is referred to as the master node. The challenge procedure is activated whenever the identity of the PCM, determined by the root node containing the PCM, appears to be uncertain. The challenge procedure resolves this uncertainty, and enables the PCM to continue to configure routings throughout the system. In one useful embodiment, the invention is directed to a method for a distributed computer system provided with multiple root nodes, and further provided with one or more PCI switches and with adapters or other components that are available for sharing by different nodes. The method includes the steps of selecting a first one of the root nodes to be the master root node for the system, and operating the first root node to implement a procedure whereby the first root node queries the configuration space of a particular one of the PCI switches. The method further includes detecting information indicating that a second root node, rather than the first root node, is considered to be the master root node for the particular switch. A challenge procedure is implemented in response to this detected information, in an effort to confirm that the first root node is in fact the master root node for the system. The configuration space querying procedure is then continued, if the first root node is confirmed to be the master root node. Otherwise, the querying procedure is aborted so that corrective action can be taken. Usefully, when the PCM is performing PCI configuration, all the root nodes are in a quiescent state. After the switched-fabric has been configured, the PCM writes the configuration information into the root switches, and then enables each of the root ports to access its configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a block diagram showing a generic distributed computer system in which an embodiment of the invention may be implemented.
FIG. 2 is a block diagram showing an exemplary logical partitioned platform in the system of FIG. 1 .
FIG. 3 is a block diagram showing a distributed computer system provided with multiple hosts and respective PCI family components that are collectively operable in accordance with an embodiment of the invention.
FIG. 4 is a schematic diagram depicting a PCI configuration space adapted for use with an embodiment of the invention.
FIG. 5 is a schematic diagram showing an information space for each of the host sets of the system of FIG. 3 .
FIG. 6 is a schematic diagram showing components of a fabric table constructed by the PCM to provide a record of routings that have been configured or set up.
FIG. 7 is a flow chart depicting steps carried out by the PCM in constructing the table of FIG. 6 , including steps for an embodiment of the invention.
FIG. 8 is a flow chart depicting a challenge protocol in accordance with the embodiment of FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a distributed computer system 100 in which a preferred embodiment of the present invention may be practiced. The distributed computer system 100 takes the form of multiple root complexes (RCs) 110 , 120 , 130 , 140 and 142 , respectively connected to an I/O fabric 144 through I/O links 150 , 152 , 154 , 156 and 158 , and to the memory controllers 108 , 118 , 128 and 138 of the root nodes (RNs) 160 - 166 . The I/O fabric is attached to I/O adapters (IOAs) 168 - 178 through links 180 - 194 . The IOAs may be single function, such as IOAs 168 - 170 and 176 , or multiple function, such as IOAs 172 - 174 and 178 . Moreover, respective IOAs may be connected to the I/O fabric 144 via single links, such as links 180 - 186 , or with multiple links for redundancy, such as links 188 - 194 .
The RCs 110 , 120 , and 130 are integral components of RN 160 , 162 and 164 , respectively. There may be more than one RC in an RN, such as RCs 140 and 142 which are both integral components of RN 166 . In addition to the RCs, each RN consists of one or more Central Processing Units (CPUs) 102 - 104 , 112 - 114 , 122 - 124 and 132 - 134 , memories 106 , 116 , 126 and 128 , and memory controllers 108 , 118 , 128 and 138 . The memory controllers respectively interconnect the CPUs, memory, and I/O RCs of their corresponding RNs, and perform such functions as handling the coherency traffic for respective memories.
RN's may be connected together at their memory controllers, such as by a link 146 extending between memory controllers 108 and 118 of RNs 160 and 162 . This forms one coherency domain which may act as a single Symmetric Multi-Processing (SMP) system. Alternatively, nodes may be independent from one another with separate coherency domains as in RNs 164 and 166 .
FIG. 1 further shows a PCI Configuration Manager (PCM) 148 incorporated into one of the RNs, such as RN 160 , as an integral component thereof. The PCM configures the shared resources of the I/O fabric and assigns resources to the RNs.
It is to be understood that any one of the root nodes 160 - 166 could support the PCM. However, there must be only one PCM, to configure all routes and assign all resources, throughout the entire system 100 . Clearly, significant uncertainties could develop if it appeared that there was more than one PCM in system 100 , with each PCM residing in a different root node. Accordingly, embodiments of the invention are provided, first to determine that an uncertain condition regarding the PCM exists, and to then resolve the uncertainty.
In a very useful embodiment, a challenge protocol is operable to recognize that a PCI switch, included in the switched-fabric of the system, appears to be under the control of a PCM that is different from the PCM currently in control of the system. Upon recognizing this condition, the challenge protocol will either confirm that the current PCM has control over the switch, or else will abort configuration of the switch. This challenge protocol or procedure is described hereinafter in further detail, in connection with FIGS. 7 and 8 .
Distributed computing system 100 may be implemented using various commercially available computer systems. For example, distributed computing system 100 may be implemented using an IBM eServer iSeries Model 840 system available from International Business Machines Corporation. Such a system may support logical partitioning using an OS/400 operating system, which is also available from International Business Machines Corporation.
Those of ordinary skill in the art will appreciate that the hardware depicted in FIG. 1 may vary. For example, other peripheral devices, such as optical disk drives and the like, also may be used in addition to or in place of the hardware depicted. The depicted example is not meant to imply architectural limitations with respect to the present invention.
With reference to FIG. 2 , a block diagram of an exemplary logical partitioned platform 200 is depicted in which the present invention may be implemented. The hardware in logically partitioned platform 200 may be implemented as, for example, data processing system 100 in FIG. 1 . Logically partitioned platform 200 includes partitioned hardware 230 , operating systems 202 , 204 , 206 , 208 and hypervisor 210 . Operating systems 202 , 204 , 206 and 208 may be multiple copies of a single operating system, or may be multiple heterogeneous operating systems simultaneously run on platform 200 . These operating systems may be implemented using OS/400, which is designed to interface with a hypervisor. Operating systems 202 , 204 , 206 and 208 are located in partitions 212 , 214 , 216 and 218 , respectively. Additionally, these partitions respectively include firmware loaders 222 , 224 , 226 and 228 . When partitions 212 , 214 , 216 and 218 are instantiated, a copy of open firmware is loaded into each partition by the hypervisor's partition manager. The processors associated or assigned to the partitions are then dispatched to the partitions' memory to execute the partition firmware.
Partitioned hardware 230 includes a plurality of processors 232 - 238 , a plurality of system memory units 240 - 246 , a plurality of input/output (I/O) adapters 248 - 262 , and a storage unit 270 . Partition hardware 230 also includes service processor 290 , which may be used to provide various services, such as processing of errors in the partitions. Each of the processors 232 - 238 , memory units 240 - 246 , NVRAM 298 , and I/O adapters 248 - 262 may be assigned to one of multiple partitions within logically partitioned platform 200 , each of which corresponds to one of operating systems 202 , 204 , 206 and 208 .
Partition management firmware (hypervisor) 210 performs a number of functions and services for partitions 212 , 214 , 216 and 218 to create and enforce the partitioning of logically partitioned platform 200 . Hypervisor 210 is a firmware implemented virtual machine identical to the underlying hardware. Hypervisor software is available from International Business Machines Corporation. Firmware is “software” stored in a memory chip that holds its content without electrical power, such as, for example, read-only memory (ROM), programmable ROM (PROM), electrically erasable programmable ROM (EEPROM), and non-volatile random access memory (NVRAM). Thus, hypervisor 210 allows the simultaneous execution of independent OS images 202 , 204 , 206 and 208 by virtualizing all the hardware resources of logically partitioned platform 200 .
Operation of the different partitions may be controlled through a hardware management console, such as hardware management console 280 . Hardware management console 280 is a separate distributed computing system from which a system administrator may perform various functions including reallocation of resources to different partitions.
In an environment of the type shown in FIG. 2 , it is not permissible for resources or programs in one partition to affect operations in another partition. Moreover, to be useful, the assignment of resources needs to be fine-grained. For example, it is often not acceptable to assign all IOAs under a particular PHB to the same partition, as that will restrict configurability of the system, including the ability to dynamically move resources between partitions.
Accordingly, some functionality is needed in the bridges that connect IOAs to the I/O bus so as to be able to assign resources, such as individual IOAs or parts of IOAs to separate partitions; and, at the same time, prevent the assigned resources from affecting other partitions such as by obtaining access to resources of the other partitions.
Referring to FIG. 3 , there is shown a distributed computer system 300 that includes a more detailed representation of the I/O switched-fabric 144 depicted in FIG. 1 . More particularly, to further illustrate the concept of a PCI family fabric that supports multiple root nodes through the use of multiple switches, fabric 144 is shown in FIG. 3 to comprise a plurality of PCIe switches (or PCI family bridges) 302 , 304 and 306 . FIG. 3 further shows switches 302 , 304 and 306 provided with ports 308 - 314 , 316 - 324 and 326 - 330 , respectively. The switches 302 and 304 are referred to as multi-root aware switches, for reasons described hereinafter. It is to be understood that the term “switch”, when used herein by itself, may include both switches and bridges. The term “bridge” as used herein generally pertains to a device for connecting two segments of a network that use the same protocol.
Referring further to FIG. 3 , there are shown host CPU sets 332 , 334 and 336 , each containing a single or a plurality of system images (SIs). Thus, host 332 contains system image SI 1 and SI 2 , host 334 contains system image SI 3 , and host 336 contains system images SI 4 and SI 5 . It is to be understood that each system image is equivalent or corresponds to a partition, as described above in connection with FIG. 2 . Each of the host CPU sets has an associated root complex as described above, through which the system images of respective hosts interface with or access the I/O fabric 144 . More particularly, host sets 332 - 336 are interconnected to RCs 338 - 342 , respectively. Root complex 338 has ports 344 and 346 , and root complexes 340 and 342 each has only a single port, i.e. ports 348 and 350 , respectively. Each of the host CPU sets, together with its corresponding root complex, comprises an example or instance of a root node, such as RNs 160 - 166 shown in FIG. 1 . Moreover, host CPU set 332 is provided with a PCM 370 that is similar or identical to the PCM 148 of FIG. 1 .
FIG. 3 further shows each of the RCs 338 - 342 connected to one of the ports 316 - 320 , which respectively comprise ports of multi-root aware switch 304 . Each of the multi-root aware switches 304 and 302 provides the capability to configure a PCI family fabric such as I/O fabric 144 with multiple routings or data paths, in order to accommodate multiple root nodes.
Respective ports of a multi-root aware switch, such as switches 302 and 304 , can be used as upstream ports, downstream ports, or both upstream and downstream ports. Generally, upstream ports are closer to the RC. Downstream ports are further from RC. Upstream/downstream ports can have characteristics of both upstream and downstream ports. In FIG. 3 ports 316 , 318 , 320 , 326 and 308 are upstream ports. Ports 324 , 312 , 314 , 328 and 330 are downstream ports, and ports 322 and 310 are upstream/downstream ports.
The ports configured as downstream ports are to be attached or connected to adapters or to the upstream port of another switch. In FIG. 3 , multi-root aware switch 302 uses downstream port 312 to connect to an I/O adapter 352 , which has two virtual I/O adapters or resources 354 and 356 . Similarly, multi-root aware switch 302 uses downstream port 314 to connect to an I/O adapter 358 , which has three virtual I/O adapters or resources 360 , 362 and 364 . Multi-root aware switch 304 uses downstream port 324 to connect to port 326 of switch 306 . Multi-root aware switch 304 uses downstream ports 328 and 330 to connect to I/O adapter 366 , which has two virtual I/O adapters or resources 353 and 351 , and to I/O adapter 368 , respectively.
Each of the ports configured as an upstream port is used to connect to one of the root complexes 338 - 342 . Thus, FIG. 3 shows multi-root aware switch 302 using upstream port 308 to connect to port 344 of RC 338 . Similarly, multi-root aware switch 304 uses upstream ports 316 , 318 and 320 to respectively connect to port 346 of root complex 338 , to the single port 348 of RC 340 , and to the single port 350 of RC 342 .
The ports configured as upstream/downstream ports are used to connect to the upstream/downstream port of another switch. Thus, FIG. 3 shows multi-root aware switch 302 using upstream/downstream port 310 to connect to upstream/downstream port 322 of multi-root aware switch 304 .
I/O adapter 352 is shown as a virtualized I/O adapter, having its function 0 (F 0 ) assigned and accessible to the system image SI 1 , and its function 1 (F 1 ) assigned and accessible to the system image SI 2 . Similarly, I/O adapter 358 is shown as a virtualized I/O adapter, having its function 0 (F 0 ) assigned and assessible to SI 3 , its function 1 (F 1 ) assigned and accessible to SI 4 and its function 3 (F 3 ) assigned to SI 5 . I/O adapter 366 is shown as a virtualized I/O adapter with its function F 0 assigned and accessible to SI 2 and its function F 1 assigned and accessible to SI 4 . I/O adapter 368 is shown as a single function I/O adapter assigned and accessible to SI 5 .
Referring to FIG. 4 , there is shown a PCI configuration space for use with distributed computer system 300 or the like, in accordance with an embodiment of the invention. As is well known, each switch, bridge and adapter in a system such as data processing system 300 is identified by a Business/Device/Function (BDF) number. The configuration space is provided with a PCI configuration header 400 , for each BDF number, and is further provided with an extended capabilities area 402 . Respective information fields that may be included in extended capabilities area 402 are shown in FIG. 4 , at 402 a . These include, for example, capability ID, capability version number and capability data. In addition, new capabilities may be added to the extended capabilities 402 . PCI-Express generally uses a capabilities pointer 404 in the PCI configuration header 400 to point to new capabilities. PCI-Express starts its extended capabilities 402 at a fixed address in the PCI configuration header 400 .
In accordance with the invention, it has been recognized that the extended capabilities area 402 can be used to determine whether or not a PCI component is a multi-root aware PCI component. More particularly, the PCI-Express capabilities 402 is provided with a multi-root aware bit 403 . If the extended capabilities area 402 has a multi-root aware bit 403 set for a PCI component, then the PCI component will support the multi-root PCI configuration as described herein. Moreover, FIG. 4 shows the extended capabilities area 402 provided with a PCI Configuration Manager (PCM) identification (ID) field 405 . If a PCI component supports the multi-root PCI configuration mechanism, then it will also support PCM ID field 405 .
It is to be understood that the PCM ID is a value that uniquely identifies the PCM, throughout a distributed computer system such as system 100 or 300 . More particularly, the PCM ID clearly indicates the root node or CPU set in which the PCM component is located.
Referring to FIG. 5 , there is shown an information space 502 , one of which corresponds to each root node or host CPU set. Each information space 502 includes a number of information fields such as fields 504 - 508 , which provide the vital product data (VPD) ID, the user ID and the user priority, respectively, for its corresponding root node or host CPU set. It is to be understood that other information fields not shown could also be included in each information space 502 . User ID and user priority may be assigned to respective root nodes by a system user, administrator or administration agent.
As is known by those of skill in the art, a unique VPD ID is assigned to a host CPU set when the unit is manufactured. Thus, respective host CPU sets of system 300 will have VPD ID values that are different from one another. It follows that to provide a unique value for PCM ID, the host CPU set having the highest VPD ID value could initially be selected to contain the PCM, and the PCM ID would be set to such highest VPD ID value. Alternatively, the host CPU set having the highest user ID, the highest user priority, or the highest value of a parameter not shown in information space 502 could be initially selected to contain the PCM component, and the PCM ID would be such highest value. The root node or host CPU unit initially designated to contain the PCM, and to thereby be the master root node for the system, could be selected by a system user, or could alternatively be selected automatically by a program.
Referring further to FIG. 5 , there is shown information space 502 having an active/interactive (A/I) field 510 . The root node at which the PCM is located shows an active status in its field 510 , and the remaining root nodes of the system each show an inactive status. As an example, host CPU set 332 of system 300 would have an active status in field 510 , since it contains PCM 370 , and host sets 334 and 336 would each have an inactive status.
An important function of the PCM 370 , after respective routings have been configured, is to determine the state of each switch in the distributed processing system 300 . This is usefully accomplished by operating the PCM to query the PCI configuration space, described in FIG. 4 , that pertains to each component of the system 300 . This operation is carried out to provide system configuration information, while each of the other host sets remains inactive or quiescent. The configuration information indicates the interconnections of respective ports of the system to one another, and can thus be used to show the data paths, or routings, through the PCI switches of switched-fabric 144 .
Referring to FIG. 6 , there is shown a fabric table 602 , which is constructed by the PCM as it acquires configuration information. The configuration information is usefully acquired by querying portions of the PCI-E configuration space respectively attached to a succession of active ports (AP), as described hereinafter in connection with FIG. 7 .
Referring further to FIG. 6 , there is shown fabric table 602 including an information space 604 that shows the state of a particular switch in distributed system 300 . Information space 604 includes a field 606 , containing the identity of the current PCM, and a field 608 that indicates the total number of ports the switch has. For each port, field 610 indicates whether the port is active or inactive, and field 612 indicates whether a tree associated with the port has been initialized. Field 614 shows whether the port is connected to a root complex (RC), to a bridge or switch (S) or to an end point (EP).
FIG. 6 further shows fabric table 602 including additional information spaces 616 and 618 , which respectively pertain to other switches or PCI components. While not shown, fabric table 602 in its entirety includes an information space similar to space 604 for each component of system 300 . Fabric table 602 can be implemented as one table containing an information space for all the switches and PCI components in the fabric, or as a linked list of tables, where each table contains the information space for a single PCI switch or PCI component.
In systems such as those of FIGS. 1 and 3 , multiple fabric managers are allowed, and can plug into any part of a multi-root aware switch such as switches 302 and 304 . As a result, and as discussed above, when the current PCM is acquiring PCM identity information from the field 606 of a particular switch, it may happen that a PCM ID associated with the switch is different from the identity of the current PCM. In order to construct a fabric table, the invention provides a challenge protocol to deal with events of this type.
Referring to FIG. 7 , there is shown a procedure usefully carried out by the PCM, in order to construct the fabric table 602 . Generally, the PCM successively queries the PCI configuration space of each switch and other PCI component. This is done to determine the number of ports a component has and whether respective ports are active ports (AP) or inactive ports. The PCM then records this information in the fabric table, together with the VPD ID of the PCI component.
Function block 702 and decision block 704 indicate that the procedure of FIG. 7 begins by querying the configuration space to find out if the component attached to a port AP is a switch. Function block 706 shows that if the component is a switch, the field “Component attached to port (AP) is a switch” is set in the PCM fabric table. Then, in accordance with decision block 707 , it becomes necessary to determine whether the switch being queried already shows a PCM ID, either the identity of the currently active PCM or a different PCM. More specifically, decision block 707 requires determining whether field 606 of the switch does or does not show a PCM ID that is equal to 0.
FIG. 7 further shows that if the determination of decision block 707 is positive, the ID of the current PCM, which is engaged in constructing the fabric table, is set in the PCM configuration table of the switch, in accordance with function block 708 . This table is the information space in fabric table 602 that pertains to the switch. Function block 710 shows that the fabric below the switch is then discovered, by re-entering this algorithm for the switch below the switch of port AP in the configuration. Function block 712 discloses that the port AP is then set to port AP-1, the next following port, and the step indicated by function block 702 is repeated.
Referring again to decision block 707 of FIG. 7 , it is seen that if the determination of block 707 is negative, the switch being queried must contain a non-zero value for PCM ID. Accordingly, as shown by decision block 730 , it becomes necessary to determine whether or not this PCM ID value is equal to the current PCM ID, that is, the PCM in control of the system. If such determination is positive, function block 732 indicates that the PCM disables the port connection to the switch, and records in the fabric table that a loop was found. The task set forth at function block 720 , which is described hereinafter in further detail, is then carried out.
Referring further to decision block 730 of FIG. 7 , a negative result for the query thereof would indicate that the switch had a PCM ID that was different from the current PCM ID. In this event, it becomes necessary to invoke the PCM challenge protocol, as shown by function block 734 . This protocol is described hereinafter, in connection with FIG. 8 , and either will or will not be won by the current PCM ID, in accordance with decision block 736 . If the challenge is won, the procedure of FIG. 7 is again advanced to function block 720 . If the challenge is lost, the procedure is aborted, as shown by function block 738 .
Referring further to decision block 704 of FIG. 7 , if the component being queried is not a switch, it becomes necessary to determine if the component is a root complex or not, as shown by decision block 714 . If this query is positive, the message “Component attached to port AP is an RC” is set in the PCM fabric table, as shown by function block 716 . Otherwise, the message “Component attached to port AP is an end point” is set in the PCM fabric table, as shown by function block 718 . In either event, the port AP is thereupon set to AP-1, as shown by function block 720 . It then becomes necessary to determine if the new port AP value is greater than zero, in accordance with decision block 722 . If it is, the step of function block 702 is repeated for the new port AP. If not, the process of FIG. 7 is brought to an end.
When the fabric table 602 is completed, the PCM writes the configured routing information that pertains to a given one of the host CPU sets into the root complex of the given host set. This enables the given host set to access each PCI adapter assigned to it by the PCM, as indicated by the received routing information. However, the given host set does not receive configured routing information for any of the other host CPU sets. Accordingly, the given host is enabled to access only the PCI adapters assigned to it by the PCM.
Usefully, the configured routing information written into the root complex of a given host comprises a subset of a tree representing the physical components of distributed computing system 300 . The subset indicates only the PCI switches, adapters and bridges that can be accessed by the given host CPU set.
As a further feature, only the host CPU set containing the PCM is able to issue write operations, or writes. The remaining host CPU sets are respectively modified, to either prevent them from issuing writes entirely, or requiring them to use the PCM host set as a proxy for writes.
Referring to FIG. 8 , there is shown a flow chart depicting a challenge protocol for an embodiment of the invention. Function block 802 indicates that the protocol is entered when a PCI switch is found to show a PCM ID that is not the current PCM ID, as described above in connection with function block 734 of FIG. 7 . Upon entering the protocol, a message challenging the switch configuration is sent to the root node identified by the PCM found at the switch, referred to hereinafter as the challenge PCM. As shown by function block 804 , the challenge message is directed to the BDF number of the identified root node. After the message is sent, function block 806 indicates that a timer loop (TL) is set to an integer N associated with a time period. N could, for example, be 5 and the time period could be 5 milliseconds. Function block 806 shows that a corresponding cycle time X is also selected. If the cycle time was selected to be 1 millisecond, 5 cycles or iterations would occur until the time period associated with N came to an end. As described hereinafter, the values pertaining to function blocks 806 and 808 are respectively selected to establish a maximum period for response.
Referring further to FIG. 8 , decision blocks 810 and 812 indicate that the challenge PCM may respond to the challenge message, sent to the identified root node, by providing its challenge PCM ID. If such response is received by the current PCM, the challenge PCM ID is compared with the current PCM ID, as shown by decision block 812 . If the current PCM ID is found to be greater than the challenge PCM ID, confirmation is provided that the current PCM is indeed the correct PCM. Accordingly, the challenge is recorded to be won, as shown by function block 814 , and the protocol is exited at 818 . Thereupon, the procedure shown in FIG. 7 is advanced to function block 720 thereof.
In the event that the challenge PCM ID is found to be equal to or greater than the current PCM ID, the challenge will be recorded as being lost, as indicated by function block 816 . The protocol will be exited and the procedure of FIG. 7 will be aborted, in accordance with function block 738 .
Referring further to decision block 810 of FIG. 8 , if the challenge PCM does not respond to the challenge message within the cycle time, the timer loop TL is decremented by one, as shown by function block 820 . For a TL of 5, TL- 1 would go to 4. If TL was not 0, the protocol would return to function block 808 , in accordance with decision block 822 . The protocol would then wait for another period of cycle time X for the challenge PCM to respond to the message. After a number of such iterations with no response, TL will reach 0. When this occurs, an error message is created and the configuration pertaining to the switch is aborted, as shown by function block 824 .
A data processing system suitable for storing and/or executing program code will include at least one processor coupled directly or indirectly to memory elements through a system bus. The memory elements can include local memory employed during actual execution of the program code, bulk storage, and cache memories which provide temporary storage of at least some program code in order to reduce the number of times code must be retrieved from bulk storage during execution.
The computer program code may be accessible from a computer-usable or computer-readable storage medium for use by or in connection with a computer or any instruction execution system. For the purposes of this description, a computer-usable or computer readable medium can be any tangible apparatus that can contain and store the program for use by or in connection with the instruction execution system, apparatus, or device.
The medium can be an electronic, magnetic, optical, electromagnetic, infrared, or a semiconductor system. The medium also may be physical medium or tangible medium on which computer readable program code can be stored. Examples of a computer-readable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk, an optical disk, or some other physical storage device configured to hold computer readable program code. Current examples of optical disks include compact disk-read only memory (CD-ROM), compact disk-read/write (CD-R/W) and DVD.
Input/output or I/O devices (including but not limited to keyboards, displays, pointing devices, etc.) can be coupled to the system either directly or through intervening I/O controllers.
Network adapters may also be coupled to the system to enable the data processing system to become coupled to other data processing systems or remote printers or storage devices through intervening private or public networks. Modems, cable modem and Ethernet cards are just a few of the currently available types of network adapters.
The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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In a distributed computer system having multiple root nodes, a challenge protocol is provided, for use in determining or confirming the root node in which a PCI Configuration Manager (PCM) actually resides. This node is referred to as the master node. The challenge procedure is activated whenever the identity of the PCM, which is determined by the root node in which it resides, appears to be uncertain. The challenge procedure resolves this uncertainty, and enables the PCM to continue to configure routings throughout the system. In a useful embodiment, a method is directed to a distributed computer system of the above type which is further provided with PCI switches and with adapters that are available for sharing by different nodes. The method includes the steps of selecting a first one of the root nodes to be master root node, and operating the first root node to query the configuration space of a particular one of the PCI switches. The method further includes detecting information indicating that a second root node is considered to be the master root node for the particular switch. A challenge protocol is implemented in response to this detected information, to seek confirmation that the first root node is the master root node. The configuration space querying procedure is continued if the first root node is confirmed to be the master root node, and is otherwise aborted.
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FIELD OF THE INVENTION
[0001] This invention relates to video and still image decoding and in particular to an approximate inverse discrete cosine transform for scaling video and still image decoding computational complexity in accordance with available quantities of computational resource units and a decoder which utilizes the same.
BACKGROUND OF THE INVENTION
[0002] As Digital Television (DTV) expands worldwide and gradually dominates the TV market, the demand for flexible architecture and scalable computation will become greater. The impetus to adopt flexible architecture is lead by the availability of a more powerful DSPCPU core and the increasing demand for new functionality. As the computational power of the DSPCPU core increases over time, video-processing functions will tend to migrate from hardware implementations on coprocessors to software implementations on the DSPCPU core. At the same time, the emergence of new audio/visual processing functionality will mandate the application of coprocessors.
[0003] Software implementation of audio/video processing functions on the DSPCPU core, creates opportunities for algorithm scalability by allowing trade-off between the usage of available computational resources (i.e. CPU cycles, cache, memory size, memory bandwidth, coprocessor load, etc.) and subjective image quality. Although the DSPCPU core is getting more and more powerful, reducing cost by constraining CPU usage while still generating satisfactory results is a big challenge for video algorithm designs driven by consumer electronics.
[0004] The application of scalable video algorithms (SVAs) will allow multiple video functions to run concurrently on the DSPCPU core and the coprocessors while the total computational resources are on constraint. SVAs can also lead to the reduction of coprocessors and other external hardware. The system cost is then reduced with smaller silicon area of the multimedia processor chip.
[0005] One potential application for SVAs is in video decoders. Video decoders should be capable of decoding incoming compressed digital video signals at real-time speed. In a typical application such as a set-top box, the computational resource available for video decoding varies over time because the total available resource has to be divided among many different tasks. When the computational resource available at any given time is insufficient, the decoder should then intelligently adapt the complexity of the decoding algorithm, albeit, with some loss in the visual quality of the decoded video.
[0006] The most prevalently used compression techniques for digital video and images are MPEG and JPEG respectively. Both these techniques use the block based DCT as one of the basic blocks in the compression. A video decoder performs the following algorithmic steps in decoding video: variable length decoding, inverse quantization, inverse DCT (IDCT) and motion compensation. The IDCT requires a substantial portion of the computational resource and by using an approximate algorithm its complexity can be adapted to scale to the available resource.
[0007] Techniques to reduce the IDCT complexity based on input data are known. These techniques classify the input data into different categories and use different IDCT algorithms of varying complexities for different categories of data. However such techniques have the additional overhead of classifying the input data into the selected categories.
[0008] Accordingly, a need exists for an IDCT having a complexity which scales to the computational resources available in the microprocessor of the decoder at any given time and which is input data-independent.
SUMMARY OF THE INVENTION
[0009] A method of scaling image and video processing computational complexity in accordance with maximum available quantities of computational resource units, the method comprising the steps of: performing a plurality of data multiplications which processes digital image and video data, each data multiplication having a data dependent value multiplied by data independent value, the performance of each data multiplication requiring a predetermined quantity of computational resource units; selecting one of the data multiplications; selecting a shift/add-operation, a shift/substract-operation, or a shift-operation using the data independent value associated with the selected multiplication that requires a quantity of computational resource units which is less than the predetermined quantity of computational resource units required for performing the selected multiplication; and approximating the selected multiplication with the selected operation.
[0010] Also described herein is a decoder which scales video and still image decoding computational complexity with available computational resources. The decoder comprises a variable length decoder; an inverse quantizer which dequantizes signals received from the variable length decoder; and an approximate inverse discrete cosine transform that scales decoding computational complexity in accordance with the above method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The advantages, nature, and various additional features of the invention will appear more fully upon consideration of the illustrative embodiments now to be described in detail in connection with accompanying drawings where like numerals are used to identify like elements and wherein:
[0012] [0012]FIG. 1 is a block diagram illustrating the steps performed by the approximate IDCT of the present invention;
[0013] [0013]FIG. 2 is a flowchart which illustrates an exemplary implementation of the approximate IDCT of the present invention; and
[0014] [0014]FIG. 3 is a schematic illustration of a video decoder in which the approximate IDCT of the present invention can be implemented.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention sets forth an approximate inverse discrete cosine transform (IDCT) for digital video and still image decoding as respectively used in MPEG and JPEG compression/decompression techniques. Conventional IDCTs utilize algorithms with fixed computational complexities to process data. Therefore, conventional IDCTs can not scale their computational complexity to the computational resources that are available in the microprocessor of the decoder at any given time.
[0016] The approximate IDCT of the present invention utilizes an algorithmic process whose complexity scales to the computational resources available in the microprocessor of the decoder at any given time. Hence, the approximate IDCT of the invention can be utilized in MPEG and JPEG to enable scalable computation decoding of digital video and still images respectively which is not possible with conventional IDCTs that utilize algorithmic processes of fixed computational complexity.
[0017] [0017]FIG. 1 is a block diagram illustrating the steps performed by the approximate IDCT of the present invention to provide complexity scaling. In step 10 , the maximum number of available computational units is observed for each multiplication to be performed by the IDCT. Step 12 it determines whether the maximum number of computational units available (the maximum computational complexity available) for each multiplication is sufficient. If it is determined that the maximum number of available computational units is sufficient, the multiplication is performed in step 14 . If it is determined that the maximum number of available computational units is insufficient, then in step 16 multiplications are replaced by one or more shift/add-operations, shift/substract-operations, or a shift-operation (all three of these operations being collectively referred to hereinafter as shift-operation) the exact number and type of such operations being dependent upon the maximum number of computational units required therefore.
[0018] Note that a multiplication requires approximately three times the number of cycles to perform as compared to an addition, a subtraction, or a shift-operation in popular INTEL architecture processors.
[0019] In particular, if it is determined that the number of computational units required for performing multiple shift/add-operations, shift/subtract-operations, or a shift-operation is greater than or equal to that required for the multiplication, the multiplication is approximated with an abbreviated shift-operation. Approximation is typically performed when the multiplication is by a value that is not a single power of two. Such a multiplication may involve a shift-operation comprised of two or more shifts, the results of which are then added or subtracted. The abbreviated shift-operation of the present invention neglects one or more of these shifts and additions/subtractions to scale the complexity of the IDCT to the available computational units.
[0020] In order to illustrate the concepts of the present invention, the following discussion references a DCT/IDCT algorithm adopted from the original Chen-Wang algorithm described by W. H. Chen, C. H. Smith, S. Fralick, “A Fast Computational Algorithm For The Discrete Cosine Transform,” IEEE Transactions on Communications, Vol. COM-25, No. 9, pp. 1004-1009, September, 1977 and by Z. Wang, “Reconsideration Of A Fast Computational Algorithm For The Discrete Cosine Transform,” IEEE Transactions on Communications, Vol. COM-31, pp. 121-123, January 1983. The reference C code of the Chen-Wang algorithm can be found in the C code of a decoder used at the University of California, at Berkeley. The decoder performs an IDCT based on a multi-stage network. It should be understood, however, that the present invention can be applied to any IDCT including IDCTs which use matrix multiplications to obtain a 2-D IDCT directly or IDCTs which use two 1-D IDCTs, one of which is performed over the rows and the other which is performed over the columns. Moreover, the present invention can also be applied to DCTs or any other computer computation involving multiplications.
[0021] Typically the above IDCT is performed on a two-dimensional block of 8 by 8 pixels. In this implementation the two dimensional IDCT is achieved by performing one-dimensional IDCT on the columns followed by one-dimensional IDCT on the rows. The following set of equations as provided below in Table 1 shows the four states of a 4-stage network. The first column of equations corresponds to the operations performed in the first stage and so forth.
TABLE 1 Stage I Stage II Y 8 = x 0 + x 1 T 8 = w 7 * (x 4 + x 5 ) Y 0 = x 0 − x 1 Y 4 = T 8 + x 4 * (w 1 − w 7 ) T 1 = w 6 * (x 3 + x 2 ) Y 5 = T 8 − x 4 * (w 1 + w 7 ) Y 2 = T 1 − (w 2 + w 6 ) * x 2 T 8 = w 3 * (x 6 + x 7 ) Y 3 = T 1 + (w 2 − w 6 ) * x 3 Y 6 = T 8 − x 6 * (w 3 − w 5 ) Y 1 = x 4 + x 6 Y 7 = T 8 − x 7 * (w 3 + w 5 ) Y 4 = x 4 − x 6 Y 1 = x 1 Y 6 = x 5 + x 7 Y 2 = x 2 Y 5 = x 5 − x 7 Y 3 = x 3 Y 0 = x 0 Stage III Stage IV Y 7 = x 8 + x 3 Y 0 = (x 7 + x 1 )>>8 Y 8 = x 8 − x 3 Y 1 = (x 3 + x 2 )>>8 Y 3 = x 0 + x 2 Y 2 = (x 0 + x 4 )>>8 Y 0 = x 0 − x 2 Y 3 = (x 8 + x 6 )>>8 Y 2 = (181*(x 4 + x 5 ) + 128)>>8 Y 4 = (x 8 − x 6 )>>8 Y 4 = (181*(x 4 − x 5 ) + 128)>>8 Y 5 = (x 0 − x 4 )>>8 Y 1 = x 1 Y 6 = (x 3 − x 2 )>>8 Y 6 = x 6 Y 7 = (x 7 − x 1 )>>8
[0022] Here x 1 are the inputs and Y 1 . are the outputs of each stage and T 1 . are temporary variables that are computed. Also, the output of each stage is the input to the subsequent stage, i.e. the output of the first stage is the input of the second stage and so on. The x 1 and Y 1 values are dependent on the received bitstream data. The w 1 values are independent of the received bitstream data and these values are replaced or approximated with shift-operations in accordance with the present invention. Accordingly, the approximate IDCT of the present invention is input data-independent, hence, avoiding the additional overhead in terms of computational resources of classifying the input data into selected categories as required in prior IDCT complexity reduction techniques.
[0023] As shown in the above set of equations, the operations in stage I require 6 multiplications, 6 additions and no shift-operations. In accordance with an illustrative implementation of the principles of the present invention, if there are insufficient computational resources or units available for performing a multiplication by w i in stage I, the multiplication can be replaced or approximated by with a shift operation as described above.
[0024] As described earlier, a multiplication can be replaced with a shift-operation if w i is a value that is equal to a single power of two because the shift-operation requires only a single shift with no additions or subtractions. Specifically, if w 7 in the first equation of stage I is 64, the multiplication by w 7 can be replaced with a single shift with no additions or subtractions because 64 is equal to a single power of two or 2 6 . Accordingly, multiplication by 64 can be achieved by left shifting the value of (x 4 +x 5 ) by 6. Assuming for example, a multiplication requires 3 computational units and a single-shift operation requires 1 computational unit, then the above shift-operation provides a savings of 2 computational units.
[0025] If w 1 , is a value that is not equal to a single power of two, the multiplication by w 1 can be replaced with a set of shift-operations and additions or subtractions if the maximum number of computational units available for the multiplication are insufficient and the number of computational units required for the shift-operations are less than what is required for the multiplication. As described earlier, values that are not equal to a single power of two can be decomposed or split into a sum of values each of which is a power of two. In particular, if w 7 in the first equation of stage I is 84 (which is not a single power of two), 84 can be split into the sum of three values each of which is a power of two or 64 (2 6 )+16 (2 4 )+4 (2 2 ). Multiplication by 84 is therefore achieved by multiplying the value of (x 4 +x 5 ) by 64, 16 and 4 and adding the results. Each of these multiplications can be achieved in the approximate IDCT of the present invention through a shift-operation, i.e. 64 * (x 4 +x 5 ) is achieved by left shifting the value of (x 4 +x 5 ) by 6, 16 * (x 4 +x 5 ) is achieved by left shifting the value of (x 4 +x 5 ) by 4 places, 4 * (x 4 +x 5 ) is achieved by left shifting (x 4 +x 5 ) by 2. Accordingly, multiplication by 84 is replaced by 3 shift-operations and 2 additions.
[0026] However, the replacement of the multiplication is performed in the present invention only if the computational resources or units required by the shift-operations and the additions is less than that required by a multiplication. If the computational resources required for the 3 shift-operations and 2 additions is not less than that required by the multiplication, then the multiplication is approximated by omitting some of the shifts and additions. Assuming again that an addition and a shift-operation are each equivalent to 1 unit of computation and a multiplication is equivalent of 3 units of computation, then the shift-operation actually requires 5 units of computation which is 2 more than the multiplication. Accordingly, an abbreviated shift-operation which omits the shifts involving the values 16 and 4 would be performed to approximate the multiplication by 84.
[0027] The above process can be used in one or more of the other multiplications in stage I as well as the multiplications in the other stages, depending upon how much scaling back of the computational complexity is needed to accommodate the available computational resources.
[0028] The values that are not equal to a single power of two can also be decomposed or split into a “difference” of values each of which is a power of two. For example, if w 7 in the first equation of stage I is 63, 63 can be decomposed or split into 64 (2 6 )−1 (2 0 ). The decision to select a decomposition made up of a sum or difference is typically based on which decomposition method requires less computational units to implement and is the best approximation of the multiplication. Using the above example, the multiplication by 63 can be replaced in its entirety by 2 shift-operations and 1 subtraction. A corresponding sum decomposition of 63 would equal 32 (2 5 )+16 (2 4 )+8 (2 3 )+4 (2 2 )+2 (2 1 )+1 (2 0 ) which requires 6 shifts and 5 additions. Hence, in this example, the difference decomposition of 63 requires less computational units to implement in its entirety than the sum decomposition of 63. Assuming again that an addition and a shift-operation are each equivalent to 1 unit of computation and a multiplication is equivalent of 3 units of computation, an abbreviated shift operation using the difference decomposition of 63 would require one computational unit, thus providing a 2 computational unit savings over the multiplication with only a small loss in accuracy. An abbreviated shift operation using the sum decomposition of 63 would also require only 1 computational unit to implement but would involve a much greater loss of accuracy.
[0029] [0029]FIG. 2 is a flowchart which illustrates an exemplary implementation of the approximate IDCT of the present invention. In the flow chart, C is the maximum number of computational units available for the multiplication (the maximum computation complexity available for the multiplication), C m is the number of computational units required to perform the multiplication w * x without any approximation, C s is the number of computational units required for shifting, C a is the number of computational units required for adding or subtracting, and C sa is total number of computational units required for shifting, adding or subtracting the powers of two.
[0030] [0030]FIG. 3 schematically illustrates a video decoder 30 in which the approximate IDCT of the present invention can be implemented. The video decoder 30 includes a channel buffer 32 , a variable length decoder (VLD) 34 , an inverse quantizer 36 , the approximate IDCT 38 of the invention, a motion compensator 40 , an adder 42 and a memory 46 for storing reference frames for motion compensation. The IDCT 38 of the invention enables the video decoder to scale its video decoding computational complexity with the computational resources available from the controller 44 of the decoder 30 .
[0031] Table II below shows the number of multiplications, additions and shift-operations required by the four different stages of equations shown in Table I above. Assuming additions and shift-operations are equivalent to one unit of computation and a multiplication is equivalent to three units of computation, the total requirement is 74 units.
Stage 1 Stage II Stage III Stage IV Number of Multiplications 6 3 2 0 Number of Additions 6 9 8 8 Number of Shift Operations 0 0 2 8 Total number of computation 24 18 16 16 units
[0032] In a preferred embodiment of the approximate IDCT of the present invention, computational complexity reduction through replacement or approximation of the multiplications required at different stages of a multistage network with shift-operations will now be described by referring again to earlier described four stage IDCT of Tables I and II. For the discussion here, all approximations utilizing abbreviated shift-operations are assumed to be accomplished with a single shift-operation. The multiplications in stage III are the preferred initial candidates to be replaced or approximated by shift-operations, since any approximations introduced at this stage propagates to only one more stage. If the two multiplications at stage III are replaced or approximated by shift-operations, then the total computation requirement is 70 units, or 70/74=94.6% of the original complexity. If the computational resources available from the controller of the decoder falls below 100% but stays above 94.6% then the decoder, via the approximate IDCT of the present invention will automatically replace or approximate the multiplications at stage III to scale to the current resource availability.
[0033] If the computational resources fall below 94.6%, the multiplications in stage II are also replaced or approximated by shift-operations in addition to the stage III replacements and approximations. If the three multiplications in stage II and the two in Stage III are replaced or approximated by shift-operations, the total computational requirement will be 64, which is 86.5%, of the original complexity.
[0034] If the computational resource falls below 86.5%, then all the multiplications in all the stages are replaced or approximated by shift-operations. Accordingly, the resulting computational requirement will be 52 units, or 70.3% of the original complexity.
[0035] Using the approximate IDCT process of the present invention, the computational requirement can be scaled to three different levels of 94.6%, 86.5% and 70.3% by replacing or approximating the multiplications at different stages with shift-operations. To obtain more levels of scalability, some of the multiplications (and not all) in each stage can be replaced or approximated. For example, to achieve a complexity level that is less than 90% (but above 86.5%), two multiplications in Stage III and two in Stage II can be replaced or approximated with shift-operations. This will result in (66/74) 89.2% complexity. To select the two out of three multiplications that are to be approximated with shift-operations at Stage II, the error introduced in approximating multiplications with abbreviated shift-operations is calculated for each multiplication and the two multiplication approximations that result in the lower error values is selected. This process can be done a priori and is data independent.
[0036] While the foregoing invention has been described with reference to the above embodiments, various modifications and changes can be made without departing from the spirit of the invention. Accordingly, such modifications and changes are considered to be within the scope of the appended claims.
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A method of scaling image and video processing computational complexity in accordance with maximum available quantities of computational resource units, the method including the steps of: performing a plurality of data multiplications which processes digital image and video data, each data multiplication having a data dependent value multiplied by data independent value, the performance of each data multiplication requiring a predetermined quantity of computational resource units; selecting one of the data multiplications; selecting a shift/add-, a shift/subtract or a shift-operation using the data independent value associated with the selected multiplication that requires a quantity of computational resource units which is less than the predetermined quantity of computational resource units required for performing the selected multiplication; and performing the selected multiplication with the selected operation. Also, a decoder which scales video and still image decoding computational complexity with available computational resources. The decoder includes a variable length decoder; an inverse quantizer which dequantizes signals received from the variable length decoder; an approximate inverse discrete cosine transform that scales decoding computational complexity in accordance with the above method; and a motion compensator
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BACKGROUND OF THE INVENTION
The invention relates to an NMR-apparatus comprising a magnet for generating a steady uniform main magnetic field, a resonator arrangement for generating an RF magnetic field which is oriented at least substantially perpendicularly to the main magnetic field, and at least one drive mechanism for an adjusting-element which mechanism drives the adjusting element for matching the resonator to an RF generator and/or for adjusting the resonator tuning.
FIG. 1 shows a NMR apparatus of this type. It comprises an electromagnet 1 with four coils which generates a steady uniform magnetic field oriented in the same direction as the common horizontal coil axis. A patient 3 positioned on a table top in the interior of the electromagnetic is enclosed by an RF coil 4, which generates an RF pulsating field which is oriented perpendicularly to the main magnetic field generated by the electromagnet. The frequency of the RF magnetic field is proportional to the flux density of the main magnetic field, which may be between 0.1 T and 2 T, depending on the construction of the electromagnet. The proportionally constant is equal to the gyromagnetic ratio. This enables nuclear spin resonance to be obtained inside the volume enclosed by the RF coil. Four gradient coils 5, which generate a magnetic field which is oriented in the same direction as the main magnetic field and which varies linearly in this direction, ensure that this excitation is restricted to a vertical layer 6.
In such apparatuses it is important that the frequency of the RF field generated by the RF coil corresponds exactly to the nuclear spin resonance frequency, dictated by the gyromagnetic ratio and the flux density of the main magnetic field, and that the resonator comprising the RF coil 4 is always matched to the RF generator which energizes the RF coil.
However, depending on the size and region of the body of the patient to be examined, the resonance frequency may change and the quality factor of the resonator may decrease. This effect is produced as a result of the dielectric properties and the electrical conductivity of the body tissues. As a result of this, the RF generator and the RF receiver, which is subsequently connected to the resonator and which receives the spin resonance signal originating from the body region to be examined, are no longer matched to the resonator at the spin-resonance frequency.
After the patient has been positioned and before the actual NMR examination is started, it is therefore necessary to re-tune the RF generator to the predetermined spin-resonance frequency and to match the resonator to the RF generator. This is possible by means of the electrical circuit shown in FIG. 2. The resonator comprises the coil 5 as well as a capacitor 9 and a variable capacitor 7, arranged in parallel with the coil 5. In the case of a suitable dimensioning the capacitor 9 may be dispensed with. Via a variable capacitor 8, this resonator is connected to an RF generator 10. Matching is effected by means of the variable capacitor 8 and tuning is effected by means of the variable capacitor 7, the two adjustments being interdependent.
Adjusting the variable capacitors is difficult. These capacitors are arranged outside the RF coil inside the electromagnet and cannot be adjusted by means of stepping motors or the like, because the ferromagnetic parts thereof would disturb the homogeneity of the magnetic field. Therefore, the stepping motors must be arranged outside the electromagnet at a distance such that they do not affect the homogeneity of the main magnetic field and their operation is not disturbed by stray fields of the electromagnet. Therefore, the stepping motors have to be coupled to the adjusting elements inside the electromagnet via long actuating rods. It is not possible to arrange the adjustable elements outside the electromagnet, because then they would have to be connected to the resonator in the interior via electrical leads whose length (in particular in the case of high magnetic flux densities and high spin-resonance frequencies) is no longer small in comparison with the wavelength and thus would give rise to disturbances.
It is the object of the invention to construct an NMR apparatus of the type specified in the opening paragraph in such a way that the drive mechanism for adjusting the adjusting elements can be arranged inside the electromagnet without affecting the homogeneity of the main magnetic field.
SUMMARY OF THE INVENTION
This object is achieved in that the drive mechanism for the adjustable element comprises a movably supported coil which is exposed to the main magnetic field. The coil is connected to a current-pulse supply means for the supply of current pulses of one polarity or the other polarity, by means of which the coil is deflected out of its rest position in one direction or the other direction. The deflection movement is transmitted to the adjustable element via a stepping mechanism which converts the reciprocating movement of the coil into a stepwise movement of the adjusting element, which stepwise movement has a direction which corresponds unambiguously to the direction of the deflection.
When a current pulse is sent through the coil, the coil is deflected out of its rest position in the main magnetic field and after the current pulse has ceased it is returned to its rest position, for example by means of return springs. If several current pulses of the same polarity are applied to the coil, it will perform a reciprocating movement. By means of the stepping mechanism this movement is converted into a stepwise (rotational or translational) movement of the adjusting element, whose direction corresponds unambiguously to the direction of the deflection and hence to the polarity of the current pulses. Such a drive mechanism does not require the use of any ferromagnetic parts. Therefore, and because the leads from the current-pulse supply means to the coil are not energized during the actual measurement, such a drive mechanism does not affect the field uniformity.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will now be described in more detail, by way of example, with reference to the accompanying drawings. In the drawings
FIG. 1 shows an NMR tomography apparatus to which the invention may be applied,
FIG. 2 shows the circuit diagram of the resonator and the RF generator,
FIG. 3 shows a first embodiment of the invention,
FIG. 4 is a plan view of the arrangement of FIG. 3, taken on the line A--B,
FIG. 5 shows another embodiment of the invention, and
FIG. 6 is a side view of the embodiment shown in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 shows an elongate solenoid coil 11 arranged on a coil former 12, whose lower end is connected to a housing frame 13 so as to be pivotable about a horizontal axis 14. The upper end of the coil former 12 is connected to an actuating member 15 in such a way that a pivotal movement of the coil former 12 is converted into a sliding movement of the actuating member 15, which is guided in a horizontal guide rail 16. Two springs 17, each connected to one end of the actuating member 15, ensure that the coil former and, hence, the solenoid coil are in a vertical position in the rest position, i.e. when not subjected to any further external forces. The coil axes then extends perpendicularly to the main magnetic field, whose direction is indicated by the horizontal arrow 18 in FIG. 3.
The terminals of the coil 11 are connected to a current-pulse supply means 19, which may comprise, for example, a direct current source which can be connected to the terminals via a controllable multi-pole switch in such a way that a current flows through the coil 11 in one direction, that no current flows, or that the current flows in the opposite direction.
When a current pulse flows through the coil 11, a magnetic field is built up in the coil. That field is oriented in the direction of the coil axis and thus perpendicularly to the main magnetic field. As a result, the coil is subjected to a force which tends to tilt the coil about the axis 14 in the direction of the main magnetic field, i.e. to the left or to the right depending on the polarity of the current through the coil. This pivotal movement of the coil is transmitted to an actuating member 15 via the coil former 12, so that this member 15 slides to the left or the right along the horizontal guide rail 16. The movement of member 15 is limited by stops 20 on the ends of the guide rail, to which the actuating member is connected via springs 17. If a plurality of current pulses of the same polarity is applied to the coil 11, the actuating element 15 will perform a reciprocating movement from the center to the left (or right) and back. This reciprocating movement is converted into a stepwise rotation of the rotor of the variable capacitor 7 or 8 by the stepping mechanism, so that the capacitance of this capacitor increases or decreases stepwise depending on the polarity of the current pulses.
As can be seen in FIG. 4, the actuating member 15 carries two ratchets 21 and 22, which are arranged symmetrically relative to the center of the actuating member 15 and which are pivotable about vertical pins 23 and 24, respectively. Springs, not shown, urge the ratchet ends which are remote from each other against two ratchet wheels 25 and 26, respectively. The ratchet wheels are offset from one another in the direction of the magnetic field and are mounted so as to be rotatable about vertical axes symmetrically relative to the rest position of the actuating member 15. A control pin 27, which is rigidly connected to the frame 13, is situated between the facing ends of the ratchets 21 and 22.
If the coil is energized with a current pulse, which causes the actuating member 15 to be moved to the right (FIG. 3) or upwards (FIG. 4), the following will happen: As the end of ratchet 21 is disengaged from the control pin 27 during of member 15, the ratchet will follow the circumference of the ratchet wheel until it butts against a flank of a ratchet tooth and rotates the ratchet wheel 25 anti-clockwise over one tooth pitch. This movement of member 15 causes the other ratchet 22 to be pressed against the control pin 27, so that this ratchet is simultaneously pivoted anti-clockwise about the pivot pin 24. Due to its shape at the side which faces the control pin 27, the other end of the ratchet 22 is disengaged from the ratchet wheel 26. Via a drive wheel 28, which is rigidly connected to the coaxial ratchet wheel 25, the stepwise movement of the ratchet wheel 25 is transmitted to a gear wheel 30 which is connected to the rotor of the variable capacitor 7 or 8 (FIG. 3). The gear wheel 30 meshes with a gear wheel 29, which is connected to the ratchet wheel 26 in the same way as the gear wheel 28 to the ratchet wheel 25.
As a result of the movement of the actuating member, the gear wheel 28 is thus rotated anti-clockwise over one tooth pitch. This results in a clockwise rotation of the gear wheel 30 which depends on the transmission ratio, causing a rotation, which is equal to and which has the same direction as that of the ratchet wheel 25, of the gear wheel 29 and consequently of the ratchet wheel 26. At the end of the current pulse the actuating member returns to its rest position shown in FIGS. 3 and 4, without the positions of the gear wheels being changed. A new current pulse of the same polarity then causes a further stepwise rotation of the gear wheels in the same direction.
Alternatively, the gear wheel 30, which is connected to the rotor of the variable capacitor, may be replaced by a gear rack 31, shown in broken lines in FIG. 4. The gear rack is in mesh with the gear wheels 28 and 29 and is connected to a dielectric which, as disclosed in DE-OS 33 47 597, is moved inside a coaxial line which functions as a stub, so that the reactance thereof is varied in steps. The translational recirpocating movement of the actuating member 15 is thus converted into a stepwise translation of the gear rack 31.
FIG. 5 and 6 show an embodiment in which the pivotal movement of the coil is converted directly, i.e. not via a translational movement. The coil 32 has one or more turns of, for example, rectangular cross-section and is rotatable about its axis of symmetry 33 which extends perpendicularly to the main magnetic field. In its rest position, the coil 32 is disposed so that the magnetic field lines 18 of the main magnetic field extend parallel to the center plane of the coil which is perpendicular to the central axis 33.
The upper end of coil 32 is rigidly connected to a lever 34, which near its end carries drive pins 35. Disposed between the pins 35 is an arm of a three-arm armature 36 whose other two arms carry ratchets 37 each cooperating with a gear wheel 38. The armature 36 is mounted on a further lever 40 so as to be rotatable about an axis 39 which is parallel to the rotational axis 33 of the coil 32. The two arms of armature 36 carrying the ratchets 37 are connected to lever 40 by springs 50 in such a way that in the rest position, those arms are disposed symmetrically with respect to lever 40. The lever 40 is again maintained in its rest position by means of springs 41. The lever 34 and the coil 32, the gear wheel 38 and the further lever 40 are rotatable about the same axis independently of each other.
When a current pulse flows in the coil 32, the coil is rotated under the influence of the force exerted on its conductors by the magnetic field, the direction of this rotation being dependent on the polarity of the current in the coil. The lever 34 is then deflected and, via the drive pins 35, it pivots the armature 36 about the axis 39 until one of the two ratchets 37 engages with the teeth of the gear wheel 38. After this, the lever 40 is pivoted in the same direction against the force of the springs 41, so that the gear wheel 38 is rotated through one step. After the current pulse has ceased the lever 40, the armature 36 and hence the lever 34 are returned to their rest positions, in which a latch 42 ensures that the gear wheel 38 retains its rotated position. Upon the next current pulse the gear wheel 38 is again rotated one tooth pitch further in the same direction.
In this way the reciprocatory pivotal movement of the lever 34 and of the coil 32 is converted into a stepwise rotation of the gear wheel 38 when the coil is energized with current pulses of a specific polarity. This rotation may be transmitted directly to the rotor of a variable capacitor or it may converted into a linear stepping movement to adjust a stub line by means of a gear rack.
Thus, in order to adjust the adjusting element the invention utilizes the forces exerted on an energized coil by the main magnetic field. The drive mechanism for the adjusting element in accordance with the invention comprises only non-magnetic materials and after matching or re-adjustment of the tuning, the coil is no longer energized, so that during subsequent NMR measurements no undesired fields are formed which may affect the homogeneity of the main magnetic field. This mechanism, which forms a constructional unit with the RF coil 4 (FIG. 1) and which may be replaced by another RF coil with associated drive mechanism, is particularly suitable for automatic matching or re-tuning by means of a computer, because for driving it is merely required to generate an appropriate number of current pulses.
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The invention relates to a drive mechanism for adjusting an element by means of which the resonance frequency in an NMR-apparatus can be varied. The mechanism comprises a coil which is exposed to the main magnetic field off the NMR-apparatus. The coil is connected to a current-pulse supply and is deflected out of its rest position by the current pulses. The reciprocating movement of the coil is converted by a stepping mechanism into a stepwise rotary or translational movement of the adjusting element which tunes or matches the RF coil to the RF generator.
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